INSTALLATION, OPERATING AND MAINTENANCE MANUAL
ALIANZA CASABE ELECTROS ELECTROSTA TATIC TIC HEAT HEATER ER TREATER TREATER R-TTE-36-1-1
CPE JOB NO. 12052
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520 70520
Job No. 12052
WARNING STATEMENT HAZARDS AND SAFETY CONSIDERATIONS
(ll personnel s!oul) !ave a complete un)erstan)ing o*$ an) compl# "it!$ all man)ator# regulations an) site operating opera ting proce)ures proce)ure s pertinent to t!e installe) equipment. !e *ollo"ing *ollo"ing in*ormation s!oul) be regar)e) as a general a)vice onl# an) s!oul) never be )eeme) to ta+e prece)ence over local regulations regulations i* a con*lict con*lict apparentl# e,ists. e,ists. Never commence commence an# "or+ involvi involving ng t!e equipment equipment until t!e appropriate aut!ori-ation !as been obtaine)$ i.e.$ i.e .$ b# issue issue o* a Permit to Wor+/. Wor+/. e*ore procee)ing$ proc ee)ing$ it is imperative imperative to !ave a *ull a"areness o* t!e potential !a-ar)s an) sa*et# precautions involve) an) to observe all relevant sa*et# an) aut!ori-ation proce)ures. Ensure t!at all emerg emergenc# enc# proce)ures an) escape escape routes are *ull# un)erstoo) an) t!at t!e location o* alarm$ communication an) *irst ai) *acilities is +no"n. The e!"#$e%& 'h(!)* %e+e e (#e&e* !%)e'' "& "' "% /!)) 'e+"e)e (%*"&"(%. !e equipment s!oul) onl# be operate) an) service) b# properl# traine) an) quali*ie) personnel. 'uc! personnel must +no" "!ic! instruments an) items o* equipment are installe) *or t!e purposes o* operational an) personnel personnel sa*et# sa*et# an) "!ic!$ "!ic!$ t!ere*ore$ 'h(!)* %(& e e$(+e*, #''e*, $(*"/"e* ( *!'&e* in an# "a# t!at ma# preu)ice sa*et#. sa*et#. uring routine maintenance or repair activities$ it must be ensure) t!at t!e equipment cannot be operate) until "or+ is complete) an) all items correctl# *itte)$ all process connections properl# ma)e$ an) t!e integrit# o* electrical an) eart! connections connec tions c!ec+e). &naut!ori-e) &naut!o ri-e) mo)i*ications mo)i*ications ma)e$ an) t!e integrit# o* non3proprietar non3pro prietar# # replacement parts ma# also invali)ate invali)ate t!e "arrant#. * queries arise relating to "or+ on t!e equipment$ al"a#s re*er to t!e speci*ic instruction )ocument *or t!e particular items6 items6 concerne) concerne) be*ore procee)ing.
n a))ition to t!e particular /"e %* e#)('"(% "'4' presente) b# !#)rocarbon liqui)s an) gases$ several ot!er !a-ar)s to sa*et# an) environmental !ealt! are commonl# encountere). encoun tere). 'ome suc! !a-ar)s$ an) precaution pre cautionar# ar# measures to minimi-e minimi-e t!em$ are set out belo". !e list is b# no means e,tensive an) t!e potential ris+s associate) "it! an# servicing activit# s!oul) be ver# care*ull# consi)ere) be*ore "or+ is un)erta+en. HAZARDOUS AREAS - FIRE AND EXPLOSION RISKS
W!ere t!e equipment is use) "it! potentiall# e,plosive or *lammable liqui)s$ gases or atmosp!eric )ust$ or "!ere t!e equipment operates in t!e pro,imit# o* suc! materials$ no "or+$ especiall# t!at involving t!e use o* an e,pose) na+e) *lame or ot!er possible source o* ignition$ s!oul) be attempte) until t!e material representing t!e !a-ar) !as been completel# remove)$ b# suitable )raining$ purging an)or ventilation. Never procee) until t!e appropriate appropria te aut!ori-ation !as been obtaine). obtaine) . Electrical apparatus$ inclu)ing test equipment$ ma# constitute constitu te an ignition ignition source an) s!oul) not be use) in t!e presence o* a *lammable gas or ot!er e,plosion !a-ar) unless it is speci*icall# )esigne) an) )ul# certi*ie) *or t!e purpose.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520 70520
Job No. 12052
WARNING STATEMENT HAZARDS AND SAFETY CONSIDERATIONS HIGH PRESSURE HAZARDS
Certain parts o* t!e equipments#stem suc! as process vesselspipe"or+$ compresse) air lines$ etc.6$ ma# retain a !ig! level o* pressuri-ation$ even a*ter complete s!ut)o"n. Ensure t!at suc! parts !ave been completel# )epressuri-e) an) vente) be*ore )ismantling an# oints$ instruments$ valves$ etc. 8ailure to )o so ma# result in a )angerous release o* pressuri-e) material$ an)or t!e eection o* parts$ "it! e,plosive *orce. TOXICITY AND CORROSIVE HAZARDS
e*ore e,posing onesel* to contact "it! process liqui)s an) *ume3la)en atmosp!eres$ establis! t!e e,tent o* t!e to,icit#corrosive !a-ar) t!at suc! materials present. (l"a#s observe t!e sa*et# regulations concerning suc! c!emical substances. !e in!alation o* an# )ust an) *umes$ or contact "it! even apparentl# !armless *lui)s$ lubricants$ etc. ma# be !arm*ul to !ealt!$ )epen)ing on in)ivi)ual allergic reactions. Certain electrical components "!ic! become bro+en or over!eate) ma# release to,ic *umes or )ust "!ic! s!oul) be treate) "it! caution an) not in!ale) or allo"e) to enter open cuts an) abrasions. t is t!ere*ore pru)ent to regar) all )amage) components as being potentiall# to,ic. ASPHYXIATION AND DROWNING HAZARDS
Ne+e e%&e a vessel$ tan+ or ot!er enclose) space "it!out *irst ensuring t!at it contains no gas or resi)ual *umes "!ic! ma# cause asp!#,iation. (l"a#s ensure t!at suc! places are a)equatel# ventilate) be*ore commencing "or+ t!erein. W!en "or+ing near t!e sea$ open containers or ot!er large volumes o* liqui)$ ensure t!at t!e ris+ o* )ro"ning is eliminate) s!oul) an# person *all into or ot!er"ise become immerse) in t!e liqui).
(l"a#s ensure t!at suc! "or+ is +ept un)er constant observation b# anot!er person or persons 3 %e+e (4 !%&&e%*e*. (lso ensure t!at a responsible aut!orit# is a"are t!at suc! "or+ is in progress. * necessar#$ an) especiall# "!en t!e personnel are obscure) *rom general vie"$ post suitabl# place) notices to "arn o* suc! activit#. ELECTRIC SHOCK HAZARDS
%et!all# !ig! voltages ma# be present in certain parts o* t!e equipment. 'uc! equipment s!oul) onl# be installe)$ service) an) maintaine) b# competent persons. '"itc! o** t!e electrical suppl# to t!e equipment$ an) "it!)ra" t!e *uses$ be*ore opening )oors or removing covers *rom an# suc! electrical part. (l"a#s replace covers properl# an) ensure t!at t!e integrit# o* t!e sa*et# eart! s#stem !as been *ull# maintaine) a*ter "or+ is complete.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
WARNING STATEMENT HAZARDS AND SAFETY CONSIDERATIONS HIGH TEMPERATURE HAZARDS
e"are o* !ot metal sur*aces an) pipe"or+$ process liqui)s$ ets o* escaping steamgas$ etc. o prevent burning an) scal)ing$ al"a#s "ear gloves an) ot!er protective clot!ing "!enever "or+ing in areas "!ere suc! !a-ar)s e,ist. HANDLING AND LIFTING HAZARDS
e*ore attempting to li*t or maneuver an# item o* equipment$ especiall# !eav# items$ t!e sa*et# implications o* )oing so s!oul) be care*ull# consi)ere). (l"a#s ensure t!at t!ere is su**icient space available to per*orm t!e tas+$ an) t!at ot!ers in t!e vicinit# are clear o* an# ris+ an) t!at t!e tas+ is "it!in t!e li*ting!an)ling capacit# o* an# li*ting )evice or ot!er apparatus involve). (l"a#s "ear suitable *oot"ear$ notabl# "it! rein*orce) toecaps$ an) gloves i* necessar# to ensure a sa*e an) a)equate grip on t!e item being !an)le). MOVING MACHINERY HAZARDS
Never un)erta+e an# "or+ in close pro,imit# to rotating or ot!er moving mac!iner# unless a)equate guar) precautions are in place or$ pre*erabl#$ until t!e moving mac!iner# !as been stoppe) an) loc+e) in a sa*e con)ition. SAFETY ALOFT
e*ore starting an# "or+ in !ig! places$ ensure t!at t!e appropriate responsible aut!orit# is a"are o* suc! "or+ in progress an) t!at suitabl# place) "arning notices !ave been poste) at )ec+ or groun) level. * sca**ol)ing is to be use)$ it s!oul) be erecte) an) inspecte) b# properl# traine) an) approve) personnel in *ull accor)ance "it! site operating proce)ures. Ensure t!at personnel use appropriate sa*et# apparatus$ suc! as proper !arnesses$ etc. Ensure t!at t!e means o* access alo*t is secure an) be"are o* "et or slipper# la))er rungs$ !an)rails an) "or+ing areas. PERSONAL PROTECTION
()equate protective clot!ing$ appropriate to t!e tas+$ s!oul) al"a#s be "orn as a precaution against inur#. 'uc! clot!ing ma# inclu)e !ea)gear$ *ace$ mas+$ overalls$ gloves$ *oot"ea r$ ear an) e#e protection. !e sa*et# aspects o* servicing activities s!oul) be care*ull# assesse) be*ore starting "or+ an) appropriate measures ta+en to eliminate or minimi-e an# !a-ar)s.
ENVIRONMENTAL CONSIDERATIONS
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
ispose o* all consumables an) replace) parts sa*el# an) in accor)ance "it! man)ator# regulations an) site operating proce)ures. C!ec+ "it! t!e responsible aut!orit# be*ore )isposing o* an# c!emical substance.
TABLE O CONTENTS
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
I.
.
esign asis
.
asic 9peration
.
nstallationCommissioning
:.
'tart3&p ; '!ut)o"n
:.
:.
roubles!ooting
De'"7% B'"'
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
tem
=3E3>?3131
:essel iameter 96$ inc!es :essel %engt! ss6$ *eet esign Pressure$ P'@ esign emperature$ A8 9perating Pressure$ P'@ 9perating emperature$ A8 @as 8lo" =ate$ <<'C8 8P 8lo" =ate
120 2> 100 1B0 >5 140 0.011 7$500 1.0 0.B4? 1.0> B5 100 0.125 104
8iel) is locate) in a ropical Environment 'ite elevationF B? meters above t!e sea level
II.
B'" O#e&"(%
!e purpose o* t!e Electrostatic 9il Deaterreater is to remove pro)uce) "ater
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
*rom cru)e oil. !is process o* )e!#)rating t!e cru)e oil is t!e pre*erre) met!o) over a stan)ar) gravit# separator since t!e "ater outlet o* 1.0 volume cannot be guarantee) using a gravit#/ separator "it!out *urt!er !eating an) electrostatic internals to en!ance t!e )roplet gro"t! an) p!ase separation. !e process requires oil to be *ree o* gas to ensure t!e electrostatic section operates *ull o* liqui). !e cru)e oil enters t!e !eating section o* t!e vessel "!ere it is !eate) to appro,imatel# 140A8. Deating o* t!e oil allo"s *or improve) separation o* t!e "ater *rom t!e oil. 8ree "ater )rops out to"ar)s t!e bottom o* t!e vessel "!ere it is )isc!arge) t!roug! a level control valve %C:3>?01(16 controlle) b# an inter*ace level transmitter %3>?01(26. !e vessel utili-es t"o 26 1.5 <<&Dr natural )ra*t burners an) 26 24/ )iameter *ire tubes to *acilitate pro)uct !eating. Process control an) emergenc# s!ut)o"n actions are controlle) b# a locall# mounte) P%C control panel. !e burner s#stems an) temperature control are accomplis!e) in t!e urner ?01(26 "!ic! is controlle) b# inter*ace level transmitters %3>?01(46. !e oil level in t!is coalescing section is maintaine) an) controlle) b# a level transmitter locate) in t!e oil buc+et %3>?01(>6. !is transmitter operates an oil )isc!arge valve %C:3>?01(>6 locate) in t!e oil outlet piping. (n e,ternall# mounte)$ oil immerse)$ !ig! voltage trans*ormer is *urnis!e) to provi)e po"er to t!e gri) section. !e trans*ormer is equippe) "it! a reactor "!ic! provi)es 100 circuit utili-ation *or continuous po"er. !e !ig! voltage secon)ar# o* t!e trans*ormer is connecte) to t!e gri)s t!roug! !ig! voltage entrance bus!ings "!ic! insulates it *rom t!e surroun)ing metals. (ll electrical components are suitable *or !a-ar)ous area installations.
rans*ormer is a Neeltran 25 H:( Da-3%oc po"er unit$ 100 reactance$ mineral oil *ille)$ !ermeticall# P ?? seale) carbon steel tan+$ o**s!ore epo,# paint *inis!$ )esigne) an) built to meet stan)ar)s *or Class 1$ iv.2 $ @roup . Primar# voltage$ 4B0 :(C$ 1 p!ase$ ?0 D-. 'econ)ar# 121?.5202>25 H:(C via pa)loc+e) tap s"itc!. 'ee (ppen)i, ( *or trans*ormer "iring sc!ematic.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
Process control an) E' *unctions are monitore) an) controlle) b# a local P%C panel. 'ee P%C an) urner
'a*et# '#stems :arious sa*et# s#stems are provi)e) on t!e unit to prevent !a-ar)ous situationsF !e *irst categor# o* sa*et# )evices provi)es alarms in case o* an abnormal process con)ition. !ese alarms in*orm t!e operator o* possible s#stem mal*unction. !e secon) categor# o* sa*et# )evice per*orms emergenc# s!ut)o"n *unctions. n t!e case o* an abnormal process con)ition suc! as a !ig!$ !ig! liqui) level$ !ig!$ !ig! temperature$ etc.$ t!ese )evices "ill respon) to prevent escalation o* t!e upset con)ition b# per*orming s!ut)o"n activities. !e t!ir) categor# o* sa*et# )evices are relie* valves "!ic! protect t!e s#stem in case o* an over3pressure con)ition. 8or *urt!er in*ormation concerning t!e concerning t!e sa*et# s#stem activities$ please see t!e Cause an) E**ect iagrams$ (ppen)i, C. Normal 9perations uring normal operations$ oil *lo" rates$ pressures$ temperatures an) t!e oil"ater inter*ace level s!oul) be monitore) )ail# an) maintaine) "it!in )esign parameters an) normal operating ranges. !e oil leaving t!e oil treater vessel s!oul) be teste) perio)icall# to veri*# compliance "it! compan# requirements suc! as ';W content. 'imilarl#$ t!e "ater leaving t!e vessel s!oul) also be anal#-e). 'ample points are provi)e) to *acilitate operators "it! )ra"ing samples *rom )i**erent sections o* t!e vessel an) *rom oil outlet piping. 9perators s!oul) c!ec+ *or lea+s on a )ail# basis. %ea+s s!oul) be repaire) imme)iatel#. 'ee process *lo" )iagram *or vessel liqui) levels.
III.
I%'&))&"(%8C($$"''"(%"%7
Electrostatic 9il reater !e commissioning o* t!e oil treater s!oul) *ollo" t!e proce)ure as outline).
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
1.
nstallationF t is ver# important t!at all units are installe) level. :eri*# an) s!im as necessar#. ()equate support un)er t!e vessel an)or s+i) must be provi)e) "!ic! t!e vessel sa))les rest on. Weig!t o* *lui) insi)e vessel an) piping in a))ition to "eig!t o* equipment s+i)$ vessel$ trans*ormers$ access plat*orms$ piping$ valves$ instrument an) insulation6 must be ta+en into consi)eration. a.
=emove all e,ternal s!ipping braces an) temporar# *lange covers. nventor# all parts.
b.
:isuall# c!ec+ t!e vessels$ couplings$ no--les$ vessel s!ell an) accessor# components. Ensure t!at none !ave been )amage) )uring s!ipment. =eport an# )amage as soon as possible.
c.
C!ec+ level an) alignment o* t!e vessels.
).
nstall all vessel accessories inclu)ing grating$ !an)rails an) interconnecting piping "!ic! "ere remove) *or s!ipment. 'ee piping assembl# )ra"ings *or re*erence.
e.
C!ec+ t!at all vessel accessories suc! as pressure gauges$ gauge glasses$ relie* valves$ etc. are installe) in proper location. =e*er to t!e )ra"ings *or no--le locations$ )imensions an) general )escription. n a))ition$ #ou ma# re*er to ven)or literature.
*.
t "ill be necessar# to enter t!e oil treater vessel to remove t!e s!ipping braces *rom t!e electrostatic gri)s. !e s!ipping braces s!oul) be painte) orange *or ease o* i)enti*ication. Re$(+) (/ &he 'h"##"%7 e' $!'& e *(%e #"( &( e%e7"9"%7 &he &%'/($e.
g.
Purge all instrument lines. C!ec+ all *lange) connections an) tig!ten nuts as necessar#.
!.
=oute all "iring bet"een unction bo,es an) t!e master panel. Connect inlet po"er to master panel. 'ee P%C an) urner
i.
nstall trans*ormer an) entrance bus!ing. 'ee NW% trans*ormer pro)uct manual$ (ppen)i, ($ *or a))itional instructions concerning receiving$ !an)ling$ storage an) installation o* trans*ormer.
.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
2.
Electrical C!ec+F THIS UNIT PRODUCES HIGH :OLTAGE ELECTRICAL CURRENTS THAT ;ILL CAUSE SERIOUS INJUR< AND8OR DEATH B< ELECTROCUTION. E=TREME CAUTION SHOULD BE USED.
a. e*ore connecting line po"er$ be sure all "iring is installe) an) connecte). (ll *use bloc+s s!oul) be )isengage). Primar# voltage suppl# s!oul) be in t!e 988 positionI veri*# "it! a voltmeter. b.
:eri*# proper groun)ing o* equipmentF 3 3 3 3
rans*ormers are groun)e) to mounting brac+ets on vessel Junction bo,es an) circuit brea+er bo,es to support rac+s :essel to s+i) or plat*orm structure6 at one sa))le 'tructural s+i) to plat*orm structure i* applicable6
c. amps. P!ase 2
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
9pen t!e circuit brea+er an) pa)3loc+ it in t!e 988 position. Enter t!e vessel an) release t!e *loat s"itc! so t!at contact "it! t!e !ig! voltage groun) ro) is ma)e.
>.
CommissioningF a.
We suggest a nitrogen purgetest be per*orme) on t!e entire unit to ensure tig!tness o* all connections as "ell as *or a))itional sa*et# )uring commissioning.
b.
Po"er on control panel. =e*er to operating proce)ures *or control panel. 8ollo" proce)ures *or unit set3up.
c.
ring t!e instrument air s#stem on line *or t!e pac+age. :eri*# appropriate
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
suppl# pressure to eac! pneumatic instrument.
I:.
).
C!ec+ all level instruments an) control valves *or proper operation.
e.
:eri*# proper inter*ace o* all t!e instruments to t!e master panel.
*.
:eri*# trip points o* pressure s"itc!es in accor)ance "it! nstrument )ata s!eets an)or as per operations personnel$ b# utili-ing inert gas to blee) valves "!ile pressure instrument is isolate).
g.
C!ec+ set pressures o* all relie* valves in accor)ance "it! equipment tag an)or nstrument ata '!eets.
!.
(s applicableF Calibrate pressure transmitters b# appl#ing inert gas to blee) valve "!ile t!e instrument is isolate).
i.
C!ec+ t!at all pressure in)icators an) temperature in)icators !ave t!e proper range in accor)ance "it! instrument )ata s!eets or ot!er process )ocumentation.
.
8inal veri*ication o* proper groun)ing o* all equipment.
+.
:eri*# t!at *uel gas s#stem in properl# installe) an) t!at all sa*et# )evices are *unctioning correctl#.
S&&-U# %* Sh!&*(%
(.
@eneral 1.
'tart3up o* t!is equipment s!oul) be per*orme) (%) b# quali*ie) personnel.
2.
:eri*# t!at all instruments !ave been calibrate). :eri*# t!at all interconnecting piping !as been properl# tig!tene). :eri*# all electrical cables !ave been reinstalle) properl# in accor)ance "it! t!e )ra"ings an) t!at main )isconnect is in t!e o** position.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
.
>.
:eri*# t!at t!e ball valves an) an# o**3s+i) )o"nstream bloc+ valves associate) "it! t!e relie* valves an) *lare !ea)er s#stem are in t!e correct position.
4.
:eri*# t!at t!e instrument air s#stem is *unctioning properl# an) all appropriate instruments !ave t!e correct air suppl#.
5.
:eri*# all level instrumentsbri)les$ isolation valves are open.
?.
:eri*# all pressure instruments isolation valves are open.
7.
:eri*# all vent an) )rain valves on instruments an) sample points are close).
B.
:eri*# control valves$ )rains an) b#pass valves are close).
G.
:eri*# vessel )rains are close).
'tart3&p 1.
solate "ater outlet line o* oil treater vessel. 2.
'lo"l# allo" *lui) to enter into t!e s#stem.
>. Closel# monitor t!e liqui) levels in t!e 9il reater an) )o"nstream equipment. 4. C!ec+ t!at pressures an) temperature o* t!e vessels are operating near t!eir operating parameters. 5. C!ec+ t!at liqui) level controls are operating correctl# as liqui) rises "it!in vessels. =e*er to p;i) *or liqui) levels$ (ppen)i, . ?.
C!ec+ t!at s#stem is lea+ *ree. 7. (s inter*ace level in 9il reater approac!es normal inter*ace level$ open "ater outlet isolation valve. B.
:eri*# oil e,its *rom 9il reater oil outlet line.
G. nitiate burner start3up. =e*er to (ppen)i, an) P%C an) urner
Energi-e on t!e trans*ormer.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
11. =e3c!ec+ levels$ pressures an) temperatures *or correct operating parameters. C.
'!ut)o"n Normal s!ut)o"n can be ac!ieve) b# use o* t!e ':Ks an)or manuall# closing bloc+ valves. 8or prolonge) s!ut)o"ns procee) "it! t!e *ollo"ing proce)uresF 1.
solate inlet an) outlet lines.
2.
urn o** an) loc+ trans*ormer.
>.
rain vessels.
4.
:ent vessels.
5.
rain oil an) "ater lines.
?.
rain instruments.
7.
Purge vessels an) lines "it! nitrogen.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
:.
M"%&e%%e
PE=9C <(NEN(NCE (N E'N@ (=E <(N(9=L 89= '(8E 9PE=(9N. (.
'a*et# :alve ( sa*et# valve requires perio)ic inspection to assure t!e operator t!at t!e valve is not stic+ing an) "ill provi)e Msa*et# relie*M. Pressure testing is t!e approve) met!o).
.
:alves an) Controls (n# valves an) controls requiring lubrication s!oul) be properl# lubricate) at selecte) intervals to assure best per*ormance.
C.
Cleaning an) nspection :essels s!oul) be cleane) an) inspecte) at t!e en) o* t!e *irst ? mont!s on !eav# oil service an) at t!e en) o* one #ear on lig!ter oil service. W!ere !eav# san) is suspecte)$ cleaning ever# ?03G0 )a#s ma# be necessar#. 8requenc# o* *uture cleanings can t!en be )etermine).
.
Please contact Custom Process Equipment$ %%C *or a))itional an) speci*ic maintenance instructions.
E.
=outine
ail#F 3 3 3 3
b.
C!ec+ pressure gauge rea)ings C!ec+ gauge glass levels clean as require)6 Note an# irregularities C!ec+ *or lea+s an) repair as require)
Wee+l#F 3 3 3 3
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
0 secon)s6 to remove contaminants nspect controls an) valves *or proper operation rain liqui) *rom all instrument air regulators C!ec+ t!at trans*ormer lig!t bulb is operative
Job No. 12052
c.
Ever# 'i, Wee+sF 3 3
).
'emi3(nnuall#F 3 3 3
e.
est level$ temperature an) pressure sa*et# )evices inclu)ing 'E %oop6 Con*irm t!at lig!t bulbs *or alarm lig!ts at Control PanelsJunction o,es are in goo) "or+ing con)ition.
C!ec+ t!e pressure relie* valves nspect vessel internals *or scale an) slu)ge accumulation an) corrosion especiall# pits6 an) clean as require) nspect$ clean an) repair valves an) controls$ replace )amage) trim
'ee NW% rans*ormer
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
:I.
T(!)e'h((&"%7
@eneral PROBLEM Vessel Low pressure
POSSIBLE CAUSE Break in production inlet flow line or other inlet components.
SOLUTION Check inlet connections, flow lines and component upstream of oil treater unit for damage or leaks. Repair as required Check P&'-3!"#" for proper operation. #d(ust as required. Check pneumatic control signal to PCV-3!"#$.
PCV-3!"#$ in fi%ed open position
Check &P-3!"#3 for proper operation. Repair or replace as required Check PCV-3!"#" actuator and )al)e for proper operation. Repair or replace as required
P*V in fi%ed open position
Check Repair or replace required Check pneumatic control signal to LCV-3!"#"
LCV-3!"#" in fi%ed open position
Check L'-3!"#+ for proper operation setting. #d(ust or repair as required
and
Check LCV-3!"#" actuator and )al)e for proper operation. Repair or replace as required anual drain )al)es on )essel leaking.
Check )al)e. Repair or replace as required.
as or liquid discharge piping leaking.
&nspect discharge piping. Repair as required.
Blanket gas has stopped flowing
Check lanket gas suppl/ Check, repair *0V-3!"#1 for proper operation.
*0V-3!"#1 is closed
Check *V-3!"#1 for proper operation. Check instrument gas suppl/
PCV-3!"#$ is in fi%ed closed position
Check, repair PCV-3!"#$ Check pneumatic control signal to LCV-3!"#3
LCV-3!"#3 is in fi%ed open position.
Check L'-3!"#3 for proper operation and setting. #d(ust or repair as required Check LCV-3!"#3 actuator and )al)e for proper operation. Repair or replace as required. Check &P-3!"#1 for proper operation. Repair or replace as required.
LCV-3!"#+ is in fi%ed open position
Check pneumatic control signal to LCV-3!"#+ Check L'-3!"#1 for proper operation and setting. #d(ust or repair as required Check LCV-3!"#+ actuator and )al)e for proper operation. Repair or replace as required.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
Check &P-3!"# for proper operation. Repair or replace as required. Check P&'-3!"#" for proper operation. #d(ust as required. Check pneumatic control signal to PCV-3!"#$. PCV-3!"#$ in fi%ed closed position
Vessel High Pressure
Check &P-3!"#3 for proper operation. Repair or replace as required Check PCV-3!"#$ actuator and )al)e for proper operation. Repair or replace as required &nspect piping for ostructions. Check that all inline )al)es are in correct position.
P*V in fi%ed closed position and2or will not relie)e pressure
Check P*V for proper operation. Repair or replace as required. Check up and downstream lock )al)es, ensure in open position.
as or liquid outlet piping plugged or )al)e in gas outlet line closed
&nspect piping for ostructions. Check that all inline )al)es are in correct position.
Liquid outlet piping plugged or )al)e in liquid outlet line closed
&nspect piping for ostructions. Check that all inline )al)es are in correct position Check appropriate le)el transmitter for proper operation. #d(ust as required.
Vessel High Liquid Level
Le)el control )al)es in fi%ed closed position.
Check pneumatic control signal to appropriate le)el control )al)e. Check &P for le)el control )al)e. Repair or replace as required Check appropriate actuator and )al)e for proper operation. Repair or replace as required
%cessi)e inlet flow rate
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Check inlet flow conditions.
Job No. 12052
Check appropriate le)el transmitter for proper operation. #d(ust as required.
Vessel Low Liquid Level
4ne or more le)el control )al)es in fi%ed open position
Check pneumatic control signal to appropriate le)el control )al)e. Check &P for le)el control )al)e. Repair or replace as required Check appropriate actuator and )al)e for proper operation. Repair or replace as required
Low or High Iner!"#e Level
0rain )al)e open
Check drain )al)es.
&nterface le)el transmitter malfunction
Check appropriate interface le)el transmitter. Recalirate, repair or replace as required.
5ater le)el control )al)e in fi%ed open position
*ee 6Vessel Low Liquid Le)el6 for resolution.
Check pneumatic control signal to LCV-3!"#+ 5ater le)el control )al)e not operating correctl/. LCV-3!"#+ %cessi)e 5ater in 4il
Check L'-3!"#1 for proper operation and setting. #d(ust or repair as required Check LCV-3!"#+ actuator and )al)e for proper operation. Repair or replace as required. Check &P-3!"# for proper operation. Repair or replace as required.
%cessi)e inlet flow rate
Check inlet flow conditions.
'ransformer not operating properl/
Check transformer for proper operation.
&ncorrect chemical treatment
Contact chemical treating e%pert.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
%cessi)e inlet flow rate
Check inlet flow conditions.
LCV-3!"#" and2or LCV-3!"#+ not operating correctl/.
Check pneumatic control signal to LCV-3!"#"2#+ Check L'-3!"#+2#1 for proper operation and setting. #d(ust or repair as required Check LCV-3!"#"2#+ actuator and )al)e for proper operation. Repair or replace as required Check appropriate le)el transmitter for proper operation. #d(ust as required.
%cessi)e 4il in 5ater
5ater le)el control )al)e in fi%ed open position. LCV-3!"#" and2or LCV-3!"#+
Check pneumatic control signal to appropriate le)el control )al)e. Check &P for le)el control )al)e. Repair or replace as required Check appropriate actuator and )al)e for proper operation. Repair or replace as required
Low Vessel Te$%er"ure
Vessel High Te$%er"ure
0rain )al)e not closed
Check )essel drain )al)es. Repair or replace as required.
&nsufficient heat.
#d(ust operating temperature.
4il-water interface le)el too low.
#d(ust interface le)el to appropriate range.
&ncorrect chemical treatment
Contact chemical treating e%pert.
'&C-3!"#+ not operating properl/ or set point is incorrect.
Check temperature setting. Raise setting if set too low. Check controller for proper operation. Repair or replace as required.
Burner not operating
Check urners for operation.
&ncreased inlet flow rate
Check inlet flow conditions.
'&C-3!"#+ not operating properl/ or set point is incorrect. Burner not operating properl/
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Check temperature setting. Lower setting if set too high. Check controller for proper operation. Repair or replace as required. Check urners for operation.
Job No. 12052
Check line pressure of fuel gas s/stem
&uel g"s %ressure oo high or oo low' BLS Indi#"ion
Check high pressure switches 7P*89 and2or low pressure switches 7P*L9 for proper operation and setting. Check appropriate pressure control )al)e 7PCV9 for correct operation. Repair or replace as required.
TSHH indi#"ion
Check Burner anagement */stem, for '*88 indication. Check indi)idual stack temperature transmitters for proper setting and operation. Repair or replace as required.
LSLL indi#"ion
Check liquid le)el in )essel to ensure normal liquid le)el is ao)e fire tues. L&'-3!"#
BSL indi#"ion
Check B* s/stem for *0 signals. Resol)e upset condition, reset s/stem as required.
Solenoid v"lves in !uel g"s r"in no o%er"ing' Burner no o%er"ing Te$%er"ure #onrol v"lves in ()ed #losed %osiion
Check B* signal to *4Vs. Check fault code on PLC Check *4Vs for proper operation. replace as required.
Repair or
Check appropriate 'CV for proper operation. Repair or replace as required. Check *4Vs for proper operation. replace as required.
Repair or
Check pneumatic signal to 'CV
Insu*#ien !uel g"s
Check fuel gas suppl/.
t is necessar# to maintain a balance) program ma)e up o* c!emicals$ !eat$ time an) electricit# in or)er *or t!e unit to per*orm at is inten)e) speci*ication. !is program must be *le,ible enoug! to allo" c!ange o* one or more variables in or)er to regain a balance) s#stem in t!e event o* an upset con)ition. 8or e,ample$ i* t!e c!emical rate is )ecrease)$ it ma# be necessar# to increase temperature to compensate *or t!e )ecrease in c!emical penetration o* t!e emulsi*ie) "ater )roplets. * all components are constant an) t!e outlet oil qualit# !as c!ange)$ it can be assume) t!e incoming emulsion !as c!ange). C!anges in emulsion qualit# are most li+el# to be procee)e) b# "ell "or+3 overs or intro)uction o* ne" "ells. W!atever t!e case$ a c!ange in t!e )e!#)rating program "ill !ave to occur. * t!e outlet oil qualit# is not to speci*ication$ t!e *ollo"ing troubles!ooting c!ec+ list s!oul) be consulte). Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
C!ec+ t!e s#stem *or t!e *ollo"ing irregularitiesF 1.
%oss o* c!emical or re)uction in c!emical rate a.
2.
E,cessive slu)ge buil)3up on t!e inter*ace o* t!e coalescing section3 a. b. c.
>.
na)equate !eat or c!emical
ncrease) *lo" rate t!roug! t!e s#stem3 a. b.
3
C!emical pump mal*unction 3 %oss o* po"er to c!emical pump 3 a) or stuc+ c!ec+ valve in c!emical pump 3 ro+en or plugge) c!emical line 3 No c!emical in tan+
8iel) surging ())ition o* ne" "ells to t!e s#stem
=ecent *iel) re"or+3 a. (ci)i-ing "ells b. Dot oiling "ells or *lo" lines
Electrical
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
No lig!t$ no voltage$ an) no current$ )e!#)ration e**icienc# )ecrease)F a. %oss o* electrical po"er to t!e trans*ormer Job No. 12052
3 3 3
Circuit brea+er open
%o" or no voltage an) !ig! current. NoteF * t!e unit is not equippe) "it! an ammeter$ a clamp3on ammeter ma# be use) to )etermine trans*ormer current. a. (n# o* t!e problems liste) in (/ o* t!is c!ec+ list can give t!ese in)ications. * t!e lig!t is glo"ing even slig!tl#$ or t!e current s!o"s some variation *rom time to time$ t!e problem is more t!an li+el# one or more o* t!ose liste) un)er (/ o* t!is c!ec+ list an) not an electrical problem.
No trans*ormer lig!t$ near -ero voltage an) current !ol)ing stea)# near ma,imum. NoteF !e ma,imum current *or #our trans*ormer ma# be )etermine) b# )ivi)ing t!e H:( rating b# t!e applie) voltage. 8or e,ample$ a 75 H:( trans*ormer operating on 4?0 volts "oul) )ra" appro,imatel# 1?> amps 75$0004?0 O 1?>6. ( 100 reactance trans*ormer s!oul) never pull more t!an t!e calculate) value o* current. a.
( lo" liqui) level in t!e coalescing section "ill allo" t!e lo" level sa*et# *loat to groun) out t!e !ig! voltage gri). 3 !is coul) be t!e result o* e,cessive "ater removal *rom t!e coalescing section an) "ill li+el# correct itsel* "!en t!e level is restore) to normal pro)uction. 3 (not!er li+el# cause is a *ault# )rain or "ater control valve.
b.
(n# one or more o* t!e irregularities liste) un)er (/ o* t!is c!ec+ list$ in e,treme$ coul) give t!ese s#mptoms an) s!oul) be c!ec+e) out be*ore procee)ing "it! t!is c!ec+ list. THIS UNIT PRODUCES HIGH :OLTAGE c. ELECTRICAL CURRENTS THAT ;ILL CAUSE SERIOUS INJUR< AND8OR DEATH B< ELECTROCUTION. E=TREME CAUTION SHOULD BE USED.
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
(n electrical s!ort "it!in t!e !ig! voltage circuitr# o* t!e s#stem is t!e most li+el# mal*unction t!at "ill give t!ese s#mptoms. NoteF !e lo" voltage si)e o* a 100 reactance trans*ormer is not protecte) b# t!e reactorI t!us a problem in t!e lo" voltage si)e "oul) not give t!ese s#mptoms. o isolate a s!ort in t!e !ig! voltage circuitr#$ ta+e t!e *ollo"ing stepsF 3 isconnect an) pa)loc+ t!e trans*ormer circuit brea+er in t!e 988/ or 9PEN/ position. e CE=(N t!at primar# po"er is not reac!ing t!e trans*ormer. :eri*# "it! a voltmeter. 3 =emove t!e li) *rom !ig! voltage unction bo, an) ma+e a visual inspection. %oo+ *or burne) "iring an)or )iscolore) insulating oil. 3 * all appears normal$ isolate t!e trans*ormer *rom t!e vessel b# )isconnecting t!e trans*ormer secon)ar# "ire *rom t!e receptacles "!ic! "ill be mar+e) 1?.5H: or 2>H:. e sure t!e connections an) lea) "ire are "ell a"a# *rom t!e !ig! voltage connections. 3 emporaril# secure t!e li) on t!e !ig! voltage unction bo, an) restore po"er to t!e trans*ormer an) observe t!e s#mptoms. 3 * t!e same s#mptoms are observe)$ lo" voltage an) !ig! current$ t!e trans*ormer secon)ar# "iring or !ig! voltage *ee) troug!s are *ault#. 3 * t!e rea)ings return to normal$ 4B0 volts an) lo" amperage$ an) no )iscoloration o* t!e oil is observe) aroun) t!e entrance bus!ing con)uit opening$ t!e problem is insi)e t!e vessel. ). * it is )etermine) t!at t!e s!ort is insi)e t!e unit b# 'tep C above$ t!e *ollo"ing proce)ure s!oul) be observe)F Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Job No. 12052
3
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
3 =ea**irm t!at t!e s#mptoms are N9 t!e result o* irregularities covere) in 'ection (/ o* t!is c!ec+ list. !e# "oul) appear as an electrical s!ort insi)e t!e unit. urn 988 all electrical po"er to unit. 3 =emove t!e s#stem *rom pro)uction an) )epressuri-e t!e unit. 3 isconnect an) remove t!e entrance bus!ing an) visuall# c!ec+ *or burne) appearance trac+ing6. e sure t!e bus!ings are clean. 'ul*i)es or buil)3up over t!e lengt! o* t!e bus!ing can cause s!orting. * t!ere are no visible signs o* )amage$ a more complete )etermination can be ma)e "it! a megger/ to )etermine i* t!ere is an# con)uctivit# bet"een t!e "ire con)uctor an) t!e pipe. Con)uctivit# !ere in)icates a ba) bus!ing. 3 * t!e bus!ing is goo)$ )rain t!e vessel an) remove man"a# cover. 3 e*ore entering t!e vessel $4e '!e )) ($#% +e''e) e%&%e #(e*!e' h+e ee% /())(e* . 9nce again be sure t!e po"er is 988 an) t!e circuit brea+er s"itc! is loc+e) in t!e 988 position. (lso$ be sure t!e vessel !as proper ventilation. :isuall# inspect t!e insulating !angers t!at support t!e c!arge) electro)e assembl#. urne) or ot!er"ise )amage) insulators s!oul) be replace). C!ec+ t!e c!arge) electro)es *or an# *oreign material t!at ma# be touc!ing eit!er electro)e an) groun). (lso$ bet"een t!e vessel "all an) t!e electro)es an) bet"een electro)es t!emselves. nspect t!e sa*et# lo" level *loat s"itc!. e sure t!e *loat assembl# moves *reel# "it!out bin)ing$ also t!at t!e *loat !as not lea+e) an) *ille) "it! liqui) preventing it *rom li*ting o** t!e gri) "!en t!e vessel is *ille). * a visual Job No. 12052
inspection !as not reveale) t!e problem$ a more complete c!ec+ "ill be necessar#. Wit! t!e *loat assembl# li*te) a"a# *rom t!e gri) assembl#$ a megger/ ma# be use) to c!ec+ con)uctivit# bet"een eac! c!arge) electro)e an) groun)$ an) eac! ot!er. (n# con)uctivit# "ill in)icate t!at one or more o* t!e insulating !angers are causing t!e problem. t ma# be necessar# to remove t!e insulators one at a time in)ivi)uall#. (n# con)uctivit# across an insulator in)icates a ba) insulator.
:oltage normal$ current ver# lo" "it! treating e**icienc# )ecrease)3 a. !is is an unli+el# s#mptom but coul) be cause) b# a bro+en or loose !ig! voltage cable. 3 ( simple c!ec+ *or t!is problem ma# be accomplis!e) b# raising t!e inter*ace level in t!e coalescing section. (s t!e current s!oul) increase )rasticall# in t!e !ig! voltage circuitr# is goo). * it )oes not$ an open )ies e,ist in t!e !ig! voltage cable "!ic! is use) to carr# t!e voltage *rom t!e en) o* t!e *ee) t!roug! bus!ing to t!e c!arge) electro)es.
Normal voltage$ normal current$ treating e**icienc# )ecrease)3 a.
( problem t!at "oul) )ispla# t!ese s#mptoms is t!e pro)uction o* a stable lo" "ater cut 23>6 emulsion so *inel# )isperse) t!at it is conceale) *rom t!e electric *iel). !is t#pe o* emulsion is li+el# to be c!emicall# stabili-e) an) usuall# t!e result o* "ell re"or+ o* stimulation.
No voltage$ normal current$ treating e**icienc# normal3 a.
8use blo"n in 100: tertiar# "in)ing o* trans*ormer 3
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
%ocate) in lo" voltage unction bo, Job No. 12052
Custom Process Equipment 4727 NW Evangeline !"# Carencro$ %ouisiana &'( 70520
Circuit brea+er +ic+s o** imme)iatel# on energi-ing3 a.
'!ort in primar# lo" voltage6 si)e o* trans*ormer or associate) circuitr#.
b.
Circuit brea+er +ic+s o** intermittentl# or on !ot )a#s3 a.
8ault# circuit brea+er
b.
rea+er si-e) too small
Job No. 12052
