Topaz Start Up OPerating Manual

Document No. Revision No. rnz integrated (m) sdn bhd (325798-x)

: P5173B-PR-MAN-1001 : 0

Date

: 06/03/09

Page

: 1 of 146

PC VIETNAM LIMITED

PROJECT TITLE

:

BASIC ENGINEERING FOR TOPAZ DEVELOPMENT PROJECT

DOCUMENT TITLE

:

START-UP, OPERATING PROCEDURE MANUAL AND SIPROD DOCUMENT

DOCUMENT NO.

:

CONTRACT NO.

CTR NO

0 Rev

06/03/09 Date

P5173B-PR-MAN-1001

PCV/TOPAZ/2007/401

:

B-PR-208

ISSUED AS FINAL Description

NHI Prep’d

SSN Chk’d

AI App’d

Client

rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL PREFACE This Start-up and Operating Manual provides the Operators with detailed information and instruction for the safe and efficient operations of the equipment and process facilities on the TPDP-A Platform.

Signature

Date

Signature

Date

Signature

Date

Signature

Date

Prepared By

Reviewed By

Endorsed By

Approved By

DOCUMENT REGISTRATION RECORD P5173B-PR-MAN-1001

PAGE 2 OF 146

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL

COPY NO. : HOLDER

:

VPD FILLING ROOM

COMPANY :

PCVL

LOCATION :

HO CHI MINH CITY

COUNTRY :

VIETNAM

Note: This is a controlled copy and shall be kept by the holder / custodian and, on his redeployment, shall be handed over to the new personnel taking over his position.

TABLE OF CONTENTS 1.0INTRODUCTION..........................................................................................................5 P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 1.1OBJECTIVES.............................................................................................................. 5 1.2ABBREVIATIONS........................................................................................................5 1.3OVERVIEW OF PLATFORM FACILITIES...................................................................8 1.3.4ENVIRONMENTAL CONDITIONS..........................................................................12 THE ENVIRONMENTAL CONDITIONS SHOWN IN THIS SECTION EXTRACTED FROM METOCEAN DATA PROVIDED BY PCVL IN DESIGN PARAMETERS AND ENVIRONMENTAL DATA REV 3...............................................................12 12 2.0OPERATION ORGANISATION AND MANAGEMENT..............................................13 4.1PROCEDURE FOR INITIAL START-UP...................................................................33

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1.0

INTRODUCTION PC Vietnam Limited (PCVL) is undertaking development of Topaz field, which is located approximately 164 km from Vung Tau Port, S.R Vietnam in Blocks 01 & 02. The platform will be installed in a water depth of 41 m approximately 16 km North East of Ruby field. The existing facilities nearby Topaz field are RBDP-A wellhead platform, RBDP-B wellhead platform, a 10 inch pipeline from RBDP-B to RBDP-A and a 10 inch flexible pipeline from RBDP-A to FPSO-Ruby Princess, while the future facilities will be a new FPSO replacing the FPSO-Ruby Princess, PLDP-A wellhead platform and associated new pipelines interconnecting the platform and new FPSO. Topaz is designated as a satellite drilling platform (TPDP-A) which would accommodate six wellhead slots. The FWS evacuation from Topaz will be directed to the new FPSO through new pipeline. First oil is scheduled in 2nd Quarter 2010. In order to execute this development project, PCVL has awarded a contract to rnz integrated (m) sdn bhd for PROVISION OF CONCEPTUAL AND BASIC ENGINEERING SERVICES FOR TOPAZ DEVELOPMENT PROJECT.

1.1

OBJECTIVES The objective of this Operating Procedures Manual is to provide the operators with detailed information and guidelines for the safe and efficient operation of the process facilities on the TPDP-A Platform.

1.2

ABBREVIATIONS AA

Approving Authority

AAR

Approving Authority Representative

ABV

Actuated Ball Valve

AGT

Authorized Gas Tester

API

American Petroleum Institute

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL BA

Breathing Apparatus

BASEEFA

British Approvals Service for Electrical Equipment in Flammable Atmospheres

BDV

Blowdown valve

bopd

Barrels Of Oil Per Day

bpd

Barrels per day

bhp

Brake Horse Power

BWPD

Barrels of Water Per Day

CA

Certifying Authority

CC

Competent Chargeman

CCR

Centre Control Room

CIMG

Carigali Inspection and Maintenance Guidelines

CITHP

Closed in Tubing Head Pressure

CM

Corrective Maintenance

cST

Centistoke

C&E

Cause & Effect Matrices

Cl

Chemical Injection

ESD

Emergency Shut Down

ESDV

Emergency Shutdown Valve

FGS

Fire and Gas System

FPSO

Floating, Production, Storage and Off-loading

FTHT

Flowing Tubing Head Temperature

FTHP

Flowing Tubing Head Pressure

FWS

Full Well Stream

F&G

Fire and Gas

GPSO

General Procedures Guide for Simultaneous Operations

HAT

Highest Astronomical Tide

HCV

Hand Choke Valve

HCMC

Ho Chi Minh City

HMI

Human Machine Interface

HPU

Hydraulic Power Unit

HSE

Health, Safety & Environment

JHA

HOLD

LAT

Lowest Astronomical Tide

MMSCFD

Million Standard Cubic Feet per Day

MOS

Maintenance Override Switches

MPFM

Multiphase Flow Meter

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL MSL

Mean Sea Level

MTG

Microturbine Generator

OIS

Operator Interface Station

PCVL

PC Vietnam Limited

PLDP-A

Pearl Drilling Platform-A

PMCS

Plant Monitoring and Control System

PSD

Process Shut Down

PTS

PETRONAS Technical Standard

PM

Preventive Maintenance

PPD

Pour point depressant

PPE

Personnel Protection Equipment

ppm

Parts per million

pptb

Pounds per thousand barrel

PSV

Pressure Safety Valve

PTW

Permit to Work

PZAHH

High-High Pressure Trip

RBDP-A

Ruby Drilling Platform-A

RBDP-B

Ruby Drilling Platform-B

Scf

Standard Cubic Feet

SDV

Emergency Shutdown Valve

SCSSV

Surface Controlled Subsurface Safety Valve

SIPROD

Simultaneous Production and Drilling

SIS

Safety Instrumented System

SOLAS

Safety of Life at Sea

SOS

Start-up Override Switches

SSV

Surface Safety Valve

TPDP-A

Topaz Drilling Platform-A

USD

Unit Shut Down

WHCP

Wellhead Control Panel

WHO

Wellhead Operator

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1.3

OVERVIEW OF PLATFORM FACILITIES Topaz (TPDP-A) Satellite Drilling Platform will be a tripod structure satellite platform designed with basic facilities and unmanned operation. The platform has a total of six (6) conductors. Four (4) of the conductors will be single completion wellheads of oil production wells and 2 (single completion wellheads) will be in spare for the future. The topside consists of well production facilities such as wellheads, well flow

lines, production manifolds, well testing (test header, well test MPFM), FWS crude heater, FWS pig launcher, FWS MPFM and Gaslift Receiver. Facilities such as vent and drain systems, utility/instrument/fuel gas system, potable and wash water system, firewater system, nitrogen supply system, diesel fuel system and chemical injection system are also provided on the platform. Provision for future FWS multiphase pump is provided to increase pressure of FWS to FPSO. Production from each of the Topaz well will pass through a choke valve and be routed to production manifold. The fluid is heated in the FWS crude heater unit and subsequently fed into the pipeline to new FPSO. The transportation of FWS is by natural flow utilizing the reservoir pressure during the year 2010 only. From the year 2011 onwards, a multiphase pump is required due to low available FTHP. The oil wells contain up to only 0.042 mole % CO 2. Corrosion is not considered as major issue but batch corrosion inhibitor injection during pigging is proposed to mitigate corrosion in FWS pipeline. No H2S is reported in the well stream. The platform shall be periodically visited by operating personnel for performing necessary functions. Monitoring and control of the critical parameters are performed from the PMCS located at the platform. The operating personnel from FPSO can perform some operations of the platform when necessary through the PMCS. The facilities are designed for simultaneous drilling and production (SIPROD). During SIPROD, the compressed air and firewater will be supplied from the drilling rig. P5173B-PR-MAN-1001

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1.3.1

Reservoir conditions and well data Table 1.3.1-1: TPDP-A Downhole Conditions Description

Miocene Sand (MI-09) 1,630 2,330 79 2,090

Reservoir Datum (TVD SS-m) Static Bottom Hole Pressure (psia) Bottom Hole Temperature (°C) Bubble Point Pressure (psia)

Table 1.3.1-2 Flowing Tubing Head Pressure for Topaz Year

FTHP bara (psia)

2010

29.59 (429)

2011 2012

17.24 (250) 17.24 (250)

2013

17.24 (250)

2014

17.24 (250)

2015

17.24 (250)

2016

17.24 (250)

Table 1.3.1-3 Wellheads Other Conditions for Topaz Description Average Flowing Tubing Head Temperature (°C) Maximum Flowing Tubing Head Temperature (°C) Minimum Flowing Tubing Head Temperature (°C) Maximum Shut-in Tubing Head Pressure bara (psia) (based on forecast at year 2009) Maximum Gas lift Pressure bara (psia)

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Miocene Sand (MI-09) 44.4 47.2 36.7 140 (2030) 82.76 (1200)

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Table 1.3.1-4: Topaz Full Well Stream Crude Properties Properties

MI-09

Solution GOR (scf/bbl)

412-562

Field Producing GOR (scf/bbl)

500-1500

Cloud Point (°C)

48.95

Pour Point (°C)

30

Wax Content (wt %)

11.8

Viscosity (cP)

0.79

API Gravity at 60 °F

31.92

Asphaltene Content (wt %)

1.94

Gel Strength

Refer to Table 1.3.15 Table 5.1-6: Gel Strength (Yield Stress) Cooling Mode

Cooling Profile

Quiescent Time (hr)

Crude Type

1

Topaz North3X

Static Cooling

3

Dead Crude

22

116.7

2

Topaz North3X

Static Cooling

5

Dead Crude

22

119.3

3

Topaz North3X

Static Cooling

24

Dead Crude

22

139

4

Topaz North3X

Static Cooling

24

Dead Crude

22

98.9

5

Topaz North3X

Static Cooling

24

Dead Crude

22

67.4

6

Topaz North3X

Static Cooling

60°C to 22°C(4°C per hour) 60°C to 22°C(4°C per hour) 60°C to 22°C(4°C per hour) 60°C to 22°C(2°C per hour) 36.7°C to 22°C(2°C per hour) 60°C to 22°C(2°C per hour)

24

Dead Crude +40% Water

22

162.6

Item

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Test temp (°C)

Experimental Gel Strength (Pa)

Sample Identificatio n

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Cut 7

Topaz North3X

Dynami c Cooling

60°C to 22°C(4°C per hour)

24

Dead Crude

22

114.9

Note: The Pour Point of the crude is 30 °C and the minimum sea water temperature is 22 °C. Therefore, continuous PPD injection is required to avoid gelling of the crude in the un-insulated FWS pipeline and to ensure FWS flow to the FPSO. The main PPD injection is into the FWS production header/pipeline and alternatively there is an injection point on the gas lift header. 1.3.1

The Topside and FWS Pipeline Design Capacity The Topside piping, equipments and the FWS pipeline are sized based on a maximum oil flow rate of 7000 bpd with the proportionate gas and water rates corresponding to the maximum oil production forecast year 2011. From the Simulation this sizing flow rates are as stated: Oil – 7000 bpd, Gas – 6.45 mmscfd and Water – 248 bpd.

1.3.2

Test Multiphase Flow Meter Design Capacity Table 1.3.3-1 Design Flow rates for flow lines and Test MPFM

Stream

Max. Oil, Max Gas Flow rate (Design)

Max. Water Flow rate (Turndown)

(2011 on Well 3P)

(2016 on Well 2P)

Oil (stb/d)

2092

309

Water (stb/d)

78

230

Gas (mmscfd)

1.7

0.96

Note: 10% design margin is included in above figures for the year 2011 after performing the simulation. 1.3.3

FWS Multiphase Flow Meter Design Capacity Table 1.3.4-1 Design Flow rates for FWS MPFM

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Max. Oil, Max Gas Flow rate7000 bpd oil

Stream

Max. Water Flow rate (Year 2016)

(Year 2011)

1.3.4

Oil (stb/d)

7000

2574

Water (stb/d)

248

371

Gas (mmscfd)

6.45

4.25

Environmental Conditions The environmental conditions shown in this section extracted from Metocean

Data

provided

by

PCVL

in

Design

Parameters

and

Environmental Data Rev 3.

Table 1.3.5-1 Ambient Conditions Description

Value

Maximum Ambient Temperature, ° C

35

Minimum Ambient Temperature, ° C

21

Maximum Humidity, %

100

Annual Averaqe Humidity, %

82.5

Minimum Relative Humidity, %

65

Table 1.3.5-2: Environmental Data Description

Value

Maximum Seawater Temperature, ° C

27

Minimum Seawater Temperature, ° C

22

High Average Tide, m

1.7

Low Average Tide, m

-2.4

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2.0

Current at Seabed, m/s

0.40

Current at Mid Depth, m/s

1.3

Current at Surface, m/s

1.7

OPERATION ORGANISATION AND MANAGEMENT 2.1

Operating Concept The TOPAZ development project is a fit for purpose facility wellhead platform (TPDP-A) and associated subsea pipelines. This satellite platform is a drilling platform which has six conductor slots (2 for future) comprising of single completion wellheads for each slot. FWS from TPDP-A flows through flowlines, production header and subsea pipeline to new FPSO for processing. The production from the wells is assisted by gas lift gas which will be supplied from FPSO. Space provision for one future 10" crude/ FWS riser and receiver is provided. The platform contains fit for purpose facilities and is unmanned, with the objective to reduce capital cost (CAPEX) and operating cost (OPEX). Maintenance is performed during periodic visits by operating personnel. TPDP-A has been designed to allow simultaneous drilling and production operations, SIPROD, to enable production whilst drilling operations continue. This arrangement reduces down time, deferment of production and hence cost. Before SIPROD is permitted, the economic advantages are evaluated against potential safety and environmental risks. Once permission is granted, a Site Specific Procedure is developed for each scenario where Simultaneous Production and Drilling operations are to be performed. The procedures clearly define the responsibilities during each phase of the operation and identify the additional facilities required to ensure the safe and effective implementation of the activities.

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2.2

Operation Organization Figure 2.2.1: Operational Organization

GENERAL MANAGER

VME MAINTENANCE

PRODUCTION MANAGER

VRIE RELIABILITY AND INTEGRITY TECHNICAL CLERK

PROJECT SUPPORT ENG.

SR. OPERATION ENG.

FIELD SUPERINTENDENT

OPERATION ENGINEER

SR. WELLHEAD OPERATORS

OPERATIONS SERV. ENG.

MARINE COORDINATOR

PROD. PLANNER

LIFTING COORDINATOR

WELLHEAD OPERATOR S

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 2.3

Operation Management System

2.3.1

Platform Logging System A log book for the platform shall be maintained at all times with the following details relating to the platform: 1. The registered name of the installation. 2. The name and address of the owner of the installation. 3. The names of personnel responsible for the platform.

Entries are to be made chronologically in the log book regarding every occurrence affecting, or likely to affect the safety of the installation or the safety, health and welfare of persons on the platform. Entries in the log book should not be erased and pages must not be removed. Changes can only be made and entries cancelled by a further entry. Such topics are listed below: 1. Assumption and relinquish of responsibility for the platform 2. Manning changes 3. Visits by vessels and helicopters 4. Adverse weather conditions 5. Collisions 6. Structural changes and major repairs 7. Safety Drills 8. Accidents, emergencies, injuries, disease and death 9. 2.3.2

Visits of government inspectors

Reporting System The following routine reports are to be submitted from offshore to HCMC office. 1. Daily Activities Report 2. Production Timeline (when there is production shutdown) 3. Monthly Operations Report 4. Monthly Inventory Report 5. Monthly Environmental Report

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 2.3.3

Permit to Work System

2.3.3.1. Objectives The Permit to Work System and pre-job safety meetings are designed to meet the following objectives: 1. To control work carried out by all personnel on board. 2. Ensure proper authorization for work to be carried out (other than normal production activity). 3. Ensure that all personnel are aware of their responsibilities. 4. To identify any hazards, limitation and conflict with other activities. 5. Ensure that the person(s) in charge are fully aware of all work being carried out on the installation. 6. Provide a formal procedure to ensure that plant equipment affected by the work is in a safe condition.

2.3.3.2. Work Permit Types A work permit may require several certificates before it may be validated. The following types of work permit are used to control works on the TPDP-A platform: 1. Cold Work Permit The cold work permit is required when any work activity is considered "non-routine", but does not warrant any other supporting certificates. 2. Hot Work Permit The hot work permit is required when any work activity is considered capable of producing a source of ignition. It is mandatory that a Gas Test be conducted before any hot work permit is issued. 2.3.3.3. Certificates The following certificates are to be used on TPDP-A platform: 1. Confined Space Entry Certificates The Confined Space Entry Certificate states that a competent person has checked the work site of a planned confined space entry and P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL identified the hazards therein and prescribed the necessary controls to ensure a safe work environment. 2. Confined Space Entry Checklist The Confined Space Entry Checklist is a list of work site conditions that must be checked by the Approving Authority before a Permit to Work can be issued. 3. Isolation Certificates These certificates state that the equipment has been drained of liquid, depressurized of gas and isolated positively from other equipment in the operating facility and from power sources. Isolation certificates contain the following: •

Physical Isolation Certificates Physical Isolation Certificates cover the work on process lines and equipment, and state they have been drained of liquid, depressurized of gas, isolated positively from other equipment in the operating facility and that suitable precautions taken to ensure they remain isolated.

•

Electrical Isolation Certificates Electrical Isolation Certificates cover the work on electrical equipment, especially high tension systems and state that an authorized and competent person has electrically isolated the equipment to be worked on and has taken suitable precautions to prevent inadvertent reconnection. For mechanical/process work which requires electrical isolation, an Electrical Isolation Certificate will be required in conjunction with the A3 Permit to Work document.

•

Safety System Bypass / Override Certificates Safety System Bypass / Override Certificates cover the work on process, mechanical and instrument equipment by bypassing or overriding one or more process control, fire and gas alarm safety systems to prevent inadvertent facility shutdown.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL No bypassed or overrides are permitted without appropriate Safety System Bypass / Override Certificate being issued. 4. Radiation Certificate The Radiation Certificate is used for the handling of Ionising Radiation Sources, and states that a Radiation Protection Officer (RPO) has granted permission to use a radioactive source, and that any related extra precautions have been carried out. 5. Lifting Certificate A Lifting Certificate is required whenever any of the following conditions prevail: •

Lifting over unprotected process equipment or wellheads. •

Removal or installation of wellhead grating.

•

Overhead lifts with sling not made of wire rope.

•

Wind velocity exceeding 30 knots.

•

Visibility less than 30 metres.

•

Sea swells exceeding 2.5 metres.

•

Greater than four leg lift.

•

Failure to fully illuminate load

•

Failure to fully illuminate path of load.

•

Multiple crane lifts.

•

Lifts exceeding 8 tons.

•

Lift inside confined spaces.

2.3.3.4. Permit Requirements and Limitations Work Permits are required for all work outside of 'normal production' activities on the platform. To be valid, the permit must be completed in full, approved and endorsed by responsible and authorised personnel. In addition to the requirements stated on the permit, a safety briefing (Tool box talk) must be given by the Supervisor or designated person to the individuals nominated to carrying out the work. A permit is valid only for the duration of the job, or for the time specified by the issuing authority. In any situation the period of validity must not exceed 12 hours. Only cold work permits can be endorsed for an additional 12 hours. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Any areas in which a permit has been issued for hot work is to be performed, must be rechecked before work can resume if personnel have been absent from the area for a period of one hour or more. When activities are to be performed in remote locations, a person designated by the Field Superintendent on the FPSO can authorise work permits. No hot work is to be carried out in Zones 0 and 1 unless the plant in the area is shut down and depressurized with the plant and area certified free of hydrocarbons. Hot work must be stopped prior to venting of hydrocarbons within or adjacent to the work area. No hot work is to be carried out whilst wireline operations are being performed. For wireline operations a cold work permit is required supported by a well data form attached to the permit to identify wellhead valve positions, SITHP, etc. 2.3.3.5. Responsibilities The following personnel have responsibilities in the operation of the Permit to Work system in platform: 1. Area Authority The Field Superintendent (or Drilling Supervisor during SIPROD) should ensure that: •

All personnel who operate and use the PTW system are trained and competent to do so.

•

The planning, issue and return of permits is properly coordinated in his respective plant or facility.

•

A secure method of electrical and process/mechanical isolations is implemented.

•

Adequate time is allowed during shift/crew changes to ensure effective transfer of information on outstanding permits.

•

The system is regularly monitored to ensure that the PTW system is implemented effectively.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL •

The list of competent personnel who are authorized to be a PTW signatory is regularly updated.

The Field Superintendent (or Drilling Supervisor during SIPROD) carries the overall responsibility for the installation and all work done under the Permit to Work system, as he is the person who endorses all work permits. He may also delegate the responsibility of endorsement to a competent Approving Authority Representative on a remote platform.

2. Approving Authority (AA) The person authorized by Management (Senior WHO) to approve and issue a permit. This person is responsible for the overall implementation of safe management of work activities for which he issues the permit. Before signing the Permit to Work form to authorize/approve work, he should verify and satisfy himself that: •

He understands the nature of the work being applied for, all the hazards associated with the job are identified and the risk has been reduced to as low as reasonably practicable.

•

The work being authorized does not jeopardize ongoing operations of the facility.

•

The Approving Authority Representative he assigns is competent to carry out all the necessary precautions required, before work begins.

•

Other permits ongoing work activities, do not conflict with the permit for the work that he is issuing.

•

Other permits/work activities that may interact are cross-

referenced. •

All supporting certificates and documents that will enhance information and add value to the safe execution of the work are attached and made known to all concerned parties carrying out the work.

•

All required equipment and PPE are adequate to carry out the

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL work safely. •

The Receiving Authority is competent and able to understand the conditions stipulated in the PTW form (and other supporting certificates if required), and that these are conveyed as necessary to other personnel under his control and involved with the work.

•

That all people who may be affected by the work are informed before the work commences, when the work is suspended and when the work is completed.

•

That effective organization exists to ensure that the work site is examined before work begins, on completion and when work is suspended.

•

That sufficient time is spent on shift/crew changes to discuss all ongoing or suspended permits with the incoming Approving Authority.

•

A joint work site visit and verification is conducted by the Approving Authority Representative and the Work Leader.

3. Approving Authority Representatives (AAR) An operations person authorized by Management and designated by the Approving Authority to implement/remove all the specified precautionary measures. 4. Receiving Authority (Applicant) (RA) The person authorized by Management to apply and receive approved permits. He is responsible for planning and supervising the execution of the work as per the precautions in the permit. He should ensure that:•

The people working for him have received adequate instruction in the PTW system.

•

He discusses the job fully with Work Leader and the person issuing the permit (AA).

•

The permit is posted at the work site and the work party is briefed on the permit details, including any potential hazards, and all the precautions taken or to be taken.

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The precautions are maintained throughout the work activity.

•

The workers understand that if circumstances change, work must be stopped and advice sought.

•

The work group stays within the limitations set out on the permit (physical boundaries, type of work and validity time).

•

On completion or suspension of the work, the site is left in a safe condition and the permit issuer is informed.

5. Work Leader (WL) A competent person who leads the safe execution of the work described on the permit. On remote platforms, the Work Leader may take the responsibilities of the Receiving Authority. His responsibilities are: •

Conforming/complying the conditions of the PTW and agree by signing.

•

Briefing the work crew on the JHA content and PTW conditions.

•

Supervising the work and remaining at the work site at all times, i.e. responsible for the work at the work site.

•

Ensuring there is no deviation from the permit conditions.

6. Work Crew Each Worker should ensure that: •

They do not start any work requiring a permit until it has been properly authorized and issued.

• They receive a briefing from the Work Leader on the particular task and they understand the hazards associated with the task and the precautions taken or to be taken. •

When they stop work, the site and any equipment they are using is left in a safe condition.

•

If they are in any doubt, or if circumstances change, they must stop work and consult with the Receiving Authority

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7. Authorized Gas Tester A person who is trained on gas testing, and who is authorised by Management to issue gas test certificates. The AGT is responsible for testing a work site or confined space with instruments to ensure the work site is free of toxic and combustible gases and not deficient in oxygen. He is also responsible for monitoring the work site and withdrawing the work permit when working conditions become unsafe. 8. Authorized Chargeman A person who holds a valid certificate of Authorisation issued by a Petronas Carigali Resident Competent Electrical Engineer. He is responsible for designating a Competent Chargeman (CC) to carry out electrical work and is the only person who may carry out isolations / switching and issue Electrical Isolation Certificates. 9. Competent Chargeman A person who holds a valid certificate of competency issued by the concerned authority which states the extent and voltage of electrical equipment on which he can work.

2.3.3.6. Permit Application and-Worksite Preparation 1. The Receiving Authority (RA) is the Applicant for the work permit and fills in the relevent sections of the work permit. He must: •

Enter the specific details of the job to be done and the exact location of the work site.

•

Identify with a cross any potential hazards associated with the job.

•

Identify with a cross the relevant PPE required for the job.

•

Nominate a Work Leader (WL).

2. The RA passes the three copies of the work permit to the Approving Authority (AA) and discusses the work activity with him. 3. The AA fills in the relevant sections of the work permit. He must: •

Indicate the area classification.

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Allocate a work, permit reference number and enter the work permit details into the Work Permit Site Log.

•

Identify and indicate with a cross any additional hazards.

•

Indicate all the precautions required, before and during the job.

•

Indicate with a cross any additional PPE requirements.

4. The AA nominates an Approving Authority Representative (AAR) on the work permit, and explains the precautions to him. He then passes the three copies of the work permit to him. 5. The Area Authority may deem that other personnel need to be aware of the stated work activity. In this case, he will enter the positions and names of these persons and request the AAR to obtain their endorsement upon reaching the remote installation. 6. The AA will enter the work permit details into the Work Permit Site Log, and pass the three copies of the permit to the AAR. 7. The AAR will take the three copies of the work permit with him to the remote installation. On arrival at the remote installation, the AAR assumes the role of the Approving Authority and Area Authority, and the nominated Work Leader assumes the role of the Receiving Authority for that installation. 8. The AAR and the WL will then make a joint site visit to the work site. The AAR will personally carry out all the specified precautions and obtain any identified endorsement initials, and confirms this by signing in. The WL confirms that he understands all the specified precautions and accepts responsibility for the job stated by also signing in the relevant section. 9. The WL will then sign as the RA, thereby accepting the permit conditions, and the AAR will also sign as the AA and Area Authority, thereby validating and endorsing the work permit. 10. The AAR will then distribute the three copies of the work permits as follows:•

Top and 3rd copy to the WL.

•

2nd copy to be placed in the display board or at a central focal

point. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 11. The WL shall then brief all the workers on the hazards and conditions of the work permit, and display the top copy at-the work site, while retaining the 3rd. copy for reference. Work can now commence.

2.3.3.7. Work Execution Process or operational conditions may change, so it is essential that the AAR should regularly check the work site. He shall stop the work at any time if the conditions have changed or the precautions are not being observed by the persons executing the work.

2.3.3.8. Work Completion 1. When the job is complete and location / equipment have been left in a safe condition, the WL will state this by signing ALL the copies of the work permit. He will also sign in as the RA, and then pass all the copies to the AAR. 2. The AAR will inspect the job site to verify that the work has been completed and that the work site is in a clean condition. If he is satisfied he will acknowledge this by signing all the copies of the work permit. 3. The AAR will also sign all the copies of the work permit as the Area Authority, thus acknowledging that the work has been completed and that the work site is ready to resume normal operations. 4. On arrival back at the main installation, the AAR will inform the AA that the work has been completed. The AA will then enter the closure details in the Work Permit Site Log. He will then file the top copy of the work permit in a "Completed Work" file. The 2nd copy of the work permit is then discarded and the 3rd copy is given back to the RA for future reference.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 2.3.4. Preventive Maintenance (PM) and Corrective Maintenance (CM) The TPDP-A facilities will be inspected and maintained in accordance with the Carigali Inspection and Maintenance Guidelines (CIMG). These guidelines are in line with the general requirements of PETRONAS guidelines and regulatory requirements and apply to all PETRONAS CARIGALI operations in the Vietnam region. 2.3.4.1. Inspection This will be performed initially on time based schedule until sufficient data has been collected, analysed and trended to provide the necessary confidence to change to a condition based schedule. The scope of inspection includes the physical inspection to detect the damage to coatings, operability of equipment and facilities. 2.3.4.2. Maintenance The objectives of maintenance are: 1. . To preserve the company assets in order to: •

Safeguard the integrity of wells, facilities and installation over the life of the asset

•

Enable the operation to achieve the availability and production targets with specified quantity

•

Provide

an

auditable

system

of

asset

performance

and

maintenance control 2. To fulfil all maintenance tasks in the most cost effective manner by the efficient deployment and use of resources. 3. To record and analyse maintenance data on asset performance in order to input such data into further company developments. Maintenance options for the PLDP-A facilities are a combination of preventative maintenance and corrective maintenance. Preventative maintenance includes activities to ensure that the equipment is operating correctly and has the necessary consumables of sufficient quality, i.e. lubricants, to continue performing satisfactorily. The planned period between preventative maintenance activities, and when they are actually performed is recorded on the Maintenance Control System. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Corrective Maintenance is performed when a piece of equipment has failed or is considered to be working inefficiently. Corrective maintenance activities are recorded in the computer based Maintenance Control System to provide an auditable trail of activities performed on each piece of equipment. 2.3.5. Valve Locking System and Tagging It is necessary to be able to isolate items of equipment using manual valves in order to facilitate maintenance activities. Such isolations must be both secured so that inadvertent operation of the isolating valve, which could create a hazardous situation, is not possible. The locking devices most commonly used for valve locked off are as follows: •

Lock and chain

•

Carriage seal with lock

•

Proprietary locking device (Smith Flow Control or similar)

•

Custom device provided as part of the valve actuator

The device should be suitable for the type of actuator, and installed in such a way as to hold the valve firmly in the required position allowing no movement which could result in the gate or plug changing position. When the isolation has been secured, the keys from the locks used in the lock off are stored in a secured lock off box located in the production shed along with a copy of the isolation certificate and work permits. The isolation is marked with a uniquely numbered red plastic tag, marked to identify the work permit to which the isolation relates. The unique number is recorded on the isolation certificate. When a valve is locked off as part of boundary isolation for activities under one or more permits, then a lock and tag should be attached for each of the work permits requiring the isolation. As each permit is signed off on completion of the work, then the lock and tag identified for the permit is removed. Positive identification of the tag as being the tag identified on the permit must be confirmed to ensure security of the isolation while other activities are performed.

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2.3.6. Rate Control and Target Before the start of each month, a Monthly Target Letter is produced specifying the production target for the month taking into account any planned downtime for wells and facilities. The letter also sets the limits on the operating parameters for each well, based on well performance and fluid sample data collected during well tests. The information is used by reservoir management to advice operations on setting the rate from each well to achieve the target rate without compromising future reservoir performance.

2.3.7. Reservoir Management The purpose of reservoir management is to maximise recoverable reserves by optimising recovery strategies. To gain the necessary understanding of how the reservoir will behave under various drainage and development scenarios, a reservoir model and simulation is developed. The model is developed using structural data gained from the seismic information consolidated and adjusted where possible from core data retrieved from the appraisal and exploration wells in the development. Further adjustment to the model and simulation is provided through the appraisal well flow tests and good quality well test information collected throughout life of field. The reservoir model is used through out life of field in order to provide information to be in the design of well completions and enhanced recovery systems, and to identify the optimum operating parameters for each injection or production well which will maximise total fluid recovery. The Reservoir Management Plan forms part of the Field Development Plan and provides information with regard to the properties and characteristics of the reservoir structure and fluids in addition to guidelines on how the reservoir is to be managed throughout field life. A review of the Reservoir Management Plan is performed every three years to re-assess the performance of the reservoir and identify possible enhancements to prolong the economic life of the field and increase recoverable reserves.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 2.3.8. FIP - Field Management Proposal In-order to be able to improve the performance of operation it is necessary to continuously assess alternative approaches to the way we operate. The need for change is identified from analysis and review of the various reports, the advent of new technology and staff suggestions. Improvement projects are usually initiated for the following reasons: •

Increase facility throughput or output

•

Reduce maintenance/operation costs

•

Improve operability and maintenability

•

Fulfill HSE requirements

•

Upgrade facilities for new technology application

•

Upgrade facilities for meet revised standards

•

To satisfy product specification

Before any change can be made it is necessary to perform a feasibility study to ensure that the change will achieve the claims of the originator without compromising other aspects of the operation, safety or the environment. The results of the study is then presented to the Field Improvement Plan (FIP) panel, along with costs and implementation plan, for further review and approval to ensure technical and cost effective implementation.

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PURGING AND PRESTART-UP PREPARATIONS 3.1

Purging Prior to start-up of the plant, air in process equipment and piping is displaced with N2 to prevent build-up of explosive hydrocarbon-air mixtures on admitting process fluids. Nitrogen is to be supplied from the nitrogen bottle rack comprising of total 32 bottles (16 bottles on each rack). Air is displaced by N2 down to a concentration of 1 vol% of oxygen by repeated cycles of pressurizing to 36 psig (2.5 barg) and depressurizing to 3 psig (0.2 barg) with N2. Portable Gas Detector (Oxygen analyser) is used to verify and measure the oxygen content in the vessel or piping segment at the end of the depressuring phase of the purge cycle. It is recommended that the plant be purged out starting from the furthest point downstream and proceeding systematically to the end of the plant. Purging shall be done beginning at the furthest upstream point and allowing the purging medium to sweep through the system to the furthest downstream point to the vent lines. Purge gas shall be vented off at vent points provided; ensuring that air in blind ends and recycle lines is removed. The following steps shall be used as a guide. During maintenance period a special procedure shall be prepared for purging any item prior to introducing hydrocarbons into the equipment and pipeworks. 1. All level gauges and level switches on vessels and any other "valved in" devices on the vessels shall be open to the vessel during purging. 2. Keep all control valves open 3. Keep all SDVs and BDVs closed. 4. Open maintenance vent valve. 5. Close all drain valves. 6. Connect purge gas venting points, by hose if necessary, into well ventilated areas to prevent risk of N2 suffocation. 7. Start purging with nitrogen at the furthest upstream points. Nitrogen will start to replace air in the pipes, headers and space above the water level in the vessels. The air will escape through the open maintenance vent line.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 8. Close the maintenance vents and pressurise the system to about 36 psig (2.5 barg). Slowly depressurise to about 3 psig (0.2 barg) by opening the maintenance vent. 9. Repeat the above steps of pressurising and depressurising until the oxygen concentration in the system falls below 1% vol of oxygen. 10. Check oxygen concentration using portable gas detector. 11. After purging is complete, leave the system in a slightly pressurised state to prevent air ingress. 12. Restore all valves to their original position. 13. The system is now ready for introduction of hydrocarbon for start-up.

3.2.

Pre-start-up Preparations The following is a general pre-start-up status checklist that may be used to confirm platform readiness: 1. The fusible plug loop system, fire fighting and critical communication facilities within the platform and to the CCR on FPSO are operational. 2. Operation and maintenance staff have been trained and sufficiently equipped on daily operations and emergency response procedures. 3. Functional logic and shutdown loop checks on the PMCS and SIS have been completed and all control, monitoring loops at PMCS and local control panels are operational. 4. Manual and remote operated valves including instrument isolation valves are all set at their normal positions. 5. Hydrotest blinds have been removed or returned to their normal positions, vessels and lines drained freed of water. All spectacle blinds are in correct position and connections for future equipment and pipework are blind flanged. 6. All PSVs have been calibrated. All PSVs outlet isolation valves are locked open position and inlet isolation valves as per P&IDs. 7. All field devices e.g. instrument, controls and trips have been calibrated and their set points are correct as per P&IDs. 4. All check valves are installed correctly.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 5. ROs for all blowdown are installed correctly. 6. All interlocked logics are functional. 7. All SDVs are in the closed position. 8. All pre-commissioning activities and checks have been performed and appropriate hand over certificates signed off.

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INITIAL START-UP

4.1

Procedure for Initial Start-up 4.1.1

Flow Chart-Initial Start-up

Ensure topside facilities are prepared and ready to receive hydrocarbon (Commissioning activities completed, gaslift supply from FPSO is available and nitrogen purge in place.

Start diesel generator and energized the switch boards

Ensure that safety systems are energised

Install overrides where required and reset ESD (PMCS/SIS are energized through UPS) Establish N2 supply to instrument gas distribution Ensure all SDVs and BDVs are in correct position as per procedure Energized trace heating where required and start closed drain heater. Pressurise gaslift pipeline and gaslift header.

Ensure WHCP is operational. Establish gas supply from gaslift header to utility gas skid and isolate nitrogen from bottles

Start microturbines one by one and syncronise main power with DEG, stop DEG.

Prepare first well for start up

Prepare FPSO for receiving TPDP-A fluids

Open first well to pressurize the facilities, if pressure is low start multiphase pump

Start crude heater unit and PPD injection

Bring other wells on line and stabilize production

Remove overrides bypass

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Prepare first FPSO well forfor receiving start upPLDP-A fluids

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Detailed Procedures of Initial Start-up Purpose: The procedure describes the initial start up of TPDP-A platform to prepare TPDP-A for production and the operation for the first oil after completion of commissioning activities with gaslift supply available from FPSO. Scope This document applies to all work carried out for the initial start up including personnel responsibilities and safety considerations. References Refer to the attached P&IDs and C&E in section 11 of this manual whilst carrying out this procedure.

4.1.2.1 Preparation for Initial Start-up Safety Radio communication shall be maintained between platform Wellhead Operators and the FPSO CCR at all times. Hot Work Permits shall be withdrawn immediately if any. Table 4.2.1-1: Plant Status before Initial Start-up

All SCSSVs

Closed

All SSVs

Closed

All SDVs

Closed

All BDVs

Open

DEG

Stopped

MTG

Stopped

Heaters

Stopped

Pumps

Stopped

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 4.1.2.2 Initial Start-up

For the initial start-up, it is assumed that the topside facilities are commissioned and ready to receive hydrocarbon and gaslift supply from FPSO is available. The commissioning activities are completed and the vent system is under nitrogen purge. All vents, drains and all supporting utility system are ready for operations. The initial start-up procedures are as follows: 1. Ensure pre-start-up preparations and purging as described in Section 3 has been completed. 2. Trips and interlocks will be over-ridden as necessary (start up overrides) to enable the start-up.

These overrides will be

removed (reset) as soon as the system pressures and other respective process parameters are established. Install overrides where required and reset ESD and ensure that the valves status is as follows: Table 4.1.2.2-1: Valves Status after Initial Start-up Valve

Location

Status

Remarks

SCSSV

Permissive at WHCP-0100

Closed

SSV


Closed

-

Nitrogen supply line

Open (Manual valves)

BDV-0401 Production header blowdown

Closed

BDV-0620 Gaslift header blowdown

Closed

BDV-5800 Utility gas system blowdown

Closed

SDVFuel gas to microturbine 7700/7710 SDV-1310 Export pipeline

Closed

SDV-0610 Gaslift supply to gaslift header

Closed

SDVUtility gas from gaslift header to 5811,5812 conditioning system

Closed - manual reset required

SDV-0111 Gaslift to individual wells to 0141

Closed

XV-6510

Closed

Open - manual reset required

UG to Open Drain Pump P-6510

SDVFuel gas to FWS heater unit 1510A and 1510B P5173B-PR-MAN-1001

Closed (Within vendor package)

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Within vendor package

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL HCV-0110 FWS Choke Valve to 0140

Closed (Manual valves)

HCV-0601 Gaslift flowline Choke Valve to 0604

Closed (Manual valves)

SDV-5820 Instrument/Utility/Fuel gas scrubber bottom valve

Closed

3. Start DEG and energise the switch boards. Ensure that the fusible plug loop is energised. 4.

Confirm power is available and safe to power up UPS (battery bank charged).

5. Energise the UPS system. 6. Energise all vital electrical loads, Telecoms and Instrument system (SIS, PMCS and FGS etc.) 7. Bypass Fire and Gas interlocks. 8. Open manual valves on the instrument/utility gas header in order to pressurise the instrument/utility gas header with nitrogen (supplied from nitrogen bottles). The isolation valve on the instrument/utility gas header upstream of the nitrogen tapping should remain closed. 9. Ensure WHCP is operational. 10. Energise the heat tracing where required and the closed drain heater (assuming the closed drain is pre-filled with diesel prior to start-up). 11. Pressurise gaslift pipeline and gaslift header with gaslift from FPSO via SDV-0610. Before opening the gas lift pipeline SDV against a high delta P, the downstream section between the SDV and the manual ball valve to be pressurized with high pressure nitrogen. Then open gaslift pipeline riser valve (SDV) and slowly pressurize the downstream system via the manual globe valve provided across the manual ball valve. 12. Open SDV-5811 and SDV-5812 to charge the Instrument/Utility/Fuel gas treatment package. Start the preheaters E-5810A and B. Control the pressure through the PCVs-5820A/B; open the SDV-5820 with LCV-5820 in closed position and in auto mode. Take the instrument/utility gas to the header and stop nitrogen from the bottles. 13. Start one unit microturbine using fuel gas from instrument gas system based on the vendor start-up procedures.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 14. Start the second unit of microturbine and auto synchronise with the first one. 15. Synchronise main power with diesel generator, transfer loads to microturbine. Open the diesel generator’s breaker and stop diesel generator once both microturbines are synchronized and stabilized. 16. Ensure hydraulic reservoir accumulator of the WHCP is pressurised. 17. Prepare and line up wells for start up. Ensure that low low pressures on the flowlines for the respective wells are overridden. 18. Prepare and line up FPSO for receiving TPDP-A fluids. 19. Inform the FPSO operators that production is about to commence. 20. Introduce gaslift into the wellhead annulus. 21. Open SCSSV and SSV. SCSSVs are self equalising type. In the event SCSSV fails to self equalise, start diesel injection upstream of manual choke valve while keeping the downstream double isolation valves on the flowline closed. This is to prevent the downstream low rating system (600#) being pressurised to a higher than design pressure. 22. Slowly open the choke valve for the first well to pressurise the platform and commence production. 23. If the FTHP is lower (year 2011 onwards), then start the multiphase pump based on the start-up procedures given by the vendor. If the available FTHP is adequate to transfer the FWS to FPSO, then bypass the multiphase pump. 24. Start the FWS crude heater unit based on the start-up procedures given by the vendor. 25. Select the duty PPD Injection Pump and start PPD injection. 26. Prepare and bring the other wells on stream to build up production. 27. Bring the FWS MPFM on line. 28. Line up the utility gas to the open drain pump. 29. Ensure one CO2 bottle is in line. 30. Remove start-up overrides when production is stabilised. 31. Ensure all the interlocks are in line. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 32. On leaving the TPDP-A Platform, the personnel must ensure that the Hand/Off/Auto Selector Switch on pumps is changed to AUTO.

5.0

SUBSQUENT START-UPS TPDP-A shutdown logic comprises of the following main levels of shutdown, arranged in an order of hierarchy. The higher levels will take precedence and enforce lower levels of shutdown. •

Emergency Shutdown with blowdown (ESD)

•

Emergency Shutdown without blowdown (ESD)

•

Process Shutdown (PSD)

•

Unit Shutdown (USD)

There is no automatic (direct) shutdown interface between new FPSO and TPDP-A. All trips initiated due to upset of the new FPSO facilities will have no automatic (direct) executive action on TPDP-A. Similarly any trip on the TPDP-A platform will have no automatic (direct) executive action on the new FPSO. In the event of ESD or PSD on the new FPSO, manual initiation of PSD on TPDP-A from soft key push button at FPSO HMl is required. This section covers the procedures for subsequent start-up following platform shutdown. However, during SIPROD mode all the PSDs and USDs as indicated in the C&E matrix are converted to ESD with blowdown.

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5.1

Procedure for Start-up following – ESD (with blowdown)

5.1.1

Flow Chart-after ESD-F/G

Start nitrogen purge to the vent system and any other system if required. Investigate the cause of ESD-F/G.



Start pipeline diesel injection pump for gel breaking, if required.

Install overrides where required and reset ESD-F/G (PMCS/SIS are energized through UPS) Establish N2 supply to instrument gas distribution Ensure all SDVs and BDVs are in correct position as per procedure Energized trace heating where required and start closed drain heater. Pressurise gaslift pipeline and gaslift header.









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Prepare first FPSO well forfor receiving start upPLDP-A fluids

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Detailed Procedures for Start-up after ESD-F/G TPDP-A ESD-F/G is initiated by the

following: •

Fire detection by fusible plugs (for equipments), detectors (for MTG)

•

Gas detection by IR detectors (for process area), open path type (for Wellhead area)

•

Manual ESD break glass on TPDP-A

•

Manual ESD and blowdown push button at OPS

•

Remote ESD and blowdown soft key push button on FPSO HMI

Upon activation of an ESD-F/G, all the well SCSSVs/SSVs and all platform SDVs will close. BDVs will open automatically to depressurise the facility. Re-start following ESD-F/G can only be done locally with operator visit to TPDP-A. Purpose The procedure describes the start-up of TPDP-A following an ESD-F/G (with blowdown) with gaslift supply available from FPSO. Scope This document applies to all work carried out following an ESD-F/G including personnel responsibilities and safety considerations. Reference Refer to the P&IDs and C&E in section 11 of this manual whilst carrying out this procedure. 5.1.2.1 Preparation for Start-up Safety Radio communication shall be maintained between platform Wellhead Operator and the FPSO's CCR at all times. Hot Work Permits shall be withdrawn immediately if any.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Task/Activity Response following an ESD-F/G shutdown: 1. The FPSO CCR shall be informed of the cause of the ESD-F/G. 2. The reason for the ESD-F/G shall be investigated. Table 5.1.2.1-1: Plant Status following an ESD-F/G All SCSSVs

Closed

All SSVs

Closed

All SDVs

Closed

All BDVs

Open

DEG

-

MTG

Tripped

Heaters

Stopped

Pumps

Stopped

5.1.2.2 Start-up Operation Operator visit to the platform is required to investigate and rectify the cause of ESD-F/G. Since ESD-F/G results in depressurisation of process and utility systems, nitrogen purge is required to displace air in the hydrocarbon system prior to platform startup. Warnings: 1. Restart after ESD-F/G can only be performed locally at TPDP-A. 2. Diesel injection into the FWS export pipeline prior to start-up is required to help de-gelling of any wax formed if the shutdown is for longer period. Once the cause of the ESD-F/G has been established and it is safe to do so (Field Superintendent shall advise), the platform shall be started in the following manner: 1. Ensure pre-start-up preparations and purging as described in Section 3 has been completed. 2. Ensure vents, drains and supporting utility systems are ready for operation. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 3. Install overrides where required and reset ESD-F/G and ensure that the valves status are as follows: Table 5.1.2.2-1: Valve Status after ESD-F/G Start-up

Valve

Location

Status

SCSSV


Closed

SSV


Closed

-


Open

Remarks

Manual valves


Closed


Closed


Closed


Closed


Closed




Closed

XV-6510


Closed

XV-XXXX

Fuel gas to Multiphase Pump gas engine Fuel gas to FWS heater unit

Closed


Within vendor package Within vendor package

SDV1510A and 1510B HCV-0110 FWS Choke Valve to 0140

Closed Closed

Manual valves


Closed

Manual valves


Closed

The start-up sequence after the ESD-F/G is same as that described in the section 4.1.2 for the initial start-up. Additionally, the diesel injection may be required for the FWS pipeline for the gel breaking if the shutdown is for longer period.

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Procedure for Start-up following – ESD (without blowdown) 5.2.1

Flow Chart – ESD (without blowdown) Investigate and rectify the cause of ESD-Without Blowdown.



Start pipeline diesel injection pump for gel breaking, if required.

Install overrides where required and reset ESD (PMCS/SIS are energized through UPS)

Ensure all SDVs and BDVs are in correct position as per procedure Energized trace heating where required and start closed drain heater. Pressurise gaslift pipeline and gaslift header.









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Detailed Procedures for Start-up after ESD (without blowdown) TPDP-A ESD without blowdown is initiated by the following: •

Manual ESD push button at OPS.

•

Manual ESD push button at WHCP (Subsurface Shutdown)

•

Remote ESD soft key push button on FPSO HMI.

Upon activation of an ESD all the well SCSSVs/SSVs and all platform SDVs will close. However, the BDVs will not open automatically to depressurise the facility. Re-start following ESD can only be done locally with operator visit to TPDP-A. Purpose The procedure describes the start-up of TPDP-A following an ESD with gaslift supply available from FPSO. Scope This document applies to all work carried out following an ESD including personnel responsibilities and safety considerations. Reference Refer to the P&IDs and C&E in section 11 of this manual whilst carrying out this procedure.

5.2.2.1 Preparation for Start-up Safety Radio communication shall be maintained between platform Wellhead Operator and the FPSO's CCR at all times. Hot Work Permits shall be withdrawn immediately if any. Task/Activity Response following an ESD shutdown: 3. The FPSO CCR shall be informed of the cause of the ESD. 4. The reason for the ESD shall be investigated.

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Table 5.2.2.1-1: Plant Status following an ESD without blowdown All SCSSVs

Closed

All SSVs

Closed

All SDVs

Closed

All BDVs

Closed

DEG

-

MTG

Tripped

Heaters

Stopped

Pumps

Stopped

5.2.2.2 Start-up Operation Operator visit to the platform is required to investigate and rectify the cause of ESD. Since ESD DOES NOT result in depressurisation of process and utility systems, nitrogen purge is NOT required prior to platform start-up. The vent system is continuously purged with nitrogen from nitrogen bottles. Warnings: 1. Restart after ESD can only be performed locally at TPDP-A. 2. Diesel injection into the FWS export pipeline prior to start-up is required to help de-gelling of any wax formed if the shutdown is for longer period. Once the cause of the ESD has been established and it is safe to do so (Field Superintendent shall advise), the platform shall be started in the following manner: 1. Ensure vents, drains and supporting utility systems are ready for operation. 2. Install overrides where required and reset ESD-F/G and ensure that the valves status are as follows:

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Table 5.2.2.2-1: Valve Status after ESD Start-up

Valve

Location

Status

SCSSV


Closed

SSV


Closed

-


Closed

Remarks

Manual valves


Closed


Closed


Closed


Closed


Closed




Closed

XV-6510


Closed

XV-XXXX


Closed




Closed Closed

Manual valves


Closed

Manual valves


Closed

The start-up sequence after the ESD is same as that described in the section 4.2.2 for the initial start-up. Additionally, the diesel injection may be required for the FWS pipeline for the gel breaking if the shutdown is for longer period. As there is no automatic depressurisation of the system, the start-up override for the flowline line low low pressure will not be required to perform.

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5.3

Procedure for Start-up following – PSD 5.3.1

Flow Chart – PSD Investigate and rectify the cause of PSD.



Install overrides where required and reset PSD (PMCS/SIS are energized through UPS)

Ensure all SDVs and BDVs are in correct position as per procedure Energized trace heating where required and start closed drain heater. Pressurise gaslift pipeline and gaslift header.








Remove overrides bypass P5173B-PR-MAN-1001

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5.3.2

Detailed Procedures for Start-up after PSD. TPDP-A PSD is initiated by the following: •

Manual PSD push button at OPS.

•

Manual PSD push button at WHCP (Surface Shutdown)

•

Remote PSD soft key push button on FPSO HMI.

•

FWS pipeline HH and LL pressure

•

Gaslift pipeline HH and LL pressure

•

Instrument gas supply pressure low low

•

Instrument gas scrubber pressure low low

•

Instrument gas preheater outlet temperature low low

•

Closed drain vessel level high high

•

Multiphase pump discharge pressure HH and LL

Upon activation of a PSD all the well SSVs and all platform SDVs will close. However, the BDVs will not open automatically to depressurise the facility. Re-start following PSD can be done locally with operator visit to TPDP-A. However, a remote reset is provided for the two pipelines HH and LL pressure scenario as these are likely to be triggered by the FPSO cause.

Purpose The procedure describes the start-up of TPDP-A following a PSD with gaslift supply available from FPSO. Scope This document applies to all work carried out following a PSD including personnel responsibilities and safety considerations.

Reference Refer to the P&IDs and C&E in section 11 of this manual whilst carrying out this procedure.

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5.3.2.1 Preparation for Start-up Safety Radio communication shall be maintained between platform Wellhead Operator and the FPSO's CCR at all times. Hot Work Permits shall be withdrawn immediately if any. Task/Activity Response following a PSD shutdown: 1. The FPSO CCR shall be informed of the cause of the PSD if it is initiated locally at TPDP-A. 2. The reason for the PSD shall be investigated. Table 5.3.2.1-1: Plant Status following an PSD All SCSSVs

Open

All SSVs

Closed

All SDVs

Closed

All BDVs

Closed

DEG

-

MTG

Tripped

Heaters

Stopped

Pumps

Stopped

5.3.2.2 Start-up Operation Operator visit to the platform is required to investigate and rectify the cause of PSD. Since PSD DOES NOT result in depressurisation of process and utility systems, nitrogen purge is NOT required prior to platform start-up. The vent system is continuously purged with nitrogen from nitrogen bottles.

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Warnings: 1. Restart after PSD can only be performed locally at TPDP-A except for the two pipelines HH and LL pressure scenario as these are likely to be triggered by the FPSO cause. 2. Diesel injection into the FWS export pipeline prior to start-up is required to help de-gelling of any wax formed if the shutdown is for longer period.

Once the cause of the PSD has been established and it is safe to do so (Field Superintendent shall advise), the platform shall be started in the following manner: 1. Ensure vents, drains and supporting utility systems are ready for operation. 2. Install overrides where required and reset PSD and ensure that the valves status are as follows:

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Table 5.3.2.2-1: Valve Status after PSD Start-up

Valve

Location

Status

SCSSV


Open

SSV


Closed

-


Closed

Remarks

Manual valves


Closed


Closed


Closed


Closed


Closed




Closed

XV-6510


Closed

XV-XXXX


Closed




Closed Closed

Manual valves


Closed

Manual valves


Closed

The start-up sequence after the PSD is same as that described in the section 4.2.2 for the initial start-up. Additionally, the diesel injection may be required for the FWS pipeline for the gel breaking if the shutdown is for longer period. As there is no automatic depressurisation of the system, the start-up override for the flowline line low low pressure will not be required to perform.

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Procedure for Start-up following – USD 5.4.1

Flow Chart - USD The USD will be initiated due to the causes related to the particular unit. The details are available on the C&E matrix. Investigate and rectify the cause of USD.

Inform FPSO operator station that the affected system is ready to start

Install overrides where required and reset USD

Restart the affected system Ensure production is satisfactory Remove shutdown bypass

5.4.2

Procedure for Start-up The following systems are affected by the USD: •

individual wellheads and flowlines

•

closed drain system

•

utility gas conditioning/distribution system

•

Crude heater unit

•

power generation system - microturbine

•

chemical injection system

The restarts of the sections above are described in section 6 and 7 of this manual.

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5.5

Procedure for Start-up SIPROD Operation 5.5.1

Flow Chart – SIPROD Operation

Ensure vents, drains and supporting utility systems are ready for SIPROD operation.

Install overrides where required and reset ESD (PMCS/SIS are energized through UPS. The power supply is from the drilling rig) Establish compressed air supply from the rig to instrument/utility gas distribution headers Ensure all SDVs and BDVs are in correct position as per procedure Energized trace heating where required and start closed drain heater. Pressurise gaslift pipeline and gaslift header.

Ensure WHCP is operational. Establish gas supply from gaslift header to utility gas skid. Get the fuel gas for multiphase pump, crude heater unit and vent system purge



Open first well to pressurize the facilities, if pressure is low start multiphase pump Start crude heater unit and PPD injection



5.5.2

Detailed Start-up procedure During SIPROD, through Normal/SIPROD mode selector key switch, all USD, PSD and ESD (without blowdown) causes will converted to result in platform ESD-with blowdown except for the following USDs: •

Hydraulic reservoir # 1/2 level low low

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WHCP common hydraulic pressure low low

•

Individual SCSSV hydraulic supply pressure low low

•

Individual SSV hydraulic supply pressure low low

•

Instrument gas preheater E-5810A/B element temperature high high

•

Instrument gas preheater E-5810A/B outlet temperature high high

•

Instrument gas scrubber level low low

•

Closed Drain Vessel liquid level low low

•

Closed Drain Vessel temperature high high and low low

•

Closed Drain Vessel heater element temperature high high

•

Glycol expansion tank level low low (part of crude heater unit) The following are changes to TPDP-A operating philosophy during SIPROD:

•

Both MTG and DEG will be positively isolated as power is supplied by the drilling rig.

•

The Gas Conditioning System will supply fuel gas to multiphase pump gas engine and the crude heater unit.

Compressed air from the

drilling rig will be used instead for instrument and utility air users. •

The Open Drain System is provided with swing spool to allow switching to overboard disposal.

Purpose The procedure describes the start up of TPDP-A platform during Simultaneous Drilling and Production (SIPROD) operations. Scope This document applies to all work carried out for start up for SIPROD operation including personnel responsibilities and safety considerations. Reference Refer to the P&IDs and C&E in section 11 of this manual whilst carrying out this procedure.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 5.5.2.1. Preparation for Start-up Safety Radio communication shall be maintained between platform Wellhead Operators and the FPSO's CCR at all times. Hot Work Permits shall be withdrawn immediately if any. Plant status following a shutdown during SIPROD mode is shown as below: Table 5.5.2.1-1: Plant Status All SCSSVs

Closed

All SSVs

Closed

All SDVs

Closed

All BDVs

Open

DEG

-

MTG

-

Heaters

Stopped

Pumps

Stopped

5.5.2.2 Start-up Operation It is assumed that platform has been converted to SIPROD mode i.e. vents, drain, instrument air system etc as per SIPROD requirement. Once the instrument/utility gas header is ready for operation with compressed air, the platform shall be started in the following manner: 1. Ensure vents, drains and supporting utility systems are ready for operation. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 1. Install overrides where required and reset ESD. Ensure that the valves status are as follows:

Table 5.5.2.2-2: Valve Status after Start-up during SIPROD

Valve

Location

Status

SCSSV


Closed

SSV


Closed

-


Closed

Remarks

Manual valves


Closed


Closed


Closed


Closed


Closed




Closed

XV-6510


Closed

XV-XXXX


Closed




Closed Closed

Manual valves


Closed

Manual valves


Closed

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 2. Connect power feeder from drilling rig and energised switch boards. Ensure that the fusible plug loop is energised. 3.

Confirm power is available and safe to power up UPS (battery

bank charged). 4. Energise the UPS system. 5. Energise all vital electrical loads, Telecoms and Instrument system (SIS, PMCS and FGS etc.) 6. Bypass Fire and Gas interlocks. 7. Establish compressed air supply from Drilling rig to "instrument/utility gas header for distribution. The isolation valves on the instrument/utility gas header upstream of the air tapping shall remain closed and the spool dropped. 8. Ensure WHCP is operational. 9. Energise the heat tracing where required and the closed drain heater (assuming the closed drain is pre-filled with diesel prior to start-up). 10. Pressurise gaslift pipeline and gaslift header with gaslift from FPSO via SDV-0610. Before opening the gas lift pipeline SDV against a high delta P, the downstream section between the SDV and the manual ball valve to be pressurized with high pressure nitrogen. Then open gaslift pipeline riser valve (SDV) and slowly pressurize the downstream system via the manual globe valve provided across the manual ball valve. 11. Open SDV-5810 A and B to charge the Instrument/Utility/Fuel gas treatment package. Start the preheaters E-5810A and B. Control the pressure through the PCVs-5820A/B; open the SDV-5820 with LCV5820 in closed position and in auto mode. Take the instrument/utility/Fuel gas to the header for distribution as fuel gas and vent purge gas. 12. Ensure hydraulic reservoir accumulator of the WHCP is pressurised. 13. Prepare and line up wells for start up. Ensure that low low pressures on the flowlines for the respective wells are overridden. 14. Prepare and line up FPSO for receiving TPDP-A fluids. 15. Inform the FPSO operators that production is about to commence. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 16. Introduce gaslift into the wellhead annulus. 17. Open SCSSV and SSV. SCSSVs are self equalising type. In the event SCSSV fails to self equalise, start diesel injection upstream of manual choke valve while keeping the downstream double isolation valves on the flowline closed. This is to prevent the downstream low rating system (600#) being pressurised to a higher than design pressure. 18. Slowly open the choke valve for the first well to pressurise the platform and commence production. 19. If the FTHP is lower (year 2011 onwards), then start the multiphase pump based on the start-up procedures given by the vendor. If the available FTHP is adequate to transfer the FWS to FPSO, then bypass the multiphase pump. 20. Start the FWS crude heater unit based on the start-up procedures given by the vendor. 21. Select the duty PPD Injection pump and start PPD injection. 22. Prepare and bring the other wells on stream to build up production. 23. Bring the FWS MPFM on line. 24. Line up the compressed air to the open drain pump. 25. Ensure one CO2 bottle is in line. 26. Remove start-up overrides when production is stabilised. 27. Ensure all the interlocks are in line. 28. On leaving the TPDP-A Platform, the personnel must ensure that the Hand/Off/Auto Selector Switch on pumps is changed to AUTO.

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5.6

Changeover Procedure: LOCAL-REMOTE and REMOTE-LOCAL Operation Mode Whenever the operation personnel are on the TPDP-A platform, the changeover from REMOTE to LOCAL operation mode is required and shall be via hardwired selector switch on the Annunciator Panel mounted on the integrated SIS/PMCS/FGS cabinet door (at TPDP-A). The changeover from LOCAL to REMOTE, on the other hand, is required whenever the operation personnel are leaving the TPDP-A platform and to enable the REMOTE Operation mode that is to remotely startup and reset the TPDP-A platform following a PSD as applicable. Remote operation is not permitted following an ESD-F/G and ESD as personnel visit is required. 5.6.1. Changeover Procedure from REMOTE to LOCAL Operation Mode 1. Manually reset the SSV at WHCP-0100 at one time for all wells 2. Press the PSD (WHCP) Closed button at PMCS HMI (FPSO) 3. Press the PSD (PMCS) Closed button at PMCS HMI (FPSO) 4. Turn the hardwired selector switch at Annunciator Panel to LOCAL

5.6.2. Changeover Procedure from LOCAL to REMOTE Mode 1. Turn the hardwired selector switch at Annunciator Panel to REMOTE (at TPDP-A) 2. Press the PSD Softkey Reset at OWS(FPSO) 3. Manually close the SSV at WHCP-0100 one at a time for all wells

5.7 Trouble Shooting Should the TPDP-A platform fail to re-start remotely following a PSD as explained in section 5.3, the potential cause are as listed below: 1. Failure to re-set the particular PSD. 2. Loss of communication between the TPDP-A Platform and FPSO. 3. Failure of the particular field device at TPDP-A Platform. 4. Failure of the particular solenoid valve/instrument at TPDP-A Platform. 5. Failure of the telecommunication equipment. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 6. Failure of the related integrated SIS/PMCS system at TPDP-A Platform

Below is the list of actions required to rectify the problem: 1. Make sure the PSD condition is made healthy (remote reset soft key available on FPSO). 2. Reset the communication system at PMCS HMI and if necessary check the radio antenna alignment between TPDP-A Platform and FPSO. If the problem persists, refer to integrated SIS/PMCS and telecommunication systems operating and maintenance manuals. 3. Manually verify the condition of the field devices at TPDP-A. 4. Manually verify the condition of the instruments at TPDP-A. 5. Replace the affected I/O modules using the spare modules. 6. Reset the integrated SIS/PMCS system. If the problem persists contact the vendor for further assistance.

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6.0 PROCESS SYSTEMS OPERATING PROCEDURES 6.1

Wells, Flowlines and Headers

6.1.1. System Description 6.1.1.1. Introduction Reservoir fluids are produced from the selected formation through the well-tubing and completion equipment to the wellhead. The wellhead constitutes as the surface termination of a well bore and provides the support for the well completion and interface with the Christmas tree. The tree connects each well to the individual flow line through a choke valve for flow control. The Christmas tree provides surface flow control and containment of the well fluids production as well as the access for well servicing. TPDP-A is designed for single completion Christmas tree. The well conductor slots are arranged in triangular pitch. Initially, 4 slots will be installed and the other 2 slots are for future.

6.1.1.2. Well Completion TPDP-A is a drilling platform with 6 conductor slots, 4 installed and 2 planned for future. Each contains a single completion FWS production well with gaslift. The well completion use 3-1/2” production tubing and the conductor is 26”.

6.1.1.3. Christmas Tree The TPDP-A wellheads are rated for API 5000. Each tree is mounted on the tubing hanger assembly such that the bores in the tree line up with the tubing strings and held in place by a two part circumferential clamps (PCVL to confirm). Control of the SCSSV and SSV is from the Wellhead Control Panel (WHCP). The flowrate from each production string is set by manual choke valve on the outlet of the tree. The maximum well Closed-in Tubing Head Pressure (CITHP) is 2015 psig. Based on the available data, the maximum Flowing Tubing Head Pressure (FTHP) is 429 psig and maximum Flowing Tubing Head Temperature (FTHT) is 47.2 °C.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL The TPDP-A FWS is waxy with the pour point of 30°C and cloud point of 48.95°C.

6.1.1.4. Well Flowlines From the wells the fluids flow into the 80 mm production flowlines via the manual choke valve on the outlet of the wing valve. Each flow line can be routed to either the production or test header using the respective manual block valves. On each flowline there is a sand probe switch at min 1 m distance from the choke valve, which provides the indication of sand production in the well fluids on the WHCP. Each flowline has a non return valve at the downstream of choke valve to prevent the reverse flow from other flowlines. Protection against high pressure in the flowline is by the high high pressure trip, PZAHH which will close the SSV for the associated well through WHCP-0100 if pressure exceeds 1227 psig. The ultimate protection is provided by means of 2x100% PSVs. If the line ruptures or the well fails, the low low pilot, PZALL will close the SSV on the associated well through WHCP-0100 when the pressure falls below 44 psig. An override is provided at the control panel on the low low pressure trip for startup.

6.1.1.5. Production and Test Headers Each flow line connects to the test and production header through double block and bleed valves, so that fluids can be either routed to the test or the production header. The production header enables fluids from the other wells to be commingled. FWS is exported to new FPSO via a 10" FWS pipeline. Fluids from a flowline can be diverted to the test header for well testing via the multiphase flow meter A-1210. 6.1.1.6. Casing Blowdown Facility Should the pressure of the well annulus become excessively high the pressure can be bleed off to an acceptable level using the casing P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL blowdown facility. PCVL's current practice is to bleed off the casing pressure regularly when the casing pressure exceeds 500 psig (HOLDPCVL to confirm). The blowdown connection on the tree is connected to the casing blowdown header. With the casing blowdown choke valve on the tree opened, flow from the casing is limited through this valve into the vent header to ensure that gas vented is below the vent system design flowrate of 4 MMSCFD.

6.1.1.7. Wellhead Control Panel Control of the SSV and SCSSV on each well and the hydraulic suppliers are provided by the wellhead control panel WHCP-0100. In the control panel, a hydraulic power pack supplies the pressure to open SSVs and SCSSVs. The hydraulic oil reservoirs are located on the top of the panel. Pressure indicators for the hydraulic and instrument gas supplies and components for control of logic are located on the panel. The WHCP operates as a hydraulic interface between the SIS and the wellhead actuated valves. The solenoid valve provides the pneumatic and electric signals for the overall control of the SSVs and SCSSVs responding to signals from the ESD and PSD in integrated SIS/PMCS system. 6.1.1.8. Hydraulic Power Pack Hydraulic oil is stored in the reservoir in WHCP. The reservoir is divided into, two compartments to provide two separate supplies to the section of the pumps and to the well control modules. There is a low level transmitter, LZA-0001 and LZA-0002 in each compartment of the tank which provides a signal to the SIS logic to close the SSVs and SCSSVs should the level in the tank reach the low limit. Hydraulic pressure for the manual operation of SCSSVs is provided by individual pneumatically operated pumps in each Well Control Module. A pneumatically operated pump equipped with a manual operator is provided as back-up hydraulic supply for the SCSSV during start-up. The back up (manual) and main SCSSV hydraulic supply pump are protected against over pressure by individual relief valves, and relieving P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL back to the tank. The pressure in the supply is indicated on a gauge inside the panel. Hydraulic fluid to operate the SSVs is provided by two primary pneumatically operated pumps equipped with manual operators. Capacity of each of the loops is provided by a pre-charged accumulator on the pump discharge. The accumulator avoids the need to wait for the pressure to recover after the operation of each SSV fed from the supply. The accumulator located on each SSV hydraulic header supplies the stored hydraulic pressure to open and close any one well for two cycles. In order to function as described above, the accumulator requires to be charged with nitrogen. The output from each pump is fed to a dedicated manifold which directs the supply to the well modules, such that half of the modules are fed from one supply. SSV supply pressure 1 and supply pressure 2 are indicated on front of the panel. Each SSV hydraulic supply pump is protected against over pressure by a relief valve, and relieving back to the tank. All hydraulic returns are piped back to the respective hydraulic oil reservoir.

6.1.1.9. Control Logic The integrated SIS/PMCS system performs the sequencing and permissive logic required for the SSVs and SCSSVs in response to open/close commands received from the PMCS HMI or within the SIS process shutdown logic. The SIS logic provides the electrical control signals to the well control modules to enable the individual SSV and SCSSV to be opened. Loss of signals results on closure of all SCSSVs as a result of an ESD-F/G and all SSVs following an ESD / PSD. Closure of all SSVs and all SCSSVs can also be initiated from WHCP on the basic sections using pushbuttons on the front panel. Individual pushbutton to close each SSV and SCSSV are provided on each of the well control module. The WHCP via the integrated SIS/PMCS system also has the facility to remotely reset a PSD (as per section 5.3) from the FPSO by energising the solenoid valve. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 6.1.1.10. Well Module Logic The well control modules are identical and interchangeable. Well control modules logic is implemented in the integrated SIS/PMCS system. Each module has the following supply connections: •

ESD-F/G electric signal to SCSSV solenoid valve

•

PSD electric signal to SSV solenoid valve

•

Hydraulic supply for SCSSV pump

•

SSV hydraulic supply

•

Manual SCSSV pump supply

•

Utility gas supply for SSV and SCSSV pump

The logic implemented in the integrated SIS/PMCS for the module enables the two valves to be opened in the correct sequence, SCSSV followed by SSV, when the ESD and PSD permissive signals are present. The logic initiates the closure of one or both of the valves on loss of the permissive and high or low pressure or low reservoir level. The SCSSV is normally opened by pressure created by the pump. When the SCSSV permissive is pressurised, following ESD reset, the open sequence is initiated to provide the control gas to the pump control logic. The control gas signal is fed to two flow control valves, both able to feed utility gas to the pump through the separate regulators, set to give the required pump output pressures respectively. On opening of the SCSSV, automatic two-stage pressurisation is provided. Initial pressurisation shall be to the equalising pressure of the SCSSV. This pressure will be increased to the full operating pressure after an adjustable time delay of 5 to 7 minutes. The time delay between automatic initiations of SCSSV closure following initiation of SSV closure is adjustable for each string over a range of 15 to 120 seconds. Individual SSV and SCSSV can be remotely opened and closed by energising and de-energising solenoid valve via the integrated SIS/PMCS from the FPSO Remote Operator Station. Remote manual closing of all SSVs and SCSSVs can be initiated from FPSO.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 6.1.2. Well Start-up Procedure Reference Refer to the following P&IDs whilst carrying out this procedure. TPDP-A-B-1100

Wellhead and Flowline (Single Completion)

TPDP-A-B-1102

Production and Test Headers

TPDP-A-B-1103

Gaslift Header

TPDP-A-B-1106

FWS Launcher

TPDP-A-B-1108

Gaslift Receiver

Plant Status 1. All the pre-start checks have been performed as described in section 3 of this manual. 2. Ensure that any ESD and PSD trips are reset. 3. The vents, drains and all other utility systems are prepared for the operation. 4. Gaslift system is ready and the utility gas is available from the gaslift system. 5. Power supply is available from MTG for energising integrated SIS/PMCS system. 6. FPSO is ready to receive well fluids from TPDP-A. 7. Power up and line up the WHCP and instrument to the well being startup. 8. Override the low pressure instruments. •

PZALL-0110 to 0140 (at flowlines, downstream of choke valve

HCV0110 to 0140). •

PZALL-1310 (FWS export pipeline)

10. Valves are position as shown in the start-up valve checklist.

6.1.2.1. Valve Checklist Note that the valve numbering here is for well string WH-0110. For other wells, their respective valve numbering applies.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Table 6.1.2.1-1: Valve Checklist Valve Number

Location/Service

Status

SCSSV-0110

Sub surface safety valve

Closed

SSV-0110

Surface safety valve

Closed

HCV-0110

Production choke valve

Closed

_

Wing valve

Closed

VB-04001

Isolation valve to production header

Closed

VB-04003

Isolation valve to production header

Closed

VG-04002

Bleed valve to production header

Closed

VB-04004

Isolation valve to test header

Closed

VB-04006

Isolation valve to test header

Closed

VG-04005

Bleed valve to test header

Closed

VB-04007, 04009

Flowline drain valves

Closed

Start-up valves positions of production and test headers are as follows: Table 6.1.2.1-2: Start-up Valve Checklist Valve Number

Location/Service

SDV-1310

Isolation valve on the production header Open to the export pipeline

SDV-0610

Isolation valve on the gaslift line from new FPSO

Open

SDV-0111

Gaslift to W-0110

Open

HCV-0601

Gaslift choke valve to W-0110

Closed

VB-04140 and 04141

Isolation valves downstream of HCV

Open

-


Closed

BDV-0401/0620/5800

Blowdown valves

Closed

SDV-5811 and 5812

Isolation valve in the UG supply line from Open gaslift header

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Status

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL VB-04061 and 04063, VB-64058 VB-04064 and 04066

Well unloading line

Closed

Test Multiphase Flow Meter inlet isolation valves

Closed

VG-04065

Test Multiphase Flow Meter inlet bleed valve

Closed

VB-04067 and 04070

Test Multiphase Flow Meter outlet isolation valves

Closed

VG-04069

Test Multiphase Flow Meter outlet bleed Closed valve

VB-62027 and 62026

Test Multiphase Flow Meter vent valve

VB-64022 and 64024

Test Multiphase Flow Meter drain valves Closed

VB-04079 and 04081

FWS Flow Meter inlet isolation valves

Open

VG-04080

FWS Flow Meter inlet bleed valve

Closed

VG-04082

FWS Flow Meter bypass valve

Closed

VB-04083 and 04086

FWS Flow Meter outlet isolation valves

Open

VG-04085

FWS Flow Meter outlet bleed valve

Closed

VB-64028 and 64039

FWS Flow Meter vent valves

Closed

VB-64019 and 64021

FWS Flow Meter drain valves

Closed

VB-04087

FWS export header

Open

VB-04088 and 04092

FWS Launcher L-1310 kicker line

Closed

VG-04091

Bleed valve at launcher kicker line

Closed

VB-13001 and 13002

FWS Launcher L-1310 outlet

Closed

VB-62003 and 62005

PSV-0111A and B outlet valve

Locked Open

VB-04097 and 04099

PSV-0111A inlet valve

Locked Open

VB-04100 and 04102

PSV-0111B inlet valve

Locked Closed

VB-04093

FWS Launcher L-1310 balance line

Closed

VB-620030 and 62031

Launcher manual depressufising line

Closed

VB-67025

Diesel injection line to export pipeline isolation valves

Closed

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 6.1.2.2. Starting up the First Well for the First Time This procedure assumes that well string W-0110 to be started first and gaslift from FPSO is available. The start-up procedure explained in section 4.1.2 to be followed.

6.1.2.3. Start-up the well following an ESD-F/G The procedure remains same as explained in section 5.1 above.

6.1.2.4. Start-up the well following an ESD The procedure remains same as explained in section 5.2 above.

6.1.2.5. Start-up the well following a PSD The procedure remains same as explained in section 5.3 above.

6.1.2.6. Start-up the well following a USD

Wellhead USD shuts in individual SSV and individual SDVs on the gas lift supply to the affected wells (2 nos). On the reservoir level low low even the SCSSV of the affected wells (2 nos) get closed. 1. Identify and rectify the cause of the USD. Reset PZALL, PZAHH or LZALL whichever that causes the USD. 2. Start production, by opening the respective gaslift SDV and SCSSV, SSV.

6.1.3

Shutdown of Well and Production Header This section provides the required procedure to manually shutdown the TPDPA production system for maintenance purposes. The procedure will cover the manual shutdown and blowdown of the topsides production system up to SDV1310. The procedure for manual shutdown and blowdown is as follows: 1. If down time is expected to be more than 5 hours, operator's intervention may be required to re-start the gelled pipeline. Diesel injection may be required to de gel the pipeline section before it can

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL be re-started. 2. Check that the vent and drain system is ready for operation. The Closed Drain Vessel has been drained and is ready to receive liquids from the production system. 3. Inform personnel in charge at FPSO that the system is ready to be shutdown and depressurised. 4. Close SDVs and HCVs on the gaslift flowlines to stop gaslift supply. 5. Close the choke valve HCVs on the well flowlines. 6. Close SSVs on the wellheads. 7. Close SCSSVs. 8. Stop multiphase pump and the crude heater unit. 9. Close SDV-1310 to isolate the FWS export pipeline. 10. Stop the microturbines. 11. Close SDV-0610 on the gaslift pipeline and stop the gas conditioning unit. 12. Start the DEG. 13. To depressurise the TPDP-topsides, manually open BDV-0401 and 0620 one by one (the hold up gas in the gas conditioning package can be utilized before depressuring that unit) or do it by opening the manual valves. If required nitrogen can be charged into the instrument gas header to operate the BDVs.

•

Slowly open valves on the test and FWS MPFMs to depressurise the test and production circuit. Similarly the manual vent from the multiphase pump can be utilized.

•

Slowly open valves vent valves on the gaslift flowlines to depressurise the system.

•

Slowly open the drain valves at the production header, test header, test and FWS MPFMs multiphase pumps and crude heater unit one by one to drain the liquid inventory into the closed drain vessel. This is required if the shutdown is envisaged for long duration.

14. Monitor the pressure in the flowlines, production header, test header and gaslift headers with the local pressure gauges. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 15. Transfer the closed drain vessel contents to the FWS pipeline by opening the SDV-1310. This is going to be small volume compared to the holdup volume in the pipeline and hence considered as safe with regards to the gelling issue in the pipeline. The remaining liquid from the closed drain vessel can be removed locally into drums.

6.1.4. Well Unloading Procedure Well unloading typically required for kicking off a weak well for which production rate is too low. The well unloading for a particular well can be performed while other wells are producing. The well kick-off operation must be fully attended. For the procedure detailed above, well W-0100 is used as an example. 1. Ensure that the drain and vent system is ready to receive well unloading fluids. If necessary, operate both the Closed Drain Transfer Pumps together to empty the contents of Closed Drain Vessel into the Production Header. 2. Check that SSV-0110, wing valve and choke valve, HCV-0110 are in closed position. 3. Install an override on PZALL-0110 to avoid a low pressure trip. 4. Ensure that valves on the production header are in closed position. 5. Close valves at the inlet of the test MPFM. 6. Line up the well to be unloaded to the closed drain vessel through the test header. 7. Open the wing valve and open SSV-0110 from WHCP. 8. Start the well unloading operation by slowly opening the choke valve using a manual hand wheel. Control the unloading rate and pressure downstream of the choke by controlling the choke opening. Monitor the level rise in closed drain vessel to ensure level does not reach LZAHH. 9. Monitor the level in the Closed Drain Vessel closely using LG-6400. Closed drain pump, P-6410A/B start on signals from LICA (H/L)-6400 to pump the liquids to the export pipeline. 10.Once well unloading is completed, switch production flow to P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL production header by opening the flowline isolation valves to production header and closing the isolation valves to test header. 11.Remove the override bypass around PZALL-0110. Well unloading during SIPROD mode will adopt the same procedure as above if the well cannot flow against the normal production pipeline pressure. 6.1.5

Well Casing Blowdown Procedure Each well casing is provided with a blowdown connection and a pressure gauge. The casing to be depressurized for any leakage pressure on a regular basis based on the plant practices.

6.2.

Well Testing 6.2.1. System Description 6.2.1.1. Introduction Well testing is normally required for measuring of well flow rates and determining other characteristics of gas, oil and water. This is performed once the production has stabilised or when unforeseen changes of well production parameters are noticed. Only one well is allowed to be tested at one time since the testing facilities are only designed for a single well flow rate. Multiphase flow meter (MPFM) is provided for the testing. Testing of the wells is carried out locally by opening associated isolation valves on the well strings to switch flow from production header to test header. The MPFM control unit is connected serially to the integrated SIS/PMCS for data transfer. The control unit is capable to calculate the individual phases flow rates, water cut, pressure, temperature, total flow rate and density etc.

6.2.1.2. Multiphase Flow Meter (MPFM) To collect well data, a multiphase flow meter is provided on the TPDP-A platform to enable the testing of individual wells without interrupting

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL production. Multiphase flow meter is installed downstream of the test header for well testing. The multiphase flow meter consists of the following components interconnected by system/signal cables: •

Field unit

The field unit consists of various sensors, valves, fittings and instrumentation to measure the parameters used in the flow calculations of oil, gas and water. The field unit measures all parameters at line conditions. •

Control unit

Control unit is complete with software for computation of flow rates. The control unit performs all the necessary computations to determine the flow rates of oil, gas and water of the multiphase mixture, based on various measurements obtained from the field sensors. The software required for computation will reside in control unit. •

Portable PC

Portable-PC is used for configuration purpose. The control unit has provision for connection of a portable service/engineering PC to be used for configuration. All well results and critical monitoring data are transmitted via serial link and further to FPSO via radio communication equipment.

6.2.2. Start-up of Multiphase Flow Meter For Operation and Maintenance of the Multiphase Flow Meter, refer to Vendor's instruction manual.

6.3

FWS Crude Heater Unit 6.3.1. System Description The FWS from the TPDP-A wells flow from the production header into the pipeline through a barred tee and are transported to the FPSO via a 10" pipeline.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Due to the waxy nature of the crude and higher pour point temperature, there may be gelling in the FWS pipeline as it is a sub sea pipeline causing the fluid temperature to drop below the pour point temperature of the crude. Therefore, the crude will be heated up to 54-60 °C in the FWS crude heater unit so as to maintain the FWS temperature above the Wax Appearance Temperature (WAT) of 49°C. The Pour Point Depressant (PPD) will be continuously injected into the FWS stream at this temperature to avoid the wax separation and hence in tern the gelling during the transport. An indirect gas fired heater is used for this purpose. The fired gas will heat up the glycol water which in tern will heat the crude in a heat exchanger. The temperature of the outlet crude is controlled by the flow of fuel gas to the fired heater. The fired heater is provided with an expansion tank to accommodate the variations in the temperature due to the crude heating. The hot glycol water will be circulated by the glycol pumps pumping back to the fired heater. The fired heater will be provided with a Burner Management System (BMS) on the skid. All the controls and shutdowns of the equipment and instrument within the system will be performed by the package PLC and shutdown system respectively with some important signals repeated in the PMCS and SIS. 6.3.2

Operating Procedure The preparation for glycol filling / top up, initial start up, normal operation, normal shut down and emergency shutdown etc. will be provided by the package Vendor. The line up of the FWS to the FWS heat exchanger will be a simple diversion of the stream from the production header or multiphase pump. The glycol heating media will be in circulation on other side and the temperature being step up to get the required crude outlet temperature.

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6.4

Full Well Stream Metering Dedicated Full Well Stream Multiphase Flowmeter (FWS MPFM) is utilized to measure the production from TPDP-A platform to FPSO. The FWS MPFM is provided with a field, mounted flow computer to perform the FWS MPFM flow computations. The MPFM control unit is connected serially to the integrated SIS/PMCS for data transfer. The control unit is capable to calculate the individual phases flow rates, water cut, pressure, temperature, total flow rate and density etc. The FWS MPFM is provided with a bypass incase of some trouble with the meter. The configuration of this MPFM will be similar to the test MPFM mentioned above.

6.5

FWS Launcher, Gaslift Receiver and Pipeline System 6.5.1. System Description 6.5.1.1. Introduction The FWS from the TPDP-A wells flow from the production header into the pipeline through a barred tee and are transported to the FPSO via a 10" pipeline. The pipeline is provided with intelligent pigging facilities. The crude has a pour point temperature of 30°C and cloud point of 48.95°C. Since the crude is being transported within a minimum ambient sea temperature of 22°C, there is the potential of wax accumulation and oil gelling inside the pipeline. The wax built up will be controlled by regular pigging of the pipeline in order to prevent flow restrictions and the pig sticking. The pigging frequency must be determined based on field operating experience but may need to start off initially once in 21 days (with the wax inhibitor in service) and thereafter based on operating experience.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL The pigging operation is also required to minimise internal corrosion as well as to increase hydraulic efficiency of pipeline. In future if the well fluid analysis indicates presence of bacteria, then Biocide need to be added in the FWS pipeline to prevent the microbiologically influenced corrosion in the pipeline. The biocide to be added through the pig launcher during pigging.

An incoming 6" gaslift pipeline is provided from the new subsea PLEM. Gaslift is supplied to the TPDP-A wells via the gaslift header and choke valves. Gaslift receiver is also provided in the event pigging of gaslift pipeline is required. The gaslift receiver is also designed for intelligent pigging. 6.5.1.2. Pipeline The following full well stream (FWS) and gaslift pipelines shall be tied-in to TPDP-A Platform: •

NB 10" FWS pipeline from TPDP-A to a new FPSO.

•

NB 6" Gaslift pipeline from new FPSO to TPDP-A

The 10" rigid carbon steel pipeline of 15.3 km transports the TPDP-A full well stream fluids to FPSO. The FWS pipeline is designed for ASME 600 lb. The 6" Gaslift pipeline is designed for ASME 900 lb. The 10" FWS and 6" Gaslift pipelines are tied-in to new subsea PLEM, and connected by new flexible risers to the new FPSO.

6.5.1.3. TPDP-A FWS Launcher The FWS launcher at TPDP-A consists of a major and minor barrel. The major barrel size is DN300 x 2200 mm and the minor barrel size is DN250 x 1500 mm. The minor barrel inside diameter matches the pipeline internal bore. The end of the barrel is sealed by a hinged quick release closure. The closure release has a pressure alert valve to indicate to the operator if the launcher is pressurised prior to the opening of the closure. Double block and bleed isolation is provided on the inlet and outlet of the launcher to provide positive isolation when the launcher is to be opened P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL with the pipeline in operation. A bypass with a kicker valve is provided around the launcher. The flow of oil is normally through the bypass with the launcher depressurised, flow being diverted through the launcher when required to launch a pig into the line. Pig signallers are located at the outlet of the launcher.

6.5.1.4. TPDP-A Gaslift Receiver The TPDP-A gaslift receiver consists of a major and minor barrel. The major barrel size is DN200 x 2950 mm and the minor barrel size is DN150 x 2800 mm. The minor barrel inside diameter matches the gaslift pipeline internal bore. The end of the barrel is sealed by a hinged quick release closure. The closure release has a pressure alert valve to indicate to the operator if the receiver is pressurised prior to the opening of the closure. Double block and bleed isolation is provided on the inlet and outlet of the receiver to provide positive isolation when the receiver is to be opened with the pipeline in operation. The flow of gaslift is normally through the bypass with the receiver depressurised, flow being diverted through the receiver when required to receive a pig into the line. Pig signallers are located at the inlet of the receiver.

6.5.2. Operation of the FWS Launcher Purpose The purpose of this procedure is to describe the pigging operation of TPDP-A pipeline and preparation necessary on the TPDP-A. Scope This document applies to all activities required to load and launch a pig to the pipeline including the personnel responsibilities and safety considerations.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Reference Refer to the following P&IDs whilst carrying out this procedure: TPDP-A-B-1106 FWS Launcher 6.5.2.1. Prepare FWS Launch Safety 1. Radio communication shall be maintained between platform wellhead operators and the FPSO CCR at all times. 2. No Permits to Work or electrical isolations are in force which may prohibit system start up. 3. The relevant tool box talks have been carried out with all personnel involved and are fully understood. 4. This procedure has been read and fully understood by all involved personnel prior to carrying out any of the actions. 5. The Control and Safety Critical Systems are available along with all associated field devices. Plant Status 1. Reservoir fluids are being produced across the platform and flowing to FPSO. 2. Operator to ensure that the production flow rate is not too low (within the normal flow) to achieve a reasonable pigging time. 3. Drain and vent systems are ready for operation (Refer to section 7.9 and section 7.10). 4. The launcher has been purged with nitrogen through the purge point provided. 6.5.2.2. Valve Checklist The wellhead operators should check the following valves to confirm the status as given in the table below. Where valves are found to be out of position, the operator should satisfy himself that it is safe to move the valve or blind before doing so. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Table 6.4.2.2-1: Valve Checklist Valve Number

Location/Service

Status

SDV-1310

Inlet to pipeline

Open

VB-04088 and 04092

Kicker line

Closed

VG-XXXXX

All bleed valves

Closed

VB-13001 and 13002

FWS launcher L-1310 outlet

Closed

VB-04093

Balance line

Locked open

VB-62030 and 62031

Manual depressurising line

Closed

VB-XXXXX

All the drain valves

Closed

6.5.2.3. Pressurise and Launch the Pig Pigging shall be performed once in 21 days (initially) to prevent the pig being trapped due to high wax build up. 1. Ensure valve status as per the table above. 2. Open vent valves and observe the pressure in the PG-1313.The pressure should be near atmospheric. Then open drain valves to ensure no liquid inside. 3. Purge with nitrogen if required. 1. After purging ensure pressure gauge PG-1313 have registered atmospheric pressure. 2. Again close all the valves. 3. Open quick release end closure and insert the pig. Ensure a good fit between the pig and the reducer on the launcher. 4. Close end closure and check that it is secure. 7.

Ensure pig signallers, ZI-1310/11 are reset.

8. Confirm with the supervisor on the FPSO that it is ready to receive the pig from TPDP-A. 9. Open kicker line pressurisation valves VB-04089 and VB-04090 and then open the kicker line main valves VB-04088 and 04092. 10.Confirm the pressure increase on both gauges PG-1310/11 to ensure pressure balance across the pig. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 11.Carefully open the outlet valves. 13. If necessary, throttle the bypass valve VB-04087 to create a slight differential pressure to help push the pig. 14. Monitor ZI-1310 on the launcher outlet and ZI-1311 on the pipeline for indication that the pig has passed the signallers. 15. Reopen fully the bypass valve VB-04087 once the pig signallers shown that the pig has left. 16. When the launching of the pig is confirmed, inform the FPSO that the pig is in the line, time of the launch and approximate transit time. 17. Close kicker and outlet valves. 18. Depressurise, drain and purge the launcher as described below. 6.5.2.4. Depressurise and Drain the Launcher After the pigging operation is complete, the depressurization and draining to be carried out as below. 1. Open vent valves VB-62030 and 62031 to ensure that the launcher is completely depressurised. 2. Check that there is no pressure in the launcher, L-1310 by observing the pressure on PG-1313. 3. Open drain valves and allow the minor and major barrels to drain, and then close the valves. 4. Open the telltale valves to check that the liquid has been fully drained from the launcher. 6. Close vent valves. 7. Purge with nitrogen. 8. Reset pig signallers, Zl-1310 and ZI-1311.

6.5.2.5. Biocide dosing During Pigging

As explained in 6.4.1.1. when bacteria is detected in the well fluid analysis Biocide to be added in the pipeline during pigging. The first 5 steps as explained in 6.4.2.3 remains same for launching the pig. At step P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 6, first pour/ fill the launcher with approximately 100-120 liter of Biocide (quantity depends upon the size of pig used) and then insert the pig followed by closing of the end closure. The other (next) steps remain same. For handling of the Biocide-please follow the supplier’s safety instructions. 6.5.3. Operation of the Gaslift Receiver Purpose The purpose of this procedure is to describe the pigging operation of TPDP-A gaslift pipeline and preparation necessary on the TPDP-A. Pigging is not foreseen as gaslift from the new FPSO is dehydrated to 6 lb H20/MMSCF and hydrocarbon dew pointed to 15°C. However, in the event that pigging is required, the following procedure applies. Scope This document applies to all activities required to receive the pig to the TPDP-A

through

the

gaslift

pipeline

including

the

personnel

responsibilities and safety considerations. Reference Refer to the following P&IDs whilst carrying out this procedure: TPDP-A-B-1108 Gaslift Receiver 6.5.3.1. Prepare Gaslift Receiver Safety 1. Radio communication shall be maintained between platform wellhead operators and the FPSO CCR at all times. 2. No Permits to Work or electrical isolations are in force which may prohibit system start up. 3. The relevant tool box talks have been carried out with all personnel involved and are fully understood. 4. This procedure has been read and fully understood by all involved personnel prior to carrying out any of the actions. 5. The Control and Safety Critical Systems are available along with all associated field devices. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Plant Status 1. Gaslift from the new FPSO is available. 2. Operator to ensure that the gaslift flow rate is not too low (within the normal flow) to achieve a reasonable pigging time. 3. Drain and vent systems are ready for operation (Refer to section 7.9 and section 7.10). 4. The receiver has been purged with nitrogen through the purge point provided.

6.5.3.2. Valve Checklist The wellhead operators should check the following valves to confirm the status as given in the table below. Where valves are found to be out of position, the operator should satisfy himself that it is safe to move the valve or blind before doing so.

Table 6.4.3.2-1 : Valve Checklist Valve Number

Location/Service

Status

SDV-0610

Gaslift supply to gaslift header

Open

VB-06003 and 06001

Kicker line

Closed

VG-06002

Bleed valve at kicker line

Closed

VB-29001 and 29002

Gaslift Receiver R-0610 inlet

Closed

VB-62035 and 62034

Manual depressurising line

Closed

VB-XXXXX

All drain valves

Closed

‘-

Spectacle blind on R-0610 drain line

Open

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 6.5.3.3. Receiving Pig 1. Ensure that the quick release end closure is closed and secure. 1. Open inlet valves and confirm that both pressure gauges PG-0613/11 have registered pressure increase. 2. Ensure pig signallers ZI-0611/10 are reset. 3. Inform the supervisor on the FPSO that the receiver is ready to receive pig. 2. Open kicker valves and throttle down on bypass valve VB-06004. 4. Ensure that pig signals have registered passage of pig. 5. Fully open bypass valve VB-06004. 6. Close kicker valves. 7. Close valves at receiver inlet. 8. Depressurise, drain and purge the receiver as described below.

6.5.3.4. Depressurise and Drain the Receiver 1. Open vent valves to ensure that the receiver is completely depressurised. Observe the pressure in the PG-0610 to near atmospheric. 2. Open drain valves on major and minor barrels. 3. After draining is complete, close the drain valves. 4. Check that there is no pressure in the Gaslift Receiver, R-0610 by observing the pressure on PG-0610. 5. Purge with nitrogen if required. 6. Refer to receiver vendor procedure to open the receiver door. Open the door and remove the pig from the barrel. CAUTION: Do not stand in front of the door when opening it. Refer to manufacturing operating instruction on the opening and closing of the door. 7. Clean any debris from the barrel. 8. Close receiver door and check that it is secure. 9. Reset pig signallers, ZI-0610/11.

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UTILITY SYSTEMS 7.1.

Instrument/Utility/Fuel Gas System

7.1.1. System Description Instrument/utility/Fuel gas on TPDP-A is supplied from the gaslift header. The Gas Conditioning System comprises of the following: •

Preheaters E-5810 A/B

•

Scrubber V-5820

•

Coalescers S-5830 A/B.

The conditioned gas is used as instrument gas to the various users including the WHCP, as utility gas to the gas driven pumps (corrosion inhibitor, wax dissolver, chemical transfer and open drain pump), for the microturbines, for the multiphase pumps gas engines, for the crude heater unit and purge gas to the vent system. 2x16 nitrogen bottle racks are provided at the Instrument/Utility Gas header to allow for black start-up and during start-up after an ESD and as back-up to instrument/purge gas. During SIPROD mode, the instrument/utility gas is replaced by compressed air from drilling rig via hose connection at main deck. The necessary valves to be isolated and the drop out spool removed on the IG/UG header for positive isolation when compressed air is to be introduced from Rig. The fuel gas is continued to feed to the multiphase pump gas engine if required and to the crude heater unit.

7.1.1.1. Instrument/Utility/Fuel Gas Supply Normal utility/instrument/fuel gas supply is from the gaslift header. Gas is routed to the Gas Conditioning Package. Within the Gas Conditioning Package, gas is preheated by 2 x 100% preheaters (usually operated as 2 x 50% in parallel) prior to pressure let down to 130 psig by 2 x 100% pressure control valves, PCV-5820A/B (normally only one PCV is opened and the other acts as hot standby if the first fails to maintain the pressure). The gas is then routed to the Scrubber. Any liquid knockedout is routed under on/off level control to the closed drain system. The gas then passes through 2 x 100% Coalescers and is supplied to the utility/instrument/fuel gas distribution header. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.1.1.2. Utility Gas Preheaters E-5810A/B The preheaters are horizontal cylindrical vessels made of stainless steel. The gas is preheated from 22°C to 75°C. In the event one heater trips, the respective inlet SDV will close and the required heating duty will be supplied by the other heater. The 2 x 100% pressure control valves, PCV-5820 A/B, will let down the pressure to 130 psig prior to entering Scrubber. Each heater is protected from overpressure due to external fire. Either one of the two heaters can be isolated for online maintenance.

7.1.1.3. Scrubber V-5820 The Scrubber is a vertical vessel provided with demister. In the scrubber, the gas velocity is reduced and gravity separation of free liquid contained in the gas stream, if any, occurs with the liquid collecting at the bottom of the vertical vessel. The utility gas leaves the top of the vessel after passing through the demister which removes the remaining entrained liquid droplets by encouraging them to coalesce and fall to the base of the vessel. The collected liquid is drained from the vessel to the closed drain system under on-off level control by LlCA-5820 (H/L) acting upon LCV-5820. A shut down valve SDV-5820 which closes upon the low low level detection by LZALL-5821, is located upstream of the level control valve. The scrubber is protected by 2 x 100% pressure relief valves, PSV5820A/B, set to relief pressure to the Vent Header when pressure in the scrubber reaches 270 psig. The sizing of the PSVs is governed by relief in the event of control valve (PCV-5820A/B) failure. The PCVs are sized such that the maximum flow through the wide open valves both together is limited to 3 MMSCFD. The scrubber also acts as buffer vessel for the instrument gas in the event the lift gas supply is suddenly stopped. This allows for the safe shutdown of the platform.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.1.1.4. Coalescers S-5830A/B From the scrubber, the gas is fed through 2 x 100% Coalescers S-5830 A/B, to remove any particulate matter and further coalescing liquids from the gas stream. These are vertical cylindrical vessels with removable coalescing elements. The gas enters the filter below the element where any free liquid is separated by gravity and drained from the filter base to the closed drain system by an auto-drainer. Any liquid coalesced by the filter element is collected in the lower part of the top section of the filter and need to be drained to the closed drain system manually. A differential pressure indicator/alarm is provided across the coalescing element. The Coalescers are protected from overpressure by relief valves PSV5830A/B respectively, set at 271 psig relieving to the Vent Header. The sizing of the PSVs is governed by relief due to liquid and/or gas expansion in the event of fire. Either one of two filters can be isolated for online maintenance.

7.1.1.5. Nitrogen Supply For black start-up and subsequent start-up after ESD/PSD/USD, when gaslift gas is not yet available, nitrogen is supplied from 2 x 16 bottle racks at 150 psig. Nitrogen is then fed directly into the instrument/utility gas header. The necessary isolation valve and check valve are provided at the upstream of the nitrogen tapping on the instrument/utility gas header. This minimizes the N2 displacement duration prior to start-up of MTG, multiphase pump gas engine and crude heater unit. A separate nitrogen line is provided from the N2 bottles at high pressure to pressurize the gas lift riser SDV-0610 downstream up to the manual isolation valve (a small spool piece) before it is opened. This is to avoid valve damage by opening against a high delta pressure after the shutdown (down stream depressurized). The same nitrogen is also used as purge gas during the above scenario.

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7.1.1.6. SIPROD Whilst the drilling rig is on location for SIPROD, the instrument control system is operated by compressed air from drilling rig supplying into the instrument/utility gas header. The necessary valves to be isolated and the drop out spool removed on the IG/UG header for positive isolation when compressed air is to be introduced from Rig. When the instrument/utility gas supply is switched back to hydrocarbon gas after SIPROD, nitrogen from the bottle racks can be fed into the instrument/utility gas header (with the drop out spool in place) to purge the systems prior to the introduction of gas. Similarly, nitrogen purging of the system is also needed prior to SIPROD to displace hydrocarbon gas before the introduction of compressed air into the system. 7.1.2. Detailed Start-up Procedure Purpose This procedure describes the required actions to prepare the gas conditioning system prior to start-up for safe and efficient operations. The following start-up scenarios will be detailed here: 1. Initial start-up 2. Start-up during SIPROD 3. Post SIPROD start-up Reference Refer to the following Process and Instrument Diagrams (P&IDs) whilst carrying out this procedure: These P&IDs for the vendor package are indicative only and are assumed to be modified based on the final vendor P&IDs/inputs. •

TPDP-A-B-1120 SHT 1

Utility/Instrument/Fuel Gas System

•

TPDP-A-B-1120 SHT 2


•

TPDP-A-B-1120 SHT 3


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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.1.2.1. Start-up Valve Position

Note: The current location/status and the number of valves are based on the indicative P&IDs for the vendor package. The final vendor P&IDs/inputs to be followed for the correct location/status/tag numbers of valves. 1. The operator to check and confirm the following valves and spectacle blinds status as given in the table below. 2. Where valves and spectacle blinds are found to be out of position, the operator should ensure it is safe for him to move the valve or blind.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Table 7.1.2.1-1: Start-up Valve Position Valve Number

Location/Service

Status

VB-60001 and Gas supply from gaslift header 60003 VB-59015 Back up/ Start-up N2 valve

Closed

SDV-5811

Shutdown valve at inlet of preheater E-5810A

Open

SDV-5812

Shutdown valve at inlet of preheater E-5810B

Open

Vendor skid

Preheater E-5810A/B gas inlet isolation valves

Open

Vendor skid

Preheater E-5810A/B gas outlet isolation valves

Open

Vendor skid

PSV-5810A and B outlet isolation valves

Vendor skid

PSV-5810A and B inlet isolation valves

Locked open Locked open

Vendor skid

Preheater E-5810A/B manual depressurizing and drain valves

Closed

Vendor skid

PCV-5820A and B inlet and outlet isolation valves

Open

Vendor skid

PSV-5820A and B outlet isolation valves

Locked open

Vendor skid

PSV-5820A inlet isolation valve

Vendor skid

PSV-5820B inlet isolation valve

Vendor skid

Utility Gas Scrubber vent to header

Locked open Locked close Closed

SDV-5820

SDV at scrubber liquid outlet

Open

Vendor skid

LCV-5820 outlet valve

Open

Vendor skid

Coalescer S-5830A gas inlet isolation valve

Open

Vendor skid

Coalescer S-5830B gas inlet isolation valve

Closed

Vendor skid

Coalescer S-5830A gas outlet isolation valve

Open

Vendor skid

Coalescer S-5830B gas outlet isolation valve

Closed

Vendor skid

Coalescers S-5830A and B purge valves

Closed

Vendor skid

Isolation valves of Auto Drainer of S-5830A

Open

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Table 7.1.2.1.2 : Spectacle Blind Position Vendor skid

Isolation valves of Auto Drainer of S-5830B

Closed

Vendor skid

Top section manual drain valves of S-5830A and B

Closed

BDV-5800

Blowdown valve at skid outlet

Closed

VB-60010

BDV-5800 outlet isolation valve

Locked open

VB-58002 and Instrument gas supply header isolation valve 58003 Isolation valve upstream of nitrogen tapping on VB-60012 instrument/utility gas header VB-58035 Isolation valve to utility gas header

Open

-

Closed

All fuel gas users isolation valves

Closed Closed

7.1.2.2. Plant Status prior to Start-up of Utility/Instrument/Fuel Gas System 1. Complete all pre-start checks as described in section 3. 2. Ensure that the system has been purged with nitrogen and has remained under positive pressure to prevent air ingress before introducing hydrocarbon gas. 3. Ensure that power is available for the preheaters. 4. Ensure the drain and vent systems are ready for operations. 5. Ensure all the isolation valves and actuated valves are lined up as per the valve check list. 6. Check that all pressure, level and flow controls including their respective valves are in order. 7. Ensure that all spades and spectacle blinds are in correct positions as per P&IDs, unless otherwise specified. 8. All drains, vents, purge and sample points are closed and blanked, unless otherwise stated in the Valve Checklist.

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9. All instrument isolation valves are opened and that the instruments vent and drain valves are closed. 10. Ensure nitrogen is available from the bottle racks to provide gas to instrument and for vent system purging until the hydrocarbon gas source is available.

7.1.2.3. Utility/Instrument/Fuel Gas System - Initial Start-up 1. Override PZALL-5820 and TZALL-5811. 2. Keep the preheater inlet SDVs and isolation valves open. 3. Start the preheaters E-5810A and B. 4.

Open VB-60001 and 60003 to admit the gas into the skid.

1. Monitor the pressure in the scrubber to check that pressure regulators PCV-5920A/B are functioning properly and controlling at 130 psig. 2. Monitor the pressurisation as described above and check system for leaks. 3. Check that when liquid accumulates in the scrubber, LCV-5820 opens and closes at the correct levels as per LICA-5820 settings. 4. Check also that the liquid collected at the coalescer is dumped through the auto drain. 5. Monitor the temperature rise as gas is heated. Once the temperature is stabilised, remove the override function of TZALL-5811. 6. Once the pressure of the Utility/Instrument/Fuel gas system is stabilised, remove the override functions of PZALL-5820. 7. Close VB-59015 to shut the supply of nitrogen from the bottle rack. 8. Prepare and start-up power generation via MTG as per Section 7.7.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.1.3. Utility/Instrument/Fuel Gas System - Operating Procedure for SIPROD mode During SIPROD mode, the instrument/utility gas supply will be replaced with compressed air from the drilling rig. The necessary isolation valves and drop out spool are provided to positively isolate the skid so that the air does not back flow. The skid continued to supply the fuel gas to the crude heater unit and multiphase pump gas engines. The purge gas to the vent system will also continue from the skid outlet. 7.1.4

Utility/Instrument/Fuel Gas System - Start-up after ESD-F/G Refer to the Initial Start-up procedures above

7.1.5. Utility Gas System - Start-up after ESD Since ESD is without automatic blowdown, system is not depressurised. 1. Override PZALL-5820/5831 if ESD is caused by instrument gas low low pressure after it has been rectified. Skip this step if ESD is not caused by PZALL-5820/5831. 2. Override TZALL-5811 to enable start-up as gaslift supply temperature could be as low as minimum seabed temperature of 22°C. 3. Then follow the initial start-up procedure.

7.1.6. Shutdown Procedure 7.1.6.1. Shutdown during Normal Operation Utility/Instrument/Fuel Gas system will be shutdown following a TPDP-A ESD-F/G and ESD and Unit Shutdown (USD) that is caused locally. USD of the Utility/Instrument/Fuel gas system resulting in total shutdown of the Utility/Instrument/Fuel gas conditioning package can be caused by the following: •

Scrubber pressure high high

•

Scrubber liquid level high high

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Other USD causes resulting in shutdown of individual component of the Utility/Instrument/Fuel Gas Conditioning Package are: •

Scrubber liquid level low low This will only close liquid outlet SDV-5820 and it is fitted with auto reset.

•

Shutdown of respective Preheaters This will only close respective gas inlet SDV-5811/5812. The remaining heater will provide the heating duty required.

•

Preheater outlet temperature high high. This will only cause the preheaters to trip.

For shutdown of Utility/Instrument/Fuel Gas Conditioning Package due to USD, nitrogen from nitrogen bottle racks is available as back-up for instrument gas. 7.2.

Diesel System

7.2.1. System Description Diesel is provided for the following purposes; 1. Fuel for Diesel Generator and pedestal crane. 2. De-gelling of the FWS pipeline after an extended shut-in. 3. For pressure equalisation across SCSSV to facilitate its opening if required. Diesel is supplied to the platform by diesel supply boat via a hose connection. From the Diesel Storage Tank, T-6700 diesel fuel is supplied to the diesel generator and crane via Diesel Transfer Pump P-6710. Diesel is injected to the pipeline by P-6730 and for equalising pressure across SCSSV a separate pump P-6720 is provided. A separate plant operating procedure / instruction is required to indicate the necessary precautions to be taken during the diesel transfer to minimize the risk of leakage.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.2.1.1. Diesel Storage Tank On board the platform, the diesel is stored in storage tank; T-6700 located in the crane pedestal and has a capacity of 10.6 m3. The base of the tank slopes away from the outlet nozzle to allow water and sludge to collect away from the nozzle. A drain valve is positioned at the lowest point to allow the collected sludge to be drained to closed drain system. The tank is equipped with audible alarm LA-6700 to alert diesel supply boat of end of tank fill-up operation.

7.2.1.2. Diesel Transfer Pump This pump has a capacity of 3 m 3/h with differential pressure of 15 psi. The pump is driven by electric motor. Operation of this pump is manual. This pump is mainly used for transferring diesel to the Pedestal Crane Day Tank and the diesel generator. It can also be used for filling the well tubing inventory before line up of the high pressure SCSSV equlisation pump.

7.2.1.3. Diesel Injection Pump Diesel Injection is an intermittent and manned operation. The diesel injection is provided to break the gel formed in the FWS pipeline following unplanned shutdown when an immediate restart is not possible. The gels are formed as the waxy crude cools in the lines restricting flow through the lines on restart. The Diesel Injection Pump, P-6730, is an electrical driven reciprocating injection pump designed for 6.0 m 3/h with discharge pressure of 1230 psi. The pressure control valves PCV-6700 is provided at the discharge header of the pump in order to control the diesel injection pressure by recycling back the diesel to the storage tank T-6700. Over pressure protection of the export pipeline is provided by PSV-6700 on this pump discharge which is set at 1363 psig, relieving to the Diesel Storage Tank T-6700. P5173B-PR-MAN-1001

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7.2.1.4 SCSSV Equalisation Pump In the event the SCSSVs fail to self equalise, this pump is used to equalise the pressure across SCSSV for initial well start-up in order to facilitate the valve opening. The SCSSV Equalisation Pump, P-6720, is an electrical driven reciprocating injection pump designed for 0.5 m3/h with discharge pressure of 2016 psi. The pressure control valves PCV-6720 is provided at the discharge header of the pump in order to control the diesel injection pressure by recycling back the diesel to the storage tank T-6700. Over pressure protection is provided by PSV-6720 on this pump discharge which is set at 3539 psig, relieving to the Diesel Storage Tank T-6700.

7.2.1.5 Pedestal Crane Day Tank The Pedestal Crane Day Tank is provided with flexible hoses on the filling, overflow and drain lines. Ensure these are in place and the isolation valve on the drain line is closed. The day tank to be filled by the diesel transfer pump while observing the level in the day tank by LG6702.

7.2.1.6 Diesel Generator Day Tank The diesel to the diesel engine generator day tank to be supplied by the diesel transfer pump. The level to be observed while filling to avoid overfilling and spillage.

7.2.2. Routine Operating Procedure To ensure continuous safe and efficient operation of the diesel system, the following checks and actions should be performed at regular intervals by the operator. There are no specific procedures to be outlined here as this is a very conventional system used. 1. Check the storage tank for water by observing the LG-6701 for the diesel/water interface. Drain the water as required. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 2. Check the crane fuel day tank and diesel generator fuel day tank for water by opening the drain valves and closing them when clean diesel shows at the drain. 3. Check the diesel inventory so as to identify when top up of the system is required. 4. Check the system for leaks, ensuring that all drain valves are closed.

7.2.3. Taking Diesel Storage Tank Out of Service for Inspection The following procedure describes the actions required to empty T-6700 for inspection: 1. To empty T-6700, start Diesel Transfer Pump to fill up DEG fuel day tank and/or crane fuel day tank as much as possible. 2. Open valve VB-64064 and 64065 to drain remaining diesel inventory into the closed drain system for containment. 3. The diesel tank T-6700 is now emptied and out of service. The vessel should be flushed with water to remove hydrocarbon prior to removal of the inspection hatch.

7.2.4. Gel Breaking Procedure During an extended unplanned shutdown i.e. ESD or ESD-F/G, there is the potential of gel formation in the subsea pipeline if operators are not able to perform any wax mitigation methods in time. In case of gel formation, diesel injection system can be utilised to supply the required pressure to break the gel formed in the line. Outlined below is the preparation and procedure to break the gel formed in the pipeline.

To break gel in the export pipeline proceed as follows: 1. Ensure that PIV-6700 at the diesel injection pump discharge to pipeline is set as 700-800 psig and the spill back is routed to the diesel storage tank. Initially the set pressure is kept low. If there is still no break through then increase the PIC-6700 setting so as to put higher pressure to break/dislodge the gel.

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2. Ensure that valves VB-13001 and 13002 at the outlet of pig launcher are closed. Also, the launcher bypass valve VB-04087 shall be closed. 3. Start diesel injection pump, P-6730. 4. Monitor the pressure on the pump discharge and stop the pump when the pressure has fallen and is steady at the low pressure. 5. Then reinstate all valves to their original positions as indicated in P&IDs for restart.

7.3.

Chemical Injection System Three types of chemicals are required for injection into the FWS pipeline on TPDP-A: •

Wax Dissolver

•

Corrosion Inhibitor

•

Pour Point Depressant

Refer to the following Process and Instrument Diagram (P&ID) whilst carrying out these procedures: TPDP-A-B-1128 (Sheets 1 to 4)-Chemical Storage and Injection System.

Note: There is no special operating procedure required to operate this unit as the skid is a standard one. General Handling Precautions 1. Personal protective clothing including full face visor, suitable protective gloves and long sleeved coverall must be worn. 2. Avoid spillage, swallowing, skin and eye contact. Wash thoroughly with soap and water after handling the substance. 3. Following spillage, immediately dilute the spilled chemical and flush to drain. 4. Study the chemical data sheet for the specific chemical to be used before handling and comply with any specific precautions.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Plant status prior to operating the system 1. All spades and spectacle blinds are in the correct positions as per the P&IDs, unless otherwise specified. 2. All drains, vents, purge and sample points are closed and blanked. 3. All instrument isolation valves are open and that the instrument vents and drain valves are closed. 4. Sufficient inventory of chemicals is available. 5. Personal protection equipment required to perform the operation is available. 6. Utility gas is available to power for the gas driven injection pumps.

7.3.1. Corrosion Inhibitor System Description The corrosion inhibitor system is a batch (once in a month) operation provided to inject corrosion inhibitor into the FWS pipeline during pigging operation. The corrosion inhibitor system consists of: •

A 2 m3 Corrosion Inhibitor Tank T-6810

•

1 x 100% CI Injection Pump P-6815

Corrosion Inhibitor Tank The corrosion inhibitor tank T-6810 is a stainless steel (SS 316L) tank. The tank operates at atmospheric pressure. The top of the tank is closed and is fitted with a filling connection, to enable gravity filling by chemical tote tank or by the chemical transfer pump on main deck and a vent. Suction for the injection pump is taken from a nozzle near the base of the tank. A level gauge is provided on the tank and a calibration pot is provided on the pump suction to check the injection rate.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Corrosion Inhibitor Injection Pump The chemical is injected into the production stream through the injection point by the corrosion inhibitor injection pump P-6815. The pump is a reciprocating injection pump powered by utility gas. The utility gas supply pressure is controlled by PCV-6815. The stroke and hence injection rate is set through a calibrated adjustment on the pump body. The pump has a discharge pressure of 363 psig and can deliver up to 50 L/hr. Injection of 150 litres per monthly pigging operation is recommended. Damper is installed on the discharge to smooth the flow to the injection point. The discharge pipe work is protected against over pressure by single pressure relief valve PSV-6815 set at 1363 psig. The valve relieves back to the storage tank.

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7.3.2. Wax Dissolver System Description Batch injection of Wax Dissolver is provided to dissolve any wax formed and prevent gelling in pipeline in the event of pro-longed shutdown i.e., scheduled shutdown and pro-longed Process Shutdown (PSD). Wax dissolver injection is recommended for 12 hours prior to a scheduled shutdown. In the event of a prolonged PSD in which TPDP-A cannot be reinstated in 5 hours, Wax Dissolver injection for 24 to 48 hours is recommended with Wax Dissolver Injection Pump started via operator intervention. Since the Wax Dissolver Injection Pump is gas driven, the Wax Dissolver injection is not possible in the event gaslift from FPSO is not available while TPDP-A status is on PSD. The wax dissolver system consists of: •

A 2 m3 Wax Dissolver Tank T-6820

•

1 x 100% Wax Dissolver Injection Pump P-6825

Wax Dissolver Tank The wax dissolver tank T-6820 is a stainless steel (SS 316L) tank. The tank operates at atmospheric pressure. The top of the tank is closed and is fitted with a filling connection, to enable gravity filling by chemical tote tank or by the chemical transfer pump on main deck and a vent. Suction for the injection pump is taken from a nozzle near the base of the tank. A level gauge is provided on the tank and a calibration pot is provided on the pump suction to check the injection rate.

Wax Dissolver Injection Pump The chemical is injected into the production pipeline through, the injection point by the gas driven reciprocating pump. The pump is driven by the utility gas through a pressure control valve PCV-6825. The stroke and hence injection rate is set through a stroke

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL adjustment on the pump body. The pump has a discharge pressure of 363 psig and can deliver at up to 10 L/hr. Damper is installed on the discharge to smooth the flow to the injection point. The discharge pipe work is protected against over pressure by single pressure relief valve PSV-6825 set at 1363 psig. The valve relieves back to the storage tank.

7.3.3. Pour Point Depressant (PPD) System Description The Pour Point Depressant (PPD) is injected continuously into the production header on TPDP-A platform to reduce the crude pour point to maintain the crude characteristics. Alternatively, the PPD can be injected into the gaslift header. The PPD system consists of: •

A 7.5 m3 PPD Tank T-6830

•

2 x 100% PPD Injection Pumps P-6835A/B

Pour Point Depressant Tank The PPD tank T-6830 is a stainless steel tank having a total capacity of 7.5 m3 and operates at atmospheric pressure. The top of the tank is closed and is fitted with a filling connection, to enable gravity filling by chemical tote tank or by the chemical transfer pump on main deck and a vent. Suction for the injection pump is taken from a nozzle near the base of the tank. A level gauge is provided on the tank and a calibration pot is provided on the pump suction to check the injection rate.

Pour Point Depressant Injection Pumps The chemical is injected into the production line through the injection point by 2 x 100% electrical driven reciprocating pumps, P-6835A and P6835B. The two PPD pumps are operating as duty / standby mode.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL The pumps have a max discharge pressure of 1328 psig and can deliver up to 40 L/h. This discharge pressure is based on the injection into the gas lift header. Damper is installed on the discharge line to smooth the flow to the injection point. The discharge pipe work for the pumps are segregated as 900# rating and 600# rating based on the two different injection locations. Each section is protected against overpressure by a separate pressure relief valves, PSV-6835A and PSV-6835B, which are set at 1639 psig and 1363 psig respectively.

7.3.4. Biocide Injection Procedure Biocide injection point is provided on open drain caisson. The biocide chemical is injected into the system by batch operation, using portable barrel pump. 1. Prior to performing the operation, the personnel must understand the necessary precautions that need to be exercised for safe handling of the chemicals. Similar procedure for safe handling of wax dissolver and corrosion inhibitor can be adopted for biocide handling. 2. Attach the hose connection to the injection point and open valve to inject biocide into open drain caisson. 1. When the operation is finished, close the valve. 3. Return the excess biocide container/tank to a proper storage area since it is a hazardous chemical.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.4.

Wash Water System

7.4.1. System Description Note: There is no special operating procedure required to operate this unit.

7.4.1.1. Introduction Wash water system is used for washing down and flushing of equipment. Each deck on the platform will be provided with wash water washdown connections. A wash water connection is provided to the toilet at personnel shelter. Wash water of potable water quality is delivered to the platform when required by supply boat. The transfer of wash water from the supply boat to the platform storage facility is by a flexible hose at boat landing. The wash water tank can be connected to the potable water distribution network. The platform end of the hose connects to hard pipe for delivery to the storage tanks T-5100A and T-5100B via a non return valve which prevents wash water from flowing back through the hose.

7.4.1.2. Wash Water Storage Tanks Onboard the platform, the wash water is stored in storage tanks, T5100A and T-5100B located on the main deck and have capacity of 5 m 3 each. The tanks are stainless steel tanks. The top of the tanks are closed and each tank is fitted with filling connection and a local atmospheric vent with bird screen. Suction for the wash water pump is taken from the base of the tank. Strainers are available at the pump suction line to collect any solid/debris/sludge from the water. A drain valve is positioned at the lowest point to allow the collected sludge to be drained to open drain header. The two tanks are provided with level gauges.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.4.1.3. Wash Water Pump The wash water pump, P-5110 is provided to transfer wash water from storage to the deck wash down connections. It is operated manually from local start/stop push buttons. The pump is motor driven and has a capacity of 2.0 m3/h. The pump is designed for a differential pressure of 49 psig.

7.5.

Potable Water System

7.5.1. System Description Potable water system is provided on TPDP-A platform for supplying potable water to the emergency eye wash and shower station near chemical injection skid and multiphase pump skid at cellar deck. An emergency eye wash is provided at the battery room. Potable water tanks T-5200A/B of SS 316L with 2 m 3 capacity each is provided on the main deck. When the first tank is about to get empty, the second (filled) has to be placed at its location with the necessary connection done and then only remove the first. These tanks are provided with flexible hose connections at the inlet, outlet and drain nozzles to enable the quick change over. The overflow connections are separate and attached to the individual tanks. However, provision is made to enable the tank to be replenished with water from the supply boat. There are self contained type eye wash and safety showers provided on the main deck near the crude heater unit and the chemical transfer area. Note: There is no special operating procedure required to operate this unit.

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7.6.

Diesel Engine Generator

7.6.1. System Description 7.6.1.1. Introduction The main power generation for normal operation is via the microturbines. Standby power supply is from a 160 kW Diesel Engine Generator (DEG), namely G-7730. This is mainly used for the black start-up and emergencies. Main power supply during SIPROD period is from the drilling barge, whereby both platform standby DEG and microturbines will not be utilised.

7.6.1.2. Diesel Engine Generator The DEG is suitable for non-hazardous, outdoor, offshore environment condition. The 1 x 100% DEG provides required power back-up to the platform, in case the black start-up and emergency. The package has an integral diesel day tank which is sufficient for 24 hours of operation at full load. The start-up, shut down and emergency handling of this package is per the vendor operating instructions.

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Micro Turbine

7.7.1. System Description 7.7.1.1. Introduction The main source of electrical power for platform facilities during unmanned

operation

in

normal

operation

mode

is

from

the

microturbines. The microturbine rating is 250 kW each and is located on the main deck.

7.7.1.2. Microturbine During

normal

operation,

i.e.

unmanned

condition,

both

the

microturbines are running continuously at 2x50% load. Upon failure of one microturbine, the other ramps up and take the full load Both the microturbines are design for 100% load.

7.7.1.3. Fuel System Fuel gas is supplied from the Utility/Instrument/Fuel Gas Conditioning Skid, The pressure of the fuel gas supply is controlled at a PCV outside the skid and will have another controller inside. Note: for the Start-up, Operating, Shutdown and emergency procedures refer to Microturbine Vendor Operating Manual.

7.8.

Electrical Facilities

7.8.1. System Descriptions 3-Phase. 400V. AC Power Distribution Main power at 400V 50Hz is distributed to users and other distribution boards via the LV switchboard, SB-7700, located on the Cellar deck. During normal operation, the 3-phase, 4-wire, 400V, 50 Hz supply is provided by the Microturbine Generators (MTGs), G-7700 and G-7710 (during manned and/or unmanned operations) or Standby Diesel Engine generator (DEG), G-7730 (as standby power supply during emergency situation). The MTG incoming feeders are fed to SB-7700 bus ‘A’ by 630A, 4 pole MCCBs. P5173B-PR-MAN-1001

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Power supply to the platform during SIPROD mode shall be from drilling barge via frequency converter. Frequency converter (offshore installed) is required to convert 480V, 60Hz system to meet platform voltage level at 400V, 50Hz. (Provision for worst case, standby diesel generator can still support the load during drilling barge is unable to supply). This supply incoming feeders are fed to SB-7700 bus 'B’ by 630A, 4 pole MCCB. The phase voltage and current to the load can be measured on the switchboard using the digital power meter located at the switchboard. Indicator lamps are provided to show incomer MCCBs status.

.7.8.1.1. SB-7700 (Drawing: E-1001) SB-7700 houses the motor controls for pumps and supplies power directly to closed drain heaters, power socket outlets, AC UPS system (UPS7800), lighting and small power distribution boards (DB-7810 & DB7820),V.Ac control panel (HCP-5010) and heat tracing distribution board (DB-7830).

7.8.1.2. Distribution Board DB-7810 (Drawing: E-1002) DB-7810 is fed through an 63A MCCB with short-circuit service breaking capacity of 20kA RMS. The board is wired in 4-wire configuration, one for each of the three phases and a neutral. The board supplies 230V loads with the total load spread across the three phases to avoid excessive imbalance between the phases. The majority of loads are lighting circuits and small power circuits. 7.8.1.3. Distribution Board DB-7820 (Drawing: E-1003) DB-7820 is fed through an 32A MCCB with short-circuit service breaking capacity of 20kA RMS. The board is wired in 4-wire configuration, one for each of the three phases and a neutral. The board supplies 230V loads with the total load spread across the three phases to avoid excessive imbalance between the phases. The majority of loads are emergency lighting circuits and small power circuits.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.8.1.4. Distribution Board DB-7830 DB-7830 is a dedicated Distribution board for heat tracing system. It is fed through a 40A MCCB with short-circuit service breaking capacity of 20kA RMS. The board is wired in 4-wire configuration, one for each of the three phases and a neutral. The board supplies 230V loads with the total load spread across the three phases to avoid excessive imbalance between the phases. Outgoing feeders from DB-7830 will be terminated at heat tracing junction boxes located at the field.

7.8.1.5. AC Uninterruptible Power Supplies (UPS) (Drawing no: E-1004) 230V AC Uninterruptible power system (UPS), are provided by UPS7800A and UPS-7800B. The UPS panel shall be located inside UPS room and its battery banks (BT-7800A and BT-7800B) are located inside Battery room on the Cellar deck. The UPS comprises of rectifiers/chargers, battery banks, inverters and static switches. The unit provides a 230V, single-phase, 2-wire, 50Hz supply to the distribution board DB-7800 for distribution to vital loads such as PMCS/SIS/FGS system, communication loads, multiphase flow meter, aviation warning lights, V.Ac control panel, etc. Backup battery bank for the UPS is 2 nos of (1 x 50%) 220V DC battery bank BT-7800A and BT-7800B located on two stainless steel rack. Input supply to the rectifiers/chargers of the UPS is 400V, 3-phase, 50Hz supplied from at SB-7700 through a 32A MCCB for each ups charger. The charger is capable of recharging the batteries to 100% capacity within 8 hours. The AC/DC converter comprising of rectifiers/chargers and transformers converts the 400V AC supply into 220V DC supply. The DC supply is used to charge the batteries and also supply power to the inverters. If the rectifier/charger fails, supply to the inverter is maintained from the battery banks. A blocking diode is provided to prevent current from the batteries flowing back to the rectifier/charger. The static inverter converts the 220V DC supply, from the rectifier charger or battery banks, to a 230V AC single-phase supply for distribution through DB-7800. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Static Switch & Manual Bypass Under normal operation, the bypass supply shall be in synchronism with the inverter output as long as the bypass supply power quality falls within an acceptable range. When the bypass supply falls out of the permitted range, the static switches will cut-off the bypass supply and initiate uninterrupted transfer of the load to the inverter supply. The static switch monitors the bypass supply frequency and adjusts the inverter output to match frequency and phase. This synchronization of the two supplies permits the change over of supply to take place without tripping the output of the UPS. Operation of the manual bypass results in the isolation of the static switch and inverter from the output; with supply being maintained from the 230V AC bypass supply. However, the alternate supply will be isolated should under voltage be detected at the bypass supply input of the UPS. The UPS panels are housed in a mild steel cabinet with epoxy coated and ingress protection of IP 31. These panels are located in the ventilated ups room on the Cellar deck.

220V DC Battery Bank The 220V DC battery banks (BT-7800A and BT-7800B) are arranged on 2 nos of stainless steel battery racks at Battery room on the Cellar deck.

7.8.1.6. 230V AC UPS Distribution Board DB-7800 (Drawing: E-1004) DB-7800 is a dedicated Distribution board for AC UPS loads. It is fed through a dual feeder from UPS panels (UPS-7800A/7800B), via 32A MCCBs withshort-circuit service breaking capacity of 20kA RMS. Load

on

DB-7800

are

mainly

platform

vital

loads

such

as

PMCS/SIS/FGS system, communication loads, multiphase flow meter, aviation warning lights, V.Ac control panel, etc.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.8.1.7. Frequency Converter FC-7740 Frequency converter shall be located at UPS room, it shall be utilised during Drilling/SIPROD period when electrical power shall be provided from the barge. The frequency converter shall convert 480V, 60Hz, 3Ph, to 400V, 50Hz, 3Ph system voltage and frequency.

7.8.1.8. Navigation Aids (Drawings: E-1006) There will be two (2 nos) of Nav.aids lanterns (NL-8901/NL-8902) for Topaz platform. Both lanterns shall be installed on the Cellar deck. The Navigational Aid system for Topaz shall be powered by dedicated solar panels. Solar panels shall also be located on the cellar deck.

7.9.

Vent System

7.9.1. System Description TPDP-A hydrocarbon disposal system consists of two segregated vents: •

Via Closed Drain Vessel The depressurisation fluid either via automatic or manual blowdown and the relief discharges are piped to closed drain vessel through the vent header. Any entrained liquid will be removed in this vessel and the dry gas is piped to vent boom via a vent header. The utility gas vents from the gas driven pumps are routed to the same vent header leading to the closed drain vessel. The vent header is continuously purged with utility gas during normal operation and with nitrogen during start-ups.

•

Atmospheric vent Atmospheric vent is open drain caisson vent.

7.9.1.1. Closed Vent TPDP-A platform venting is via the vent header, the closed drain vessel and finally the vent boom. The vent system is designed to handle

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL automatic blowdown operations which include the FWS system, gaslift blowdown and Utility/Instrument/Fuel gas conditioning skid blowdown. The vent system is equipped with CO2 snuffing system. Three CO2 snuffing bottles are provided on the platform. One bottle will be in line and the other two as standby. Upon detection of a flame, CO 2 snuffing can be manually activated locally or remotely from FPSO. The XV on the bottle will remain open for 10 min duration and then get closed automatically. Depending on the situation it is recommended to have three snuffing each of 10 min duration. During SIPROD, utility and instrument gas is supplied from compressed air from drilling rig. The air vent will be routed locally and the necessary valves and blinds are provided. 7.9.1.2. Atmospheric vent This is an atmospheric venting provided on the open drain caisson. Flows to the open drain caisson are generally from drip pans, tundishes and atmospheric storage tanks and hence very little or no vapour is expected to be generated from these sources. This LP vent is fitted with flame arrestor at the open end, to avoid flash back into the vent header in the event of lighting strike. Open drain header is provided with swing spool to allow switching to overboard disposal during SIPROD.

7.9.2. Vent System Operating Procedure Purpose The purpose of this procedure is to describe the start-up of the vent systems. Scope This document applies to all activities required to be performed to operate the vents including personnel responsibilities and safety considerations.

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Reference Refer to the following P&IDs whilst carrying out this procedure TPDP-A-B-1123

Closed Drain and Vent

System TPDP-A-B-1122

Vent and Closed Drain Headers

TPDP-A-B-1122

Hazardous Open Drains System

7.9.2.1. Prepare Vent System Prior to Start-up Safety 1. Radio communication shall be maintained between platform wellhead operators and the FPSO CCR at all times. 2. No Permits to Work or electrical isolations are in force which may prohibit system start up. 3. The relevant tool box talks have been carried out with all personnel involved and are fully understood. 4. This procedure has been read and fully understood by all involved personnel prior to carrying out any of the actions. 5. The Control and Safety Critical Systems are available along with all associated field devices.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Plant Status 1. Ensure all the pre-start checks have been performed as described in section 3 of this manual. 2. Ensure that gas is available from the nitrogen back up system. 3. Ensure that the drain system is on line. 4. The control and instrumentation are functioning properly. 5. Valves are positioned as shown in the P&IDs.

7.9.2.2. Preparing the Vent System for Continuous Purging 1. Purge the vent header, closed drain vessel and the vent boom using nitrogen by opening VB-59015 at the Instrument/Utility Gas header. Open the bypass on the normal vent header purge PCV-5801. 2. Maintain N2 purging until purge gas is available from the Utility/Instrument/Fuel Gas Conditioning System. Then stop nitrogen. 3.

Close the bypass on PCV-5801 and take PCV-5801 in line for continuous purging with utility gas.

7.10.

Drain System

7.10.1. System Description Two independent drain systems, namely the closed and open drains are provided on the TPDP-A platform for the safe and environmentally friendly disposal of liquid. The closed drain system is designed for the collection and disposal of primarily hydrocarbon liquids drained from process equipment and pipework during maintenance operations. The open drain system is designed for the collection of liquids which have accumulated in drip pans, deck drains and tundishes.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.10.1.1.Closed Drain Vessel Operation Closed drain vessel collects liquid discharges from the closed drain header and vent header. The closed drain vessel also acts as a knock out drum before the hydrocarbon gas is disposed to atmosphere. Collected hydrocarbon liquids are pumped by closed drain transfer pumps to the production header, while hydrocarbon gas is routed from the vessel to the platform vent. The closed drain vessel is- required to operate normally as a two phase separator. It is also provided with sand jetting connection to be used during shutdown. During sand jetting the contents can be discharged to open drain system as well as collected manually in drums.

7.10.1.2.Closed Drain Transfer Pumps Closed drain transfer pumps, P-6410A/B are provided to transfer collected liquids back to the production system. Two electric motor driven pumps that require low NPSH and offer stable and robust operation are selected for this service. The pumps operate in lead/lag configuration and on/off mode based on liquid level setting.

7.10.1.3.Closed Drain Vessel Heater The closed drain vessel is also equipped with an electric heater, E-6430 to continuously maintain the bulk hydrocarbon liquid temperature to about 45-50°C (above crude pour point). Since the vessel is not continuously receiving the warm fluids, the collected hydrocarbon liquid may fall to the minimum ambient to form oil gel and wax. For this reason, the heater is provided. High temperature trip is provided should the temperature of bulk liquid exceed 55°C. This heater is located in the boot of the vessel where the remaining liquid can be effectively heated. The heater operates on on-off mode based on the temperature of liquid in the boot.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.10.1.4.Open Drain System The TPDP-A open drain system consists of two separate collection systems, one for the deck drains and one for drip pans. Both systems are classified hazardous as both provide drainage for areas designed as hazardous. In the caisson, hydrocarbons separate and float on top of the water displacing clean water out of the open bottom of the caisson. Recovery of the hydrocarbon is by the open drain pump, P-6510 which is located on the sump deck. Liquid hydrocarbons collected in the open drain caisson are pumped back to the closed drain vessel. The pump is a positive displacement gas driven type. Any hydrocarbon gases evolving in the open drain caisson are released to atmosphere via a flame arrestor and dedicated vent. 7.10.1.5. Open Drain Pump Operation of the open drain pump, P-6510 is automatic and intermittent. Should the open drain pump start-up during well unloading then the inflow to the closed drain vessel will exceed the pump out rate. This situation can be handled either by reducing the liquid inventory in the closed drain vessel to a minimum prior to commencing well unloading, or by inhibiting start-up of the open drain pump during well unloading.

7.10.2. Closed Drain System Start-up Procedure Purpose The purpose of this procedure is to describe the start-up of the closed and open drain system. Scope This document applies to all activities required to be performed to operate the drains including personnel responsibilities and safety considerations.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Reference Refer to the following P&IDs whilst carrying out this procedure TPDP-A-B-1121

Hazardous Open Drain

System TPDP-A-B-1122

Vent and Closed Drain Headers

TPDP-A-B-1123

Closed Drain and Vent System

Safety Considerations 1. Radio communication shall be maintained between platform wellhead operators and the FPSO CCR at all times. 2. No Permits to Work or electrical isolations are in force which may prohibit system start up. 3. The relevant tool box talks have been carried out with all personnel involved and are fully understood. 4. This procedure has been read and fully understood by all involved personnel prior to carrying out any of the actions. The Control and Safety Critical Systems are available along with all associated field devices.

7.10.2.1. Preparation for Starting-up Closed and Open Drain System Plant Status prior to Start-up 1. Ensure all the pre-start checks have been performed as described in section 3 of this manual. 2. The closed drain and vent system has been purged with nitrogen. 3. Electrical power supply is available from DEG. 4. Drain and vent valves within the closed drain system are closed in position. 5. The utility gas system has been commissioned. 6. Ensure the production facilities are prepared to receive hydrocarbon from closed drain transfer pumps.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 7.10.2.2. Operation of the heater, E-6430 and the Closed Drain Transfer Pumps (P-6410A/B) 1. Prior to starting heater, E-6430, ensure that the liquid level in the closed drain vessel is at LAL of 450 mm. For initial system start-up, the vessel may be first filled with diesel to LAL to check the heater operation. 2. Switch on the heater to maintain the temperature inside the vessel at about 50°C. In normal operation the heater will switch on-off automatically to maintain the temperature. 3. Check that as the liquid level in the vessel rises up to 1000 mm (from boot BTL), the lead pump will start. If the level still rises, then the lag pump will start at a level of 1500 mm (from boot BTL). 4. The pumps will automatically stop once the level decreases to 750 mm. This ensures the liquid is contained only in the boot and the heater is immersed in liquid. 5. In case the pumps do not trip at 750 mm level, they will trip on LZALL set at 150 mm.

7.10.3.SIPROD Mode Operation During SIPROD mode, the closed drain system operates with the same procedure as normal operation.

For conversion to SIPROD mode

operation, open drain header with swing spool is switched to overboard disposal for the deck drains.

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8.0

MISCELLANEOUS OPERATION PROCEDURES 8.1.

Crude Sampling Procedure An accurate and detailed analysis of a crude oil sample is worthless if the sample is not representative of the product. Before flushing of the sample point and collection of the samples are performed, all hot work in the area should be stopped and equipment made safe. All personnel on the platform should be informed of the situation and gas alarm should be isolated. If a metal container is used to collect the flushed oil or sample, the container should be earthed to prevent sparks due to static electricity which may be generated in the line. Sampling should be performed at a recognised sample point with a good unrestricted flow from the flow line. Before the sample is collected, the sample line must be flushed with fresh oil and allowed to warm through to be the same temperature as the flow line. This action ensures that the collected sample is fresh and any residues in the sample line, such as sand or wax is removed. Flushing should be performed to a suitable container, preferably plastic, rather than the platform open drains. When conditions are stable, the sample should be drawn slowly with no foaming or undue agitation. Light ends are lost easily and will affect the results of the analysis. Perform sand, pour point and B&W test as and when required to verify the well test result (MPFM).

8.2.

Well Safety Valve Testing Procedures

8.2.1. Preparation Prior to Test Open all Christmas tree valves on the tree to be tested as per normal operating position but with the isolation valves to production header and test header closed. Record the shut in tubing head pressure.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Commence valve testing following the sequence below. 8.2.2. Wing Valve Test 1. Close wing valve, bleed off pressure down stream of wing valve to 0 psig by opening the drain valve. 2. Close the drain valve. Wait for 10 minutes and observe the pressure built up. Record the gauge pressure.

8.2.3. Surface Safety Valve (SSV) 1. Close SSV. Open wing valve and bleed off pressure to 0 psig by opening the flow line drain valve. 2. Close wing valve. Wait for 10 minutes. Record the gauge pressure at swab valve.

8.2.4. Surface Controlled Subsurface Safety Valve (SCSSV) 1.

Close SCSSV. Open wing valve and SSV.

2. Bleed off pressure to 0 psig by opening the drain valve on the flow line. Close wing and drain valve. 3.

Wait for 15 minutes. Record the gauge pressure at the swab

valve. On completion of the tests return to the well to production. IMPORTANT: If any problems are encountered, contact the field superintendent immediately. Report any valve leak and faulty timing on SSV and SCSSV in valve test report form.

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8.3 Well Handover for Wire Line Operation Procedures

8.3.1. Handling the Well Over to Wire Before a well is handed over by production for wire line operations the following preparation work should be performed: 1. Apply fusible cap on SSV actuator. 2. Close isolation valves to production and test headers. 3. Ensure wing valve is closed. 1. Ensure SCSSV is opened. Close the needle valve on the hydraulic supply to the SCSSV. 2. Drain and depressurize flowline. The SSV will attempt to close due to line pilot PEL. Ensure the pressure is 0 psig. 3. Close drain valve and wing valve. 4. At the WHCP, select SCSSV closed. Ensure control pressure goes down to 0 psig. 5. Disconnect and cap hydraulic tubing in Christmas tree. 6. Proceed to permit documentation and handover the well.

8.3.2. Receiving Well after Wire Line To return a well to production following wire line operation, the following actions should be performed: 1. To receive a well, the well status must be as per hand over. 2. Ensure drain valve and wing valve are closed. 3. Reconnect the SCSSV hydraulic control line to WHCP. 4. At WHCP, open SCSSV and SSV. Observe the control line pressure. 5. Remove SSV cap and replace thread protector. 6. Open SCSSV hydraulic needle valve at Christmas tree. 7. Open wing valve to flow the well with predetermined choke if required or close the SSV to leave it shut in (whichever is applicable).

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8.4.

Choke Bean-up Procedures When a well has been shut in even for a short period, separation of the well fluids take place in the production tubing results in a gas cap at the tree and the heavier fluids in the well tubing. As the well starts to flow the column of separated fluids rises through the tubing modifying the hydraulics of the well and affecting the Bottom Hole Pressure (BHP). Flow from the tubing results in draw down at the perforations as fluid is drawn down into the well which also results in a fall in BHP. A further effect on the well is the back pressure applied by the choke as the fluid passing through the choke changes from gas to oil/water and on to a combination of three. When the well is brought on line it is important to adjust the well choke in such a way as to avoid sudden changes in flow which could result in pressure changes at the perforations.

A reduction in BHP can release

more gas if the pressure falls below the bubble point, and will result in sand production if the lower BHP threshold is exceeded. The stages for beaning up the choke are as follows: Stage 1 The choke should be cracked open, not more than 10%, to bleed the gas cap from the tubing. The Tubing Head Pressure (THP) will fall as the liquid column rises in the tubing. If the pressure approaches the minimum set by reservoir engineering, reduce the choke setting to maintain pressure. Stage 2 As the liquid column reaches the choke, indicated by an increase in THP and a change in sound from the choke, slowly open the choke to maintain the well flow rate while keeping the THP choke above the lower limit then hold. As fresh fluid enters the tubing, the pressure will steadily increase as the liquid column lightens. Stage 3 When the tubing head pressure has stabilised, indicating that the tubing is now full of fresh fluids, open the choke in steps, allowing conditions to stabilised between each change. Continue until the required choke P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL setting is reached, or alternatively until the required flowing pressure is achieved. Monitor the flowing pressure at the tree and adjust as necessary as the well stabilises. Lab testing procedure (BSW and Sand) 9.0

INTEGRATED SIS/PMCS/FGS AND COMMUNICATION SYSTEMS 9.1.

Integrated Safety Instrumented System/Process Monitoring Control System/Fire and Gas System (SIS/PMCS/FGS) Safety Instrumented System (SIS) and Process Monitoring and Control System (PMCS) are installed on the satellite platform to provide safe operation and shutdown. Due to a very limited I/O for PMCS and power supply constraint on the platform, the PMCS will be integrated with the SIS and FGS, in line with the unmanned facilities philosophy of minimising deck space, electrical power and maintenance requirement. The integrated SIS/PMCS/FGS is installed under a shelter exposed to outdoor environment. The shelter will be located in unclassified area, separated from the process area by a fire wall. The integrated SIS/PMCS/FGS equipment shall be ATEX approved and certified suitable for used in I EC Zone 2, Gas Group IIA, and Temperature Class T3 hazardous area by statutory approving authority. The integrated SIS/PMCS/FGS system cabinet shall be suitable for outdoor installation, weatherproof and has an ingress protection to IP65 of lEC 60529 as a minimum. The cabinet and the components inside shall be corrosion resistant, suitable for use in salt laden, marine saliferous environment without air-conditioning. The Process Monitoring and Control System (PMCS) function shall be carried out by the PLC-based SIS which integrates the PMCS functionality of the platform. TPDP-A platform is designed for remote operation from the Operator Work Station (OWS) Human Machine Interface (HMI) located in the FPSO Central Control Room (CCR), where the operator at CCR shall have full operating capabilities over TPDP-A facilities via the radio link utilizing DMR-UHF technology. The process control and monitoring functionality of the TPDP-A shall include:

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Monitoring of process and utility parameters as well as safety operation of the equipment on the platform

•

Performing logic function, PID control function

•

Control of process variables

•

Process alarms annunciation

•

Start/stop of motors, electrical pumps and heaters

•

Communicating with OWS at the FPSO

•

Communicates with Well Testing MPFM, FWS MPFM, Multiphase Pump Skid local control panel, Crude Heater Unit local control panel, DEG, MTG, and UPS Panel via non redundant serial link on the satellite platform.

•

Well testing data acquisition from Test Multiphase Flow Meter (MPFM) flow computer

•

Metering data acquisition from FWS MPFM flow computer

•

Alarming of process variables

•

Function independently even in the case of communication failure with

FPSO. Safety Instrumented System (SIS) and Fire and Gas System (FGS) shall carry out the required process safety, fire & gas functions and protection functions on the satellite platform. The primary objective of the SIS and FGS is to safeguard personnel, equipment and prevent pollution of the environment. The safety and protection functionality of the unmanned platform shall include: •

Safety shutdown of the platform upon detection of relevant abnormal conditions i.e. ESD-Fire and Gas, PSD or USD. Shutdown status shall be relayed back to the FPSO.

•

Perform shutdown logic as per the Process Cause and Effect Matrix

•

Perform Wellhead Control System logic

•

ESD and PSD initiation from ESD and PSD pushbuttons located at

WHCP •

Remote ESD/PSD initiation from FPSO

•

Remote reset and restart from FPSO on selected PSD which the cause is originated from the FPSO, e.g. shutdown of gaslift,

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL production hold. •

ESD-F and Gas and ESD of the platform shall be reset and restarted

locally •

Activate GPA beacon lights and sounders

•

Alarm annunciation via the EWS/HMI and annunciation of selected alarm via the annunciator panel indication lights at the integrated SIS/PMCS/FGS cabinet door.

•

Provide maintenance and startup override function

•

SIPROD mode of application

•

Fusible plug loop transmitters 2oo3 voting

•

Alarming for gas detection. Alarms for point type flammable gas shall be at 20% LEL and 60% LEL and open path gas detector shall be 1 LEL-meter.

The design concept is based on unmanned operation with remote monitoring and control by the operation personnel at FPSO CCR. In the unmanned mode, Operator Work Station (OWS) which will be the Human Machine Interface (HMI) installed at FPSO CCR shall be the primary operations single window for the remote operation of TPDP-A. In the manned mode the laptop PC shall be the primary operations single window for the local operation of TPDP-A. However OWS at FPSO shall be able to monitor TPDP-A platform. This will be achieved by Remote/ Local mode selector switch at TPDP-A platform. The OWS at FPSO shall be capable to do monitoring and control of key process variables functions. These functions shall also be implemented in the maintenance laptop PC (for local use on the satellite platform during crew visit). As such this laptop PC shall be equipped and configured with Human Machine Interface (HMI) software. A Programmable Logic Controller (PLC) based system shall be used for the integrated SIS/PMCS/FGS functions with the ability to function as a control and monitoring, data transfer and safety system on the platform. In addition, the integrated SIS/PMCS/FGS will also perform the 2oo3 voting scheme of the fusible plug loop pressure transmitters as well as initiating alarm upon gas detection.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL All wellhead control logic shall be performed in the integrated SIS/PMCS/FGS in which the Wellhead Control Panel (WHCP) shall act as the hydraulic interface only.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL The integrated SIS/PMCS/FGS shall be of redundant configuration with redundant power supply and communication to have high reliability and availability. The system shall be designed to meet the requirements for SIL3 PLC in accordance with (EC 61508). The PLC-based system shall justify the requirement for safety equipment, which comply with TUV Class VI as a minimum in accordance to DIN VVDE19250 and DIN VVDE 0801 standards. The laptop PC and the remote Operator Work Station (OWS) are configured to have same data base and shall have same HMI software. The integrated SIS/PMCS/FGS front system cabinet door shall be mounted with annunciators, pushbuttons, Normal/SIPROD mode selector keyswitch and group permissive Maintenance Override Switches (MOS). •

Annunciators The following status indications shall be annunciated with indication lights at the panel:

•

•

ESD Activated Indication Lamp

•

PSD Activated Indication Lamp

•

MOS-Enabled (SIS) Indication Lamp

•

MOS-Enabled (FGS) Indication Lamp

•

SOS-Enabled (SIS) Indication Lamp

•

SOS-Enabled (FGS) Indication Lamp

Pushbuttons (PB) The following pushbuttons shall be provided at the panel for local activation: •

ESD Manual Pushbutton

•

ESD Blowdown Manual Pushbutton

•

PSD Manual Pushbutton

•

Acknowledge / Horn Silence Pushbutton

•

ESD Reset Pushbutton

•

Lamp Test Pushbutton

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The following key switch shall be provided at the panel for local activation: • SIS Maintenance Override (MOS) Key Switch • SIS Start-up Override (SOS) Key Switch • FGS Maintenance Override (MOS) Key Switch • FGS Start-up Override (SOS) Key Switch

• Normal/SIPROD Mode key switch. A key switch is required for selection of normal or SIPROD mode of operation on the platform. The status signal of the selected mode of operation shall be relayed to the FPSO.

• Local/ Remote Mode key switch. A key switch is required for selection of local or remote mode of operation on the platform. The status signal of the selected mode of operation shall be relayed to the FPSO.

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9.2.

Safety Instrumented System (SIS) The Safety Instrumented System (SIS) prevents an uncontrollable sequence of events following process upsets or abnormal plant conditions. In such events, the shutdown system initiates the necessary shutdowns in a controlled manner to bring the facilities to a safe state. SIS carries out the required process safety, fire & gas functions and protection functions on the satellite platform. The primary objective of the SIS is to safeguard personnel, equipment and prevent pollution of the environment. SIS detects potential excursions of the process outside the designed operating envelope and shall necessarily shutdown in a controlled manner to bring the facilities to a safe state. The SIS is a fail-safe system. System faults occurrence is revealed to prevent to cause any unwanted shutdowns. Unrevealed faults are minimized as much as possible. The system has no sources of common mode failures. As a minimum the SIS performs the following functions: •

Safety shutdown of the platform upon detection of relevant abnormal conditions i.e. ESD, PSD or USD. Shutdown status shall be relayed back to FPSO.

•

Wellhead Control System Logic.

•

Remote initiation of ESD/PSD of platform from FPSO.

•

Remote start up after PSD from the FPSO.

•

TPDP-A platform shutdown shall be manually reset and restarted locally after ESD on the platform.

•

Fail safe operation of all shutdown equipment.

•

SIPROD mode of application.

•

Alarming for gas detection. Alarms for point type IR flammable gas shall be at 20% LEL and 60% LEL and open path IR gas detector shall be 1 LEL-meter.

•

Provide maintenance and start-up override function.

•

Alarm annunciation via the EWS/HMI and annunciation of selected

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL alarm via the annunciation panel indication lights at the SIS/PMCS cabinet door. •

Fusible plug loop transmitters 2oo3 voting.

There is no automatic shutdown interface between new FPSO and TPDP-A. In the event of ESD or PSD on FPSO, manual interface of TPDP-A PSD using PSD soft key pushbutton at the FPSO OIS is activated. The OIS is located in the FPSO OCR. 9.3.

Fire and Gas System (FGS) The FGS is a non fail-safe system. The primary objective of the FGS is to safeguard personnel, equipment and prevent pollution of the environment due to fire or gas detection. FGS detects potential gas leakage or flame and shall necessarily shutdown in a controlled manner to bring the facilities to a safe state. As a minimum the FGS performs the following functions:

•

Alarming for gas detection. Alarms for point type IR flammable gas shall be at 20% LEL and 60% LEL and open path IR gas detector shall be 1 LEL-meter.

•

Alarm annunciation via the EWS/HMI and annunciation of selected alarm via

the

annunciation

panel

indication

lights

at

the

Integrated

PMCS/SIS/FGS System cabinet door. •

Fusible plug loop transmitters 2oo3 voting In order to provide a means for fire detection, fusible plugs are judiciously employed at strategic locations on the platform and monitored at the host platform. ESD break glass manual station is located around key areas of the platform to enable personnel to raise the alarm on discovery of a hazardous condition. Gas detectors are provided at wellhead and manifold area to facilitate gas detection and are transmitted back to FPSO via integrated SIS/PMCS system.

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9.3.1. Fire Detection Fire detection on the platform is via fusible plug loops. The fusible plug loops are installed in the open process/utility areas for storage, production or processing of combustible gas or liquid. Fusible plug loops in TPDP-A are driven by instrument gas. For normal applications, plugs melt at 70°C. For applications where the ambient temperature or temperature of the equipment being protected is likely to affect the fusible plug, then higher melting fusible plug will have its temperature setting hard stamped on the fitting body. Activation of a fusible plug is detected by pressure transmitters in the loop wired to the integrated SIS/PMCS/FGS system. Three pressure transmitters are utilised for two out of three (2oo3) voting scheme. Visual flame detector using pattern recognition technology is used to detect fire at the vent boom.

9.3.2. Gas Detection Point type gas detectors are provided at the wellhead and manifold area to facilitate gas detection. The gas detection is for alarming and shutdown.

The gas detectors are hardwired to the integrated

SIS/PMCS/FGS system. The point type gas detectors are mounted near the potential leakage sources, such as flanges. Location of the gas detectors is also taken into account the wind direction and the aspect of accessibility for operation and maintenance. All detectors are accessible for

calibration

purposes

and

are

provided

with

calibration

point/connection. Open-path combustible gas detectors are provided at the wellhead area. The detectors detect the presence and build up of the potentially explosive concentration of hydrocarbon gas cloud from accidental release or leakage dispersion of the hydrocarbon gas. Open-path gas detectors are the primary means of combustible gas detection in the open process area. Open path type gas detectors are provided for alarming and shutdown in the integrated SIS/PMCS/FGS System. P5173B-PR-MAN-1001

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9.4.

Logic for Wellhead Control Panel The wellhead control logic in the integrated SIS/PMCS/FGS includes all wellhead valves sequencing control for well start-up (locally and remotely) and shutdown. The WHCP follows a fail safe design such that loss of hydraulic supply shall result in release of actuating medium pressure and sequentially timer based closure of SSV and SCSSVs. The WHCP interfaces with the integrated SIS/PMCS/FGS via hardwired signals. Pushbutton is provided at the WHCP for local commands. A WHCP pushbutton command signals are relayed to the integrated SIS/PMCS/FGS via hardwired for consecutive action performed by the wellhead control logic in the integrated SIS/PMCS/FGS. The SIS is used to perform the logic for controlling the sequential opening and closing of the SSVs and SCSSVs associated with the production wellheads on TPDP-A platform. Contact inputs from pushbuttons in the WHCP initiate the individual valve operation and SIS outputs energize electric solenoid in the WHCP to stroke the valves. PMCS provides open and close command to SIS to open and close these

valves

for

operating

requirements.

Shutdown

commands

generated by the SIS in response to the process safeguarding logic close these valves. The SIS commands override the PMCS commands.

9.5.

Logic for SIPROD During SIPROD, all PSDs and USDs are converted to result in ESD, through

Normal/SIPROD

mode

key

switch

at

the

integrated

SIS/PMCS/FGS cabinet door annunciator Panel. Al! ESDs initiated during SIPROD mode initiate automatic blowdown. SIPROD Alarm Panel is provided on the drilling rig near the driller's console to alert personnel on the rig of the platform abnormal condition, through pneumatic horn in the panel. The panel pneumatic horn is activated upon platform ESD driven from the integrated SIS/PMCS/FGS. A pneumatic horn driven by the drilling rig SIPROD Alarm Panel is provided at the platform which is activated to acknowledge successful P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL activation of the drilling rig's pneumatic horn. Instrument air supply is provided by the drilling rig operator during SIPROD operation. Drilling rig is provided with ESD manual break glass stations at the SIPROD Alarm Panel and at strategic locations of the rig. Activation of the manual break glass stations and confirmed fire signal from the rig shutdown system activate ESD from the drilling rig to initiate audible and visual alarm on the platform through the integrated SIS/PMCS/FGS. 9.6

Override Facilities

9.6.1. Maintenance Override Switches (MOS) Group Permissive Maintenance Override Switches (MOS) are provided via key switch per protection group for the SIS and FGS field devices and is hardwired to the integrated SIS/PMCS/FGS. Individual device override is through soft-buttons at the EWS/HMI. Bypass to any device in the MOS group light the bypass indication light of the MOS group mounted on the annunciator panel on the integrated SIS/PMCS/FGS cabinet door. Status of the group permissive MOS key switch as well as the individual device override is relayed to the FPSO. The group permissive MOS key switch is located at the Annunciator Panel mounted on the integrated SIS/PMCS/FGS cabinet door. Maintenance override is removed by either un-bypassing the device via the software link at the integrated SIS/PMCS/FGS, EWS/HMI soft-button or returning the group permissive MOS key switch to normal position.

9.6.2. Start-up Override Switches (SOS) Start-up Override Switch (SOS) is provided for all shutdown circuits that are in low low shutdown condition during start-up. SOS is provided to override these circuits during start-up. The functionality of start-up override is provided in the integrated SIS/PMCS/FGS software. SOS for group permissive and individual circuit override is provided in softbuttons at the EWS/HMI. To implement remote startup from FPSO, SOS for group permissive and individual circuit override is provided in softbuttons at the FPSO PMCS HMI.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Protection (password, access level, etc) is applied on the platform EWS/HMI as well as the FPSO PMCS HMI to avoid accidental operation of the button. Double confirmation is requested as the soft-buttons is toggled to ensure safety of the process.

9.7.

Communication System Communication facilities installed on the platform consist of a radio link to the FPSO utilizing (1+1) Hot Standby Space Diversity DMR-UHF technology, equipped with a minimum capacity of 4E1 VHF-FM radio telephone terminal and 'tie-in' facilities for Drilling communications). The equipments convert any other power voltage requirement internally.

9.7.1. DMR-UHF Radio System (1+1)Hot standby Space diversity DMR-UHF Radio system with the minimum capacity of 4E1 is installed at TPDP-A for intra platform communication to FPSO. This backbone communication will function for integration purposes of voice and data transmission from TPDP-A to FPSO. The provision of UHF Radio system will be used as process control, monitoring and telemetry signals in real time fashion between TPDP-A and FPSO. The radio system have built in capability to provide voice, data interface to equipment for interconnection with existing PABX and

Integrated

PMCS/SIG/FGS

System

and

others

equipment

packages.

9.7.2. VHF-FM Radio System One unit of VHF-FM marine based transceiver radio c/w l.S. type handheld VHF-FM radio is provided on TPDP-A platform to facilitate radio communication between the platform and FPSO as well as supply boat and vessel in the vicinity.

9.7.3. Drilling Rig Communication System The drilling contractor is provided his own separate IEC approved communication equipment which shall include HF / SSB, VHF / FM and VHF / AM ground-to-air using PCSB frequencies. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Two communication channels (for telephone) is provided to enable Drilling rig system to be tied-in to TPDP-A.

9.7.4. Telecommunication System The telecommunication equipment is installed in the FPSO control room. The antenna location is located at the line of sight between TPDP-A and FPSO. Omni directional antenna is used. Installation of antenna and other

telecommunication

equipment

is

done

after

taking

into

consideration the movement of the FPSO. 10.0

FIRE AND SAFETY SYSTEM 10.1.

General Safety Precautions

10.1.1.Fire and Accident Prevention The prevention of fires and accidents on the platform depends upon: •

Good design.

•

Continuous control and monitoring of the process, through the automatic and manual control systems and equipment to detect failures such as gas detectors.

•

Through strict control of work activities, through the Permit to Work system and HSEMS.

The process instrumentation automatically controls the process within set operating limits. If the operating parameters drift outside of these set limits a shut down is initiated to a level determined by the nature of the problem. Control of work is by the use of the Permit to Work system which ensures that personnel involved fully understand the safety requirements and that a safe work environment is provided in which the task can be performed. To ensure that equipment installed on the platform is suitable for the environment the platform is divided into areas classified from IP 15 as follows: •

Hazardous Area, Zone 0

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL The part of a hazardous area in which a flammable atmosphere is continuously present or present for long periods. •

Hazardous Area, Zone 1 The part of a hazardous area in which a flammable atmosphere is likely to occur in normal operation.

•

Hazardous Area, Zone 2 That part of a hazardous area in which a flammable atmosphere is not likely to occur in normal operation, and if it occurs.-will exist only for a short period. An area is designated as non-hazardous if an explosive gas/air mixture is not expected to be present in such quantities that special precautions are required. Effective training of personnel in operation and safety techniques and a program for planned maintenance and inspection are the best methods of accident prevention.

10.1.2.Hazardous Gas Events The platform ventilation system design maximises the use of natural ventilation in all open areas. The personnel shelter located at the cellar deck is in the safe area. 10.1.3. Lifesaving Arrangements Currently located on the platform is two numbers of 12-man inflatable lift rafts located at the South East and North West corner of the cellar deck, for use of means of escape, in the event of a fire on board. Embarkation into the lift rafts is by emergency rope ladder, where no fixed ladders are provided. 48 nos of lifejackets are also stored in stainless steel containers near the life rafts. Each container contains 12 nos of lifejackets and located at the strategic positions on all decks of the platform. There are 13 life buoys to assist in rescuing a man from the sea. Where personnel might come into contact with hazardous chemicals e.g. at the chemical transfer area at main deck and chemical injection skid area at cellar deck, a self contained and fixed emergency safety shower and eye wash stations are provided respectively. The platform P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL operators to ensure that sufficient water is available in potable water tank to support the fixed safety shower at all time. The exact location of the equipment is shown on Equipment Layout Drawings in Appendix-II.

10.1.4.Alarm and Shutdown Visual and audio alarms are provided at strategic location on the platform. These alarms are indicated upon fire and gas detected.

10.1.5.Safety Shutdown Philosophy The process shutdown functions of TPDP-A wellhead platform is implemented via Safety Instrumented System (SIS) for safe shutdown of the platform. Automatic shutdown of a process unit and/or the overall platform is initiated once the process sensors are triggered due to process abnormalities within the process system and/or by the fire and gas detection by FGS. The manual shutdown can be activated locally using the manual pushbutton located on the Integrated PMCS/SIS/FGS System or remotely using the "soft" pushbutton from the operator station on- FPSO via the communication link. WHCP serves to operate and control the hydraulic system of the wellhead safety valves e.g. SSV and SCSSV for each well string. By having the wellhead control logic performed in the Integrated PMCS/SIS/FGS System, the WHCP only acts as the hydraulic interface. The Integrated PMCS/SIS/FGS System interfaces with the WHCP via hardwired signals for SSV(s)/SCSSV(s) status and open/close command and the hydraulic system status. Remote control capabilities from OWS on FPSO are provided for the following: •

Initiation of ESD with blowdown, ESD without blowdown and PSD of

TPDP-A platform •

Reset and restart of USD and PSD for TPDP-A from the FPSO when it is safe to do so (local reset is required for a shutdown due to ESD).

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There are no automatic shutdown interface between new FPSO and TPDP-A. All trips initiated due to upset of the new FPSO facilities have no automatic executive action on TPDP-A. Any trips on the TPDP-A platform also have no automatic executive action on the new FPSO. In the event of ESD or PSD on the new FPSO, manual initiation of PSD on TPDP-A from soft key push button at FPSO HMI is required.

10.2.

Fire Precautions

10.2.1. Fire Fighting The requirements for effective fire fighting are as follows: •

Personnel should be familiar with fire fighting equipment and posses the necessary skills to use it effectively.

•

Establishment of fully trained fire fighting teams.

The instruction and training in fire fighting bring attention to the following general points: •

Organisation and methods for fire fighting, classification of fires and methods of extinguishing

•

Knowledge of the materials and equipment

•

Types of detection and alarm signals

•

Measure to control escalation of fires and to provide the water supply (during SIPROD only) for fire fighting etc.

Drills should be held regularly using various realistic scenarios where the fire fighting team operates the equipment and familiarise themselves thoroughly the layout of the platform. Drills must be held at least as frequent as the regulations specify. The drills should be entered in detail in the platform log book. All personnel working on the platform should be aware of the location of the life buoys and lift raft station and should know the safe access route to these stations. Drills should include familiarisation with access routes and procedure for wearing lifejackets. P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 10.2.2. Ignition Sources Electrical systems which could produce a spark of sufficient energy to ignite a flammable gas mixture are protected in accordance with IEC 60079. Surface temperatures of other equipment are treated in the same way and are reduced by insulation or by cooling the contents of the system where practicable. The hot exhausts from combustion equipments are considered as potential sources of ignition. To eliminate this problem, all exhausts are taken to the edge of a non-hazardous area and extended into this nonhazardous area by minimum of 1 meter. Flame arrestors are available on open areas. Within a hazardous area, the maximum external surface temperatures of equipment, piping systems and exhausts are limited to 200°C. Other potential sources of ignition which may be present in hazardous areas during the project such as welding or gas cutting are controlled by the Permit to Work system.

Electrical Equipment Electrical equipment installed in a hazardous area is certified for the use in the appropriate zone classification and comply with the requirement of IEC 60079. The equipment is certified with minimum temperature classification of T3 (200°C) maximum surface temperature. The electrical equipment is classified for use in the presence of group IIA gases.

Mechanical Equipment All mechanical equipment installed in hazardous areas is manufactured to ensure the rotating parts are non-sparking and adequately protected against the generation of a static charge. Surface temperatures shall not exceed 200°C. The use of aluminium is restricted. 10.2.3. Fire Prevention P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Fire is a present risk and PREVENTION is better than cure. Most fires may be prevented simply by attending to the following: •

Proper storage of flammable materials both solids and liquids

•

Good house keeping by keeping all areas clean and tidy

•

The correct use of electrical equipment

•

Being conscious of the risk and observing the relevant regulations

There are three requirements to enable fire to exist: FUEL, OXYGEN and HEAT. The basic way of fighting a fire is to remove one of these requirements: •

By removing the FUEL Such as removing fuel from a burning tank to shorten the duration of fire

•

By preventing the supply of OXYGEN By covering with a bore blanket or spreading the dense foam over the burning material.

•

By reducing the HEAT

By using a cooling medium, such as water to reduce the temperature of a material to a point where combustion ceases. The most successful fire fighting techniques use a combination of two or all of these methods though any one will reduce the intensity of fire. When a flammable mixture of petroleum vapour burns, the mixture expands. On an open deck the rapidly expanding gases quickly dissipate without resistance. In a tank or other enclosed space, the rapidly expanding gases are confined, the resulting instantaneous built up of pressure results in mechanical failure releasing more fuel and explosion. Hydrocarbon fires start very easily and once started they are difficult to extinguish. To prevent hydrocarbon fires and explosion, mixtures of hydrocarbon vapour and air must NEVER be allowed to come into contact with sources of ignition. 10.2.4. General Procedures P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL Platform personnel must: •

Know the location of all emergency equipment

•

Know when and how to use alternative emergency equipment

•

Maintain all emergency equipment in a clean and operable condition ready for immediate use

•

Ensure the drainage system for liquid spills are kept clear at all times to limit pool fire size

Fire may be controlled and extinguished using the following: •

Water Water is used primarily on fires involving wood and papers as in domestic fires. If water is to be used on hydrocarbon fires, it should be applied in the form of fine spray. If too much water is used on a hydrocarbon fire, the fire could be spread as the burning oil floats away on the water. Water should not be used on electrical fires until it has been ascertained that the power supplies are cut off.

•

Dry chemical powders Dry chemical is suitable for most types of fire and is provided in portable appliances located at strategic points around the platform. When dry powder is used to extinguish an oil fire, re-ignition is extremely likely. Application to an oil fire should be followed by foam or water spray to ensure that fire does not re-ignite. Dry chemical is effective against electrical fires and suitable as there is no danger of electric shock. However, the chemical may leave a powdery deposit on electrical contacts.

•

Carbon Dioxide Carbon dioxide is suitable for electrical fire and enclosed area and is provided at instrument area, Electrical area and shelter.

•

Foam Solution Foam solution is suitable for hydrocarbon fire and spills and is provided in portable appliances located at strategic location around the platform.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL 10.3. Firewater System A dry firewater ring main is installed on the platform. Firewater supply during drilling (SIPROD) operations is provided from the drilling rig/barge while firewater supply during scheduled maintenance is from the supply boat. A 150mm firewater tie-in is provided at the main deck for connection into rig firewater pumps. Other firewater tie-ins (two separate) are also provided at the boat landing for standby boat connection. The firewater supply is fed from the firewater pumps located on the drilling vessel or via water pumps located on standby or work vessels to the 150 mm fire water ring main. The firewater distribution system consists of a firewater ring main located on the cellar deck with risers up to the main deck. Hydrants are not provided, however there are four monitors, two at main deck, and two at cellar deck level. Firewater monitors located on the main deck shall be of the easy removable type to cater for drilling rig approach. The ring main pressurisation is maintained at approximate 11 barg which, conform to design pressure as 16 barg. The drilling rig shall supply a 700 US gpm filtered firewater supply. Rig operators shall ensure firewater system is tested regularly during SIPROD operation procedure confirms that the main firewater pump and standby firewater pump deadhead pressure is within the design pressure rating. A system preservation procedure is developed to ensure firewater system integrity for later drilling campaign. When switching to NORMAL mode of operation, the firewater ring main is drained and kept isolated.

10.4. Fusible Plugs Fusible plug loops is provided for the open process/utility areas of the platform with the fusible plugs installed/distributed on TPDP-A facilities. The fusible plugs are located above process equipment accordingly such that any possible fire will have an acceptably high probability of quickly melting a nearby plug.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL During fire, the pressurised fusible plug loop is depressurised through the melted plug(s). Confirmed fire detection is by low pressure detection using three (3) pressure transmitters loop-powered from the integrated SIS/PMCS/FGS

with

two

out

of

three

(2oo3)

voting

scheme.

Depressurisation of fusible plug loop till low pressure detection of the pressure transmitters do not exceed 45 seconds.

10.5. Fire & Gas Devices Point type infrared combustible gas detectors (i.e. for hydrocarbon gas) are preferred over the catalytic-type detectors. Point type gas detectors are provided at the wellhead and manifold area to facilitate gas detection. Alarms for point type HC gas detection shall be at 20% LEL and 60% LEL. Open-path combustible gas detectors are provided at the oil production and gaslift manifold. The initial set point is set at 1 LEL-meter (gas cloud of 5 meter having an average concentration of 20% LEL). The gas detectors are hardwired to the integrated SIS/PMCS/FGS with alarm indication function provided. Flame detector is provided for the utility gas vent header. The operation of the flame detector is only initiating an alarm.

10.6. Active Fire Protection and Fire Fighting Fire protection for the platform is provided through active fire systems comprised of a variety of portable fire extinguishers positioned at strategic locations around the platform. The smaller portable units are housed in conspicuous red stainless steel boxes for whether protection. The portable extinguishers are supplemented by monitors supplied with firewater from the drill rig through the fire water ring main. Wheeled and portable fire extinguishers are located at strategic locations throughout the platform. Portable extinguishers located in exposed areas are mounted in weather proof stainless steel cabinets. The portable 9 kg dry powder fire extinguisher units which are pressurised to eject the powder from the nozzle on the end of a short flexible hose are provided on the platform. The cylinder is pressurised P5173B-PR-MAN-1001

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL using a small C02 cylinder mounted on the cap of the extinguisher. The gas is released as the extinguisher is operated and time should be allowed for the cylinder to pressurise before the valve on the dispenser nozzle is opened. Failure to do this will result in mal-operation of the extinguisher. After use the unit must be taken out of service for cleaning and replenishment. The AFFF (Aqueous Film Forming Foam) extinguisher produces a foam blanket to smother a fire from a 1 % solution of AFFF in water. The foam solution is contained in a cream cylinder which is pressurised on operation to aerate the solution to produce foam which is ejected from the dispenser nozzle under pressure. The cylinder is pressurised using a small C02 cylinder mounted on the cap of the extinguisher the gas being released when the extinguisher is operated. After use the unit must be taken out of service for cleaning and replenishment The portable 5kg C02 fire extinguisher is provided at the Instrument, Electrical and temporary shelter area, total 5 nos. The extinguishers containing carbon dioxide in liquefied and compress state. After use the unit must be taken out of service for cleaning and replenishment. Five 45 kg dry powder extinguisher are provided in the Main deck (3 nos) and cellar deck (2 nos). The powder drum is pressurised to expel the powder by a manually operated C02 cylinder mounted on the unit. When required for operation the unit should be wheeled to a location from which the hose can easily reach the fire. The valve on the C0 2 cylinder should then be opened and time allowed for the drum to pressurise before opening the dispenser nozzle. When the unit has been used, whether fully or partially depleted, the cylinder valve should be closed and the unit depressurised through the dispenser nozzle. The hose and dispenser should be blown out using air, C02 cylinder replaced and the drum refilled before the unit is put back into service. A vent snuffing by the C02 snuffing system is provided to extinguish the flame at the vent tip in the event of accidental ignition. C0 2 snuffing can be activated either remotely from FPSO or locally at integrated SIS/PMCS system.

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Escape Routes & Safety Sign and Safety Equipment The escape routes and location of safety equipment on the TPDP-A platform are shown on the following drawings: X-2402

Safety and Fire Fighting Equipment Layout and Escape Route – Helideck/ Main Deck

X-2403

Safety and Fire Fighting Equipment Layout and Escape Route – Cellar Deck

X-2404

Safety and Fire Fighting Equipment Layout and Escape Route – Closed Drain/Sump Deck

X-2405

Safety Sign Layout - Helideck/ Main Deck

X-2406

Safety Sign Layout - Cellar Deck

X-2407

Safety Sign Layout - Closed Drain/Sump Deck

10.8. Hazardous Area Classification The hazardous areas for the PLDP-A platform are shown on the following drawings: E-9500 (sh 1 to 3)

Hazardous Area Classification Schedule

EL-9501

Hazardous Area Classification Helideck/Maindeck

EL-9502

Hazardous Area Classification Cellar Deck

EL-9503

Hazardous Area Classification Sump Deck

EL-9504

Hazardous Area Classification Elevation Looking East

EL-9505

Hazardous Area Classification Elevation looking South

EL-9506

Hazardous Area Classification Helideck/Maindeck -

SIPROD

10.9.

Platform Evacuation Procedure Since the TPDP-A platform is normally unmanned a procedure for evacuation has been developed which is published and included in the safety briefing for all personnel visiting the installation. The responsibility for ensuring that the necessary actions in an evacuation have been performed lies with the Sr. Wellhead Operator, nominated as being in overall charge by the Field Superintendent.

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rnz integrated (m) sdn. bhd (325798-X) TOPAZ DEVELOPMENT PROJECT START UP AND OPERATING MANUAL If a hazardous situation develops on the platform resulting in an ESD, the Sr. Wellhead Operator ensures that all work sites have been made safe. In the case of a gas escape there are visual and audible alarms activated with automatic shutdown so it is the responsibility of the individual identifying the situation to initiate an ESD pushbutton manually at the SIS or manual ESD stations around the escape route and inform the nominated supervisor of the situation. There are visual and audible alarms on the platform so if the hazardous situation occurs, the nominated supervisor must ensure he has communication links with ALL personnel on the installation and all personnel are accounted for. The Sr. Wellhead Operator should inform the FPSO of the situation and any casualties then organise his resources to correct the situation be it fire or process incident, using the emergency equipment available on board, without further risk to life or limb. If the incident escalates a decision is made by the nominated Sr. Wellhead Operator to evacuate all personnel from the platform. To do this he will call in the field support vessel and organise a muster of all personnel on the boat landing to ensure everyone are assembled at the boat landing transfer to the field support vessel can commence. 11.0

APPENDICES APPENDIX A

Process and Instrumentation Diagrams (P&IDs)

APPENDIX B

Platform Layout Diagrams

APPENDIX C

Cause & Effect Matrices

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APPENDIX A PROCESS AND INSTRUMENTATION DIAGRAMS (P&IDS)


APPENDIX B PLATFORM LAYOUT DIAGRAMS


APPENDIX C CAUSE & EFFECT MATRICES

Topaz Start Up OPerating Manual

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