Section 3 Oil Processing System

OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM

SECTION 3 OIL PROCESSING SYSTEM

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TABLE OF CONTENTS 1

INTRODUCTION ............................................................................................................4 1.1 1.2 1.3 1.4

2

OVERVIEW .................................................................................................................. 4 SCOPE ......................................................................................................................... 4 RESPONSIBILITIES ....................................................................................................... 5 SAFETY PRECAUTIONS AND SYSTEM HAZARDS .......................................................... 5 1.4.1 Safety Precautions ........................................................................................ 5 1.4.2 System Hazards............................................................................................. 5

SYSTEM DESCRIPTION ................................................................................................ 11 2.1

INTRODUCTION ........................................................................................................ 11 2.1.1 HP Separation ............................................................................................. 11 2.1.2 LP Separation .............................................................................................. 11 2.1.3 Electrostatic Dehydrator ............................................................................. 12 2.1.4 Electrostatic Desalter .................................................................................. 12 2.2 PROCESS DESCRIPTION ............................................................................................. 12 2.2.1 Start‐Up ...................................................................................................... 12 2.3 PROCESS TRAIN DESCRIPTION .................................................................................. 13 2.3.1 HP Separator V‐T6201 ................................................................................ 13 Figure 1 Design Levels for HP Separator V‐T6201 ..................................................... 14 2.3.2 Crude/Crude Heat Exchanger E‐T6202A/B .................................................. 16 2.3.3 Crude Oil Heater E‐T6203A/B...................................................................... 17 2.3.4 LP Separator V‐T6202 ................................................................................. 18 Figure 2 Design Levels for LP Separator V‐T6202 ...................................................... 18 2.3.5 Crude Oil Pumps P‐T6201A/B...................................................................... 21 2.3.6 Dehydrator Inlet Heater E‐T6204A/B .......................................................... 21 2.3.7 Electrostatic Dehydrator V‐T6203 ............................................................... 22 2.3.8 Electrostatic Desalter V‐T6204 .................................................................... 24 2.3.9 Crude Oil Cooler E‐T6205A/B ...................................................................... 26 2.4 ASSOCIATED SYSTEMS .............................................................................................. 27 3

SYSTEM OPERATION ................................................................................................... 29 3.1

CONTROL PHILOSOPHY ............................................................................................ 29 3.1.1 Duty/Standby Pump Controls ...................................................................... 30 3.1.2 Simple Control Loops .................................................................................. 30 3.2 SYSTEM CONTROL LOOPS ......................................................................................... 31 3.3 PRE‐START CHECKS ................................................................................................... 33 3.3.1 Valve Position Checklist .............................................................................. 36 3.3.2 ..........................................................Spectacle Blind/Spool Piece Checklist 60

3.3.3 Instrument Checklist ................................................................................... 63 3.4 SYSTEM START‐UP .................................................................................................... 67 3.5 SYSTEM SHUTDOWN ................................................................................................ 71 3.5.1 Level 1 Shutdown (USD) .............................................................................. 72 3.5.2 Level 2 Shutdown (PSD) .............................................................................. 72 MANUAL No.

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3.6

BLOWDOWN AND MANUAL VENTING ..................................................................... 73 3.6.1 Blowdown ................................................................................................... 74 3.6.2 Manual Venting .......................................................................................... 74 3.7 SYSTEM TRIPS ........................................................................................................... 74 3.8 ROUTINE CHECKS ...................................................................................................... 76 3.9 OIL, WATER AND GAS SAMPLING ............................................................................. 78 3.9.1 Sample Points ............................................................................................. 79 Figure 3 Sample Point ‐ Liquid with Cooling .............................................................. 79 Figure 4 Sample Point ‐ High Pressure Gas ............................................................... 80 Figure 5 Sample Point – Low Pressure Liquids .......................................................... 80 3.10 TROUBLESHOOTING ................................................................................................. 81 4

OPERATING DATA....................................................................................................... 83 4.1.1 4.1.2

5

Separator Vessel Internals .......................................................................... 86 Electrostatic Treater Internals..................................................................... 87

REFERENCES ............................................................................................................... 87 5.1 5.2

REFERENCE DOCUMENTS ......................................................................................... 87 REFERENCE DRAWINGS ............................................................................................ 87 ILLUSTRATIONS Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8

Design Levels for HP Separator V‐T6201 ..................................................... 14 Design Levels for LP Separator V‐T6202 ...................................................... 18 Sample Point ‐ Liquid with Cooling .............................................................. 79 Sample Point ‐ High Pressure Gas ............................................................... 80 Sample Point – Low Pressure Liquids .......................................................... 80 System Schematic ....................................................................................... 89 Equipment Locations................................................................................... 90 Typical Internals for Electrostatic Treater .................................................. 91

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1 1.1

INTRODUCTION OVERVIEW Refer to PFD DTT92027&DTT92028 The main components of the Oil Processing System referred to in this procedure are accommodated in modules 1, 2, and upper deck, and comprise the following: Tag No

Top side Equipment

Module

V‐T6201

HP Separator.

M01

E‐T6202A/B

Crude/Crude Heat Exchanger.

M01

E‐T6203A/B

Crude Oil Heater.

M01

V‐T6202

LP Separator.

M01

P‐T6201A/B

Crude Oil Pumps.

M01

E‐T6204A/B

Dehydrator Inlet Heater.

M01

V‐T6203

Electrostatic Dehydrator.

M02

V‐T6204

Electrostatic Desalter.

M02

E‐T6205A/B

Crude Oil Cooler.

M01

A‐T6210

Oil Fiscal Rundown Meter.

M09

The oil process train as listed above is a system in which live crude oil is stabilized by the separation of oil, gas and produced water in a three stage, three phase process. Finally the processed crude is pumped into the vessel’s cargo storage tanks via a crude oil fiscal metering unit, from these tanks the dead crude oil is then offloaded to a trading tanker. Gas associated with the well fluids is flashed off in the HP separator, LP separator and produced water flash vessel. HP separator gas is dried and compressed prior to its usage for gas lift and fuel gas. Produced gas from the LP separator is compressed by the booster gas compression system prior to routing to the main gas compressor for gas lift or export. Any excess gas can be flared although a minimum flaring policy is to be adhered to. Produced water from the separators is initially separated from the crude oil by gravity and finally by an electrostatic coalescing process before being degassed, cooled, de‐ oiled and discharged overboard. 1.2

SCOPE The scope of this manual covers the start up, operation, routine checking and shutdown of the Oil Processing System.

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1.3

RESPONSIBILITIES Only the following personnel should use this procedure:

1.4 1.4.1



Production operations personnel qualified to operate the facilities



Personnel training under the supervision of a qualified person

SAFETY PRECAUTIONS AND SYSTEM HAZARDS Safety Precautions The following list of safety precautions are derived from SIDVIN safe working practises intended to protect operating personnel:

1.4.2



The SIDVIN specified personal protection equipment must be worn at all times when working on the process train.



In the vicinity of any process or equipment producing high noise levels (as indicated by warning signs) approved hearing protection must be worn.



All isolations on a process or utility system must be performed in accordance with current SIDVIN mechanical isolations policy. Positive isolation will be via the use of blinds or double valve arrangements. The Permit to Work system shall ensure that appropriate precautions in respect of isolation and monitoring are implemented for maintenance activities of this sort.



No equipment modifications shall be made without prior authorisation and, if applicable, a risk assessment should be carried out.



All work on electrical equipment must be carried out by suitably qualified personnel and in accordance with SIDVIN isolation standards.



Prior to the issue of a Work Permit for repair or intrusive maintenance work(s) depressurising shall be confirmed using a certified pressure gauge and vent/drain valves.

System Hazards Safety protection in the form of automatic sensing systems and trips have been provided throughout the FPSO systems, but operators must make every effort to ensure that the process is operated within its design parameters and that process upsets do not occur. The primary hazards associated with the Oil Processing system are: 

Hydrocarbon fluids and gas under pressure.



High temperature fluids.



High voltage electricity (electrostatic treater).



Hazardous chemicals.



Rotating machinery.

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1.4.2.1 Operational Hazards Note: Most of the potential hazards and problems detailed below will initiate a unit or process shutdown before the situation becomes critical and other items will have been engineered out by the initial design. However, operators must be aware that these hazards exist and should not rely entirely on safety trips to prevent them occurring. The following list of potential process train hazards and upsets is intended as guidance to what can occur in the event of instrument malfunction, mechanical failure, or operator error: 

Process equipment overpressure.



Live crude/gas discharge into the produced water system.



Gas discharge into the crude handling system.



Crude oil or water carryover into the gas handling system.



Contact between gas or water and HV electrodes in electrostatic treater.



Crude oil pumps seal leakage.



Blockages in crude oil pump suction line.



Crude oil pump discharge line blockage.



Backflow from electrostatic treater to crude pumps.



Crude leakage from plate & gasket heaters E‐T6203A/B.



Uncontrolled discharge/leakage of HP/LP gas to flare.



Produced water carryover into crude oil flow.



Heating medium leakage from heaters E‐T6203A/B.



Inaccurate fluid and gas metering.

a) Process Equipment Overpressure All items of process equipment are fitted with one or more pressure safety valves that relieve pressure to vent automatically. In addition each separator vessel is equipped with a high/high pressure sensor that will initiate a unit shutdown. CAUTION: OPERATORS MUST BE AWARE THAT DURING START‐UP, FAILURE TO CARRY OUT THE REQUIRED PRE‐START CHECKS COULD RESULT IN OVERPRESSURING SECTIONS OF THE PROCESS TRAIN DUE TO A FAILURE TO OPEN DESIGNATED LINE VALVES. LOCATION

TAG NO.

SIZE

SETTING

T62‐PSV‐0041A T62‐PSV‐0041B

8” x 10” 8” x 10”

14.3 barg 15.0 barg

HP Separator V‐T6201 Refer to: DTT62008 Topside HP Separator Top mounted gas relief Top mounted gas relief MANUAL No.

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LOCATION Top mounted gas relief

TAG NO.

SIZE

SETTING

T62‐PSV‐0041C

8” x 10”

15.7 barg

3” x 4” 3” x 4”

15.0 barg 15.0 barg

1” x 2” 1” x 2”

15.0 barg 15.0 barg

3” x 4” 3” x 4”

15.0 barg 15.0 barg

3” x 4” 3” x 4”

15.0 barg 15.0 barg

1” x 2” 1” x 2”

15.0 barg 15.0 barg

LP Separator V‐T6202 Refer to: DTT62009 Topside LP Separator Top mounted gas relief Top mounted gas relief

T62‐PSV‐0061A T62‐PSV‐0061B

Dehydrator Inlet Heater E‐T6204A/B Refer to: DTT62001 Topside Dehydrator Inlet Heater Top mounted gas relief E‐T6204A Top mounted gas relief E‐T6204B

T62‐PSV‐0010 T62‐PSV‐0011

Electrostatic Dehydrator V‐T6203 Refer to: DTT62006 Topside Electrostatic Dehydrator Top mounted gas relief Top mounted gas relief

T62‐PSV‐0021A T62‐PSV‐0021B

Electrostatic Desalter V‐T6204 Refer to: DTT62007 Topside Electrostatic Desalter Top mounted gas relief Top mounted gas relief

T62‐PSV‐0031A T62‐PSV‐0031B

Crude oil cooler E‐T6205A/B Refer to: DTT62003 Topside Crude oil cooler Cooling medium inlet

T25‐PSV‐0017 T25‐PSV‐0018

Note: The design pressure of the LP Separator is consistent with the HP Separator the relief valves on the LP Separator have been set at 15.0 Bar to provide protection for the Crude Oil Heater E‐T6203 of which the cold side is only rated to 15.0 Bag. b) Live Crude/Gas Discharge into the Produced Water System These circumstances can be caused by the following process malfunctions: 

Interface level control failure.



Failure of emulsion breaking and/or anti‐foaming chemical injection.

In the latter case, a chemical injection malfunction causing either too much, too little or no chemical at all to be injected is likely to upset the interface separation process that in turn may cause level problems throughout the train. This scenario is likely to occur if the production wells have a high water cut and ‘tight’ emulsion characteristics.

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Interface and general level control problems will also occur if the anti‐foaming chemical injection rates are insufficient or excessive. To prevent the accidental discharge of live crude into the produced water system a low/low level detected in the reception section of either separator vessel will cause a unit shutdown. Refer to para. 3.6 System Trips. The vessel slop tanks have sufficient capacity both liquid and gas handling to cope with a short term accidental crude discharge. However, this is an undesirable process upset that operators should take care to avoid. c) Gas Discharge into the Crude Handling System A failure of the level control systems in either the HP or LP separation vessels could result in a loss of crude oil level and gas entering the crude handling system. In this event a dual function high/high, low/low level sensor in the oil section after the weir will cause a unit shutdown. d) Crude Oil or Water Carryover into the Gas Handling System In the event that a blockage occurs to either the water or crude vessel outlets, failure to shut down quickly enough could result in crude from a HP and/or LP separation vessel overflowing into the gas handling and flare systems. Blockages could be as a result of operator error or line valve problems. To prevent this occurring, a dual function high/high, low/low level sensor in the oil section after the weir will cause a shutdown and closure of protective SDVs. Oil carryover could also occur in the event of a sudden surge or ‘slug’ of flow, possibly caused by opening a well too quickly. The liquid ‘slug’ so created could exceed the crude design handling capacity of one or more of the separation train vessels. e) Contact between Gas or Water and HV Electrodes in Electrostatic Treater A major fall in the liquid level within the Electrostatic Treater would result in the HV electrodes being exposed to gas and oil vapour. Level switches T62‐LS‐0020/0021 protect against this by switching off the power to the transformers when a low/low level is sensed. In addition both a high/high and a low/low water level will also cause a shutdown. f) Crude Oil Pump Seal Leakage Failure of a crude pump seal could result in crude spillage to the local area. The seal leak detection system of each pump has a high pressure switch which will cause the pump to automatically shutdown should the seal leak. g) Blockages in Crude Pump Suction Line Lack of pressure in the crude pumps’ suction header caused by a blocked LP separator outlet could initially cause severe cavitation followed by overheating or a catastrophic pump failure. To prevent this occurring a low/low pressure sensed in either on‐line pump’s suction will stop the pump involved.

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A strainer in each pump suction line will trap sand and other foreign matter thus preventing pump damage. However, these should be checked for blockages in the event of a detected low suction pressure. h) Crude Oil Pump Discharge Line Blockage A downstream blockage will cause the pump discharge pressure to rise and a unit shutdown to occur via a high/high pressure sensor. However, crude pumps are of the centrifugal type and can operate for short periods against a closed discharge valve. i) Backflow from Electrostatic Treater to Crude Pumps Check valves are located adjacent to the electrostatic treater bottom entry point in order to prevent backflow. Check valves are also sited in each pump discharge. Failure of any one of these check valves has the potential to allow backflow of crude from the treater vessel whilst the pumps are shutdown. j) Crude Leakage from Plate & Gasket Heaters E‐T6203 Plate and gasket heat exchangers are used for heating live crude exiting the production separator. Should the exchanger distort, the rubber seals incorporated in the matrices and pipe work connections may fail and allow crude oil to be expelled. The most likely cause of such an occurrence would be exposure of the exchanger to a sudden pressure or temperature change. Protective barriers have been provided to protect personnel against fluid spray from a leak.

! HAZARD

Haz 51

CAUTION: WHEN REASSEMBLING PLATE AND GASKET EXCHANGERS, SO AS TO AVOID DAMAGE TO THE EQUIPMENT, THE SUPPLIERS RECOMMENDED TORQUE SETTINGS MUST NOT BE EXCEEDED. k) Uncontrolled Discharge/leakage of HP/LP Gas to Flare In the event that the HP separator pressure control valve should fail in the open position, HP gas will discharge to the flare header causing a loss of crude drive. The effect of this will be a rising level in the vessel, liquid carryover, pressure alarms and ultimately a high/high level trip. l) Heating Medium Leakage from Heaters E‐T6203 A plate failure within the plate & gasket heater could result in an uncontrolled release of hot water to atmosphere. A mechanical barrier has been provided to contain this type of leakage and protect personnel. m) Inaccurate Fluid and Gas Metering Flow meters have been provided at the oil, water and gas outlets from each process vessel. Operators should be aware that fluid metering inaccuracies could occur in the event that gas ‘breaks out’ of the fluid as it leaves the separator. This could occur if the incoming well fluid flow exceeds the design capacity of the vessel allowing insufficient residence time in the separator to allow the entrained gas to flash off.

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Note: Ultrasonic flowmeters have a different operating principle to turbine meters and consequently the presence of gas is immediately detected. However, turbine flowmeters are prone to inaccuracy and will indicate a disproportionate increase in flow where gas is present. In the case of gas metering, excessive foaming in the vessel and/or liquid carryover will cause fluids to appear in the flow orifice lines thus causing inaccurate sensing pressures. Access platforms above HP and LP separators

! HAZARD

Haz 214

The access platforms above the HP and LP separators have only one escape route and therefore these should only be used when there is a clear operational requirement.

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2 2.1

SYSTEM DESCRIPTION INTRODUCTION Refer to P&ID DDT62001/2/3/4/5/6/7/8/9110 and Figure 6 The primary objective of the separation train and associated equipment is to process and stabilize live crude produced from subsea wells in order to meet storage and export specifications for BS&W, temperature, salinity and vapour pressure. These are listed below. 

BS&W (ASTM D4377/4007) < 0.5 vol%.



Salt content (ASTM D3230) < 570 mg/l – NaCl.



Reid Vapor Pressure (ASTM D323) = 10 psia @ 37.8°C.

Note: There are no additional crude washing facilities for removal of salt from the flow stream as it is not expected to cause a problem. The gas outlet from the separators has a design liquid carry‐over of less than 0.1 gallon/MMScf @ design capacity (API). The procedures in this section cover the processing of live crude from the production swivels to the topside discharge point of stabilized crude into the FPSO storage tanks. Processing and handling of the associated produced water is described in Section 05. There are two live crude flow streams: 

18” header from production swivel to separation vessels.



10” header from test swivel to the test heater and test separator vessel. Refer to Section 2 Crude Reception Facilities.

An additional 100% spare swivel can be used for production or test. 2.1.1

HP Separation (V‐T6201) The well fluids (live crude) are routed to the HP production manifold in the turret via subsea flowlines and flexible risers. The fluids are transferred to the topsides via the production swivels and routed directly to the HP Separator. Crude from the HP separator flows under pressure gradient to the LP separator via intermediate heating in the Crude/Crude Exchanger and the Crude Oil heater. Gas from the HP separator is routed to the lift gas compression system and HP flares. Produced water from the production separator is routed to the produced water flash vessel under interface level control. To aid separation and inhibit foaming, foam inhibitor and demulsifier chemicals are injected into the well flow upstream of the separator.

2.1.2

LP Separation (V‐T6202) Whereas the purpose of the first stage of separation was the bulk separation of water and gas, the second stage separation is used to achieve the specified crude stability

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prior to crude oil dehydration and storage in cargo tanks of the vessel. The crude stability (low volatility) is achieved by removing light (volatile) components out of the crude to the extent that no flashing in the cargo tanks of the vessel occurs. Crude from the HP separator is depressurized over a level control valve, heated by taking heat from the crude to storage in the Crude/Crude Exchanger, and from heating medium in the crude oil heater, and then routed to the LP separator. Gas from the LP separator is routed to the booster compression system or LP flare. The produced water drains into the produced water flash vessel under interface level control. 2.1.3

Electrostatic Dehydrator (V‐T6203) The crude oil from the LP separator is pumped into the electrostatic dehydrator via a bottom entry nozzle and an internal pipe distributor by the duty crude pump (2 x 100%) through dehydrator inlet heater. Using high voltage electrodes the water is separated off from the crude oil and discharged under interface control to the produced water flash vessel. Gas is vented back into the second stage separator whilst the crude oil leaves the vessel via a top entry nozzle to the electrostatic desalter.

2.1.4

Electrostatic Desalter (V‐T6204) The crude oil from electrostatic dehydrator is entered into the electrostatic desalter via a bottom nozzle and an internal pipe distributor. The crude oil intimately mixed with wash water, which is dispersed in the crude oil as small droplets. The high voltage electrical field accelerates separation of the water laden with salt and other contaminants combined in oil. The water & salt is separated off from the crude oil and discharged under interface control to the produced water flash vessel. Gas is vented back into the second stage separator whilst the crude is progressively cooled and piped to the FPSO storage tanks

2.2

PROCESS DESCRIPTION Refer to PFD DTT92027&DTT92028

2.2.1

Start‐Up It is envisaged that each well will be started up using the test separator. The test separator can be operated at either booster gas suction pressure, or higher, at gas lift compressor suction pressure. This provides the option of a greater draw down to aid well start‐up. Note Some well clean‐up “debri fluid” may be present in the crude flows during this initial start‐up and therefore it is advisable to flow through the test vessel instead of the production separator. Refer to Crude Reception Facilities Section 02 of this manual for details.

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As soon as gas is available from the separators, the gas compression train, gas dehydration and fuel gas systems will be put on line so as to minimize flaring and maintain a steady well flow. The topsides process flow facilities provide a low water cut/maintenance option: During periods of very low water cut or treater maintenance, crude flow can be diverted to bypass the electrostatic treater. Note: The water outlet from the treater is provided with a line that recycles water to the suction of the crude oil pumps. This is operated under flow control and will be used to maintain the minimum percentage of water needed to run the treater. Maximum fluid flow will be determined by the sum of the wells on‐line and the process train design capacity. The test separator cannot be used to increase flow by ‘de‐bottlenecking’ the process train. 2.3

PROCESS TRAIN DESCRIPTION Refer to Figure 6 at the end of this section. Process train vessels are described in the order in which the live crude is processed, i.e. as the live crude flows from swivel outlet header to FPSO storage tanks. One 18” production swivels Q‐M6101 is provided at the turret to topsides interface. Demulsifier, Scale Inhibitor and foam inhibitor injection points (3) are provided in this line. Refer to Section 15 Chemical Injection System for details.

2.3.1

HP Separator V‐T6201 Refer to:DTT 62009 ‐ Topsides HP Separator P&ID The HP separator has been designed to accommodate all operating scenarios. Recycled condensate drained from the gas system scrubbers is injected into the crude flow at the separator inlet. All incoming condensate lines are protected from backflow by check valves. A well fluid is entered 3‐phase horizontal separator vessel via a 18” entry nozzle and an anti‐foam, cyclonic inlet device. The designed vessel retention time and an emulsion breaking chemical assist this crude oil/water emulsion to separate, forming a water layer and a clear interface with the oil. Note: Injection of a foam inhibiting chemical enhances the vessel’s efficiency,however if it is overdosed this can result in an increase in foaming rather than a decrease. A corrosion coupon is located in the pipe work upstream of the fluid entry point. Production separator V‐T6201 has been designed to operate in the normal ‘overflow’ weir mode (i.e. not flooded) at a pressure of 9 barg and a temperature of 72°C.

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The separator is fabricated from Duplex SS fitted with internal baffles to ensure performance is maintained under maximum operational motion conditions of the FPSO. Design capacity provides for the accommodation of slugs of up to 10 m3 above the normal liquid level without reaching the high level alarm point. Gas leaves the vessel through a vane pack, with a liquid down comer line to minimize droplet carryover. The separate oil, gas and water streams leaving the separator are each monitored and recorded as follows. Oil flow

Turbine flow meters T62‐FT‐0041 and 0042

Water flow

Electro‐magnetic meter T24‐FT‐0040

Gas flow

V‐Cone flow meter T71‐FE‐0040 & 0041

Note:

Liquids and gas flow volume readings are corrected for temperature and pressure. Refer to para. 1.4.2 for potential metering problems.

Level Control The design levels are shown in the diagram below. Vessel Volume including 2 Heads = Vessel Volume including 1 Head =

339.47 325.88

3

m 3 m

TBC

Upstream of Weir Weir Height 3350 Levels

mm

NLL

3200

HIL NIL LIL LLIL

2150 2000 1700 300

Downstream of Weir HHLL HLL Overflow Weir

3500 3350

mm mm

NOL

3200

mm

OLL OLLL

2900 2200

mm mm

Figure 1

Design Levels for HP Separator V‐T6201

The emulsion of oil and water settles in the water compartment of the vessel behind the weir and will separate to form an interface. Efficient separation at this point is aided by residence time, a cyclonic inlet device, anti‐foam and emulsion breaking chemicals and a coalescer pack. Oil/water interface liquid levels are monitored by two independent instrument bridles, One comprising a visual gauge and a level transmitter and other have al level transmitter. Multiple sample ‘try cocks’ are provided on the separator, to allow MANUAL No.

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confirmation of actual contents at fixed points. One nozzle is located on the interface with two more above and below at 100mm intervals. Transmitter T62‐LST‐0042 a capacitance sensor monitors the interface liquid level. The objective being to initiate warning and shutdown signals to prevent the possibility of oil entering the produced water system. It will initiate a shutdown on sensing a low/low interface level, resulting in closure of the water outlet emergency valve T24‐SDV‐0040. Transmitter T62‐LT‐0041, a capacitance sensor, monitors the oil/water interface level and automatically sets level control valve T62‐LCV‐0041 proportionally open and closed in order to maintain the level by removing produced water. Gauge glass T62‐LG‐0040 provides operators with visual indication. Oil separated from the water flows over the internal weir into the oil section of the separator before exiting through a vortex breaker into the 16” outlet line. Level transmitter T62‐LT‐0045 is a diaphragm sealed capillary dP cell sensor, this solely monitors oil level. The instrument loop proportionally controls pneumatic level control valve T62‐LCV‐0045 from closed to open, in order to maintain the level at its set point. Level transmitter T62‐LST‐0043, is a diaphragm sealed capillary dP cell sensor, located in the oil section of the vessel responds to both very high and very low oil levels. It will automatically cause a shutdown on sensing either a low/low or high/high level. Visual indication is also provided, by level gauge T62‐LG‐0044. Crude oil leaving the HP separator, containing less than 20% (design projection) of the water from the inlet flows to the LP separator V‐T6202 through exchanger E‐ T6202A/B and heater E‐T6203A/B. Pressure Control Crude oil from the HP separator falls in pressure across the oil level control valve, above. It is then heated by indirect contact with first hot dead crude in the crude/crude heat exchanger E‐T6202A/B and then heating medium in the heater E‐ T6203A/B before entering the three‐phase LP separator vessel at an estimated pressure of 2.9 barg. The HP vessel pressure is held constant by pressure control loop by setting load share of the gas lift compressors. For occasions when the compressors cannot accept all of the gas, a pressure control loop driven by T71‐PIC‐0042 will operate. This controls a pneumatically actuated 10” pressure control valve T71‐PCV‐0042 proportionally venting gas into the HP flare gas header from the separator gas outlet line to maintain a constant pressure. T71‐PIC‐0042 is tuned to act in a more aggressive manner, so that high/high pressure shutdowns are avoided. And Blow down valve T62‐BDV‐0040 is provided & acted in the event of emergency shutdown. During an ESD Level 3 the solenoid T71‐SXV‐001 will be de‐energized resulting in T62‐BDV‐0040 to air fail open Liquid levels are maintained such that there is always a vapour space above the oil, allowing gas to flash off and freely flow out of the vessel, through 16” nozzle N2. The MANUAL No.

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associated gas leaving the separator is piped and reduced through an 16” header to gas lift compression. The HP separator operates within a specific pressure range. Excessive deviation from this span will cause a shutdown. Pressure transmitter T62‐PST‐0040, on sensing either high/high or low/low pressure will initiate a shutdown. Three parallel relief valves provide overpressure protection, these relieve into the HP flare header at the design pressure of the vessel. Utilities A corrosion inhibitor chemical is injected into the outgoing gas stream to protect against the effects of CO2. Monitoring of corrosion rates is carried out using a corrosion coupon located downstream of the chemical injection point. Corrosion coupons can be changed out when on line by the use of specialised extraction tooling. CAUTION: AS THIS OPERATION CAN BE COMPLETED ‘LIVE’ WITHOUT THE NEED FOR A SHUTDOWN, IT SHOULD ONLY BE CARRIED OUT BY APPROPRIATELY TRAINED PERSONNEL USING THE PROPRIETARY TOOL AND A VENDOR APPROVED PROCEDURE. Two 24” manways provide access for vessel inspection and cleaning. The base of the water compartment of the vessel, in front of the weir, is fitted with sand flush connections to facilitate a sand flush/water jetting operation using de‐ aerated seawater. Multiple drain connections are also provided from the compartment; during normal operations these are maintained closed and blinded. Note: Vessel draining shall only be carried out under a permit to work when the vessel has been completely isolated, de ‐pressured and nitrogen purged. Drain points are flanged to accept a suitable hose connection enabling draining to a hazardous open drain or vessel designed for the purpose 2.3.2

Crude/Crude Heat Exchanger E‐T6202A/B Refer to: DTT 62005 – Topside Crude‐Crude Exchanger P&ID Crude oil from the HP separator enters the plate and gasket type heat exchanger. The cool side of the heat exchanger carries the mainly crude oil fluid from HP separator, whilst the hot side carries ‘dead’ crude from the electrostatic desalter. The purpose of the exchanger is to both raise the temperature of the incoming well fluids from an estimated 72°C to 93°C and to cool the 140°C outgoing dead crude exiting the desalter to 92°C. The exchanger has a 100 % flow capability, with both a cold and hot side heater bypass is also provided, with the bypass valves in the normally closed.

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A 12” Cross Over line (locked closed) is provided to allow stabilized crude from the electrostatic treater to enter the live crude inlet of E‐T6202A/B. This provides a facility to circulate warm crude to mitigate wax formation during a shutdown. Crude‐Crude Exchanger E‐T6202A/B is provided with a welded T type strainer at the live crude inlet to prevent and contamination of the plates. Local indication of the differential pressure across both the live crude oil (cool) side and the dead crude oil (hot) side of the exchanger is provided by T62‐PDG‐0006 and T62‐PDG‐0007 to monitor for blockages. Should it be deemed necessary, for either coarse temperature adjustment or maintenance reasons, it is possible to bypass both sides of this exchanger either partially or completely.

! HAZARD

Haz 42

CAUTION: THE LIVE CRUDE SIDE OF THE HEAT EXCHANGER SHALL BE DRAINED UPON BLOCK‐IN TO AVOID OVER‐PRESSURISATION DUE TO THERMAL EXPANSION.

2.3.3

Crude Oil Heater E‐T6203A/B Refer to:DTT 62002 – Topsides Crude Oil Heater P&ID This heater is of plate and gasket construction, a barrier is fitted to contain fluid spray in the event of a leak. The temperature of the crude oil leaving the Crude/Crude Heat Exchanger E‐T6202A/B, estimated at 93°C, is increased to 110°C by flowing through this heater. Heating of the crude is by indirect contact with a heating medium (inhibited fresh water). Local indication of differential pressure across the heaters is provided by T62‐PDG‐0110 to monitor for blockage. A cold side heater bypass is also provided, with the bypass valve normally closed.

! HAZARD

Haz 42

CAUTION: THE CRUDE SIDE OF THE HEAT EXCHANGER SHALL BE DRAINED UPON BLOCK‐IN TO AVOID OVER‐PRESSURISATION DUE TO THERMAL EXPANSION. Temperature Control Temperature of the heater is controlled by T25‐TCV‐0005. This controller proportionally increases or decreases the heat medium flow in response to signals from T62‐TIC‐0005. Should it be deemed necessary for coarse temperature adjustment or maintenance reasons, it is possible to bypass the cold side of the heater, partially or completely dependent on the perceived problem.

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CAUTION: TO COMPLETELY BYPASS THE COLD SIDE THE HEATING MEDIUM FLOW MUST FIRST BE ISOLATED 2.3.4

LP Separator V‐T6202 Refer to: DTT 62005 – Topsides LP Separator P&ID The second stage separator is operated at a pressure of 2.9 Bara and temperature of 110°C. Similar to the HP separator an oil/water interface forms in the reception section of the vessel with oil flowing over the weir into the oil section.

! HAZARD

Haz 64]

CAUTION: THE SEPARATOR GAS IS ROUTED TO THE BOOSTER COMPRESSOR AND OPERATION AT LOW PRESSURE AND/OR HIGH TEMPERATURE COULD RESULT IN HEAVY ENDS BEING IN THE GAS RESULTING IN CONTAMINATION OF THE BOOSTER COMPRESSOR LUBE OIL. The construction and layout of the vessel internals closely follows that of the HP separator. These internals have been designed to ensure performance is maintained under maximum operational motion conditions of the FPSO. Recycled condensate drained from the gas system scrubbers is injected into the crude flow at the separator inlet. All incoming condensate lines are protected from backflow by check valves. Level Control The design levels are shown in the diagram below. Vessel Volume including 2 Heads = Vessel Volume including 1 Head =

274.10 266.39

3

m 3 m

TBC

Upstream of Weir Weir Height 3100 Levels

mm

NLL

2900

HIL NIL LIL LLIL

1850 1550 900 300

Downstream of Weir HHLL HLL Overflow Weir

3300 3100

mm mm

NOL

2900

mm

OLL OLLL

2000 1100

mm mm

Figure 2

Design Levels for LP Separator V‐T6202

Liquid levels are maintained such that there is always a vapour space above the oil allowing gas to flash off and freely flow out of the vessel through 14” nozzle N2.

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Oil/water interface liquid levels are monitored at two independent instrument bridles, One comprising a visual gauge and a level transmitter and other having a level transmitter. Sample cocks are provided on the separator, to allow confirmation of actual contents at fixed points. One is sited on the interface with two further cocks located either side at 200mm intervals. Transmitter T62‐LST‐0062, a capacitance sensor, monitors the interface liquid level. The objective being to initiate warning and shutdown signals to prevent the possibility of oil entering the produced water system. It will initiate a unit shutdown on sensing a low/low interface, this closes the water outlet shutdown valve, T24‐SDV‐ 0060, from the vessel. Transmitter T62‐LT‐0061, a capacitance sensor, also monitors the oil/water interface level and automatically sets level control valve T62‐LCV‐0061 proportionally open and closed in order to maintain the level by removing produced water. Gauge glass T62‐ LG‐0060 provides operators with a local visual indication. Oil separated from the water flows over the internal weir into the oil section of vessel, it then exits through a vortex breaker into the 20” outlet line to the crude oil pumps. Oil level is monitored by level transmitter T62‐LT‐0065, a diaphragm sealed capillary, dP cell sensor. The instrument loop proportionally controls pneumatic level control valve T62‐LCV‐0065 from closed to open, to maintain the level at its set point. The latter control valve is located downstream of the fiscal metering skid, not adjacent to the separator. Level transmitter T62‐LST‐0063, a similar diaphragm sealed capillary dP cell sensor located in the oil section of the vessel will cause a shutdown on sensing either a low/low or high/high level. Visual indication is provided by level gauge T62‐LG‐0064. Crude oil leaves the second stage separator under level control to enter the crude pumps’ suction manifold; from here it is pumped to the dehydrator inlet heater E‐T6204A/B. Pressure Control The design intent of the LP separator pressure control is to maintain a constant operating pressure. This control loop also provides a special facility to limit the flow to the LP flare system in case of high‐pressure upset conditions (e.g. gas blow‐by from upstream system). Normal pressure control of the LP separator is by means of the booster compressor suction pressure control. If the booster compressor cannot maintain the pressure desired in the LP separator, control loop T71‐PIC‐0061 will cut in to maintain pressure by relieving excess gas to the LP flare. The set point of pressure control loop T71‐PIC‐ 0061 shall be well above the normal operating pressure of the LP separator, e.g. 2.5 barg. If the pressure builds up to 5 barg the pressure controller will limit the opening of the pressure control valve T71‐PIC‐0061 to a maximum opening correlating to a Cv, value of 400. MANUAL No.

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Vessel pressure is maintained within a specific range. Excessive deviation from this range will cause a shutdown. Pressure transmitter T62‐PST‐0060, on sensing a high/high pressure will initiate the shutdown. A pair of parallel relief valves (2 x 100%) provide vessel overpressure protection by venting into the HP flare header at 15 barg. Utilities Two 24” manways provide access for vessel inspection and cleaning. Note:

Vessel draining shall only be carried out under a permit to work when the vessel has been completely isolated, depressured and nitrogen purged. Drain points are flanged to accept a suitable hose connection enabling draining to a hazardous open drain or vessel designed for the purpose.

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2.3.5

Crude Oil Pumps P‐T6201A/B Refer to: DTT 62004 ‐ Crude Oil Pumps P&ID Motor driven centrifugal pumps P‐T6201A/B (2 x 100%) pump treated crude from the oil outlet of the LP separator V‐T6202 up into dehydrator inlet heater E‐T6204A/B. Crude oil flow pressure is boosted from an estimated 1.9 barg at the pump suction to 11.9 barg at the pump discharge. During periods of low flow, a minimum flow control loop driven by T62‐FIC‐0001 will cause control valve T62‐FCV‐0001 to open proportionally and recycle crude back into the LP separator. Normal operation is one pump on line whilst the other is on standby. Pump operation is by operator intervention allowing mode selection as required from Auto/Duty/Standby modes. Refer to para. 3.1.1 for details. Each pump is protected by a pressure switch in the suction line that will trip the pump if the pressure falls below a pre‐determined limit. Similarly, each discharge has a pressure switch that will also initiate a pump shutdown if the pressure is either too high or too low. A strainer in each suction line prevents sand or other foreign matter entering the pump. A seal leak detection system monitors oil leakage past the pump seals. In the event of leakage, a high pressure will cause a pump shutdown. Treater Bypass An option has been provided whereby the crude flow can be pumped directly to the cargo tanks via the heat exchanger and cooler, thus bypassing the treater. It is likely that the bypass option will only be used during maintenance of the treater or when the crude water cut is very low.

2.3.6

Dehydrator Inlet Heater E‐T6204A/B Refer to:DTT 62001 – Topsides Dehydrator Inlet Heater P&ID This heater is of plate and gasket construction, a barrier is fitted to contain fluid spray in the event of a leak. The temperature of the crude oil leaving the Crude oil pumps E‐T6201A/B, estimated at 110°C, is increased to 140°C by flowing through this heater. Heating of the crude is by indirect contact with a heating medium (inhibited fresh water). Local indication of differential pressure across the heaters is provided by T62‐PDG‐0100 to monitor for blockage. A cold side heater bypass is also provided, with the bypass valve normally closed. Overpressure protection is provided on the crude (clod) inlet by T62‐PSV‐0010 &T62‐ PSV‐0011 by venting into the HP flare header at 15 barg.

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! HAZARD

Haz 42

CAUTION: THE CRUDE SIDE OF THE HEAT EXCHANGER SHALL BE DRAINED UPON BLOCK‐IN TO AVOID OVER‐PRESSURISATION DUE TO THERMAL EXPANSION. Temperature Control Temperature of the heater is controlled by T25‐TCV‐0003. This controller proportionally increases or decreases the heat medium flow in response to signals from T62‐TIC‐0003. Should it be deemed necessary for coarse temperature adjustment or maintenance reasons, it is possible to bypass the cold side of the heater, partially or completely dependent on the perceived problem. CAUTION: TO COMPLETELY BYPASS THE COLD SIDE, THE HEATING MEDIUM FLOW MUST FIRST BE ISOLATED

2.3.7

Electrostatic Dehydrator V‐T6203 Refer to: DTT62006 – Topsides Electrostatic Dehydrator P&ID V‐T6203 is an electrostatic dehydrator, fabricated from carbon steel fitted with transformers T‐T6203. It has been designed to process a maximum oil production of 106,700 bpd of oil plus 5% water carry over from the LP separator. The treater transformers supply a high voltage, direct current, to electrodes installed inside the vessel. The effect of this voltage is to attract the polarized water molecules, causing entrained water droplets to coalesce and settle out in the lower section of the vessel; from here the water flows under gravity, via T62‐LCV‐0024, to the produced water handling system. Refer to Section 05 Produced Water Handling. Produced water can also be recycled to the V‐T6201 in the event that the water cut is below the 5% required to operate the Electrostatic dehydrator. This is achieved by manually inputting a bypass flow rate to transmitter T24‐FT‐0004 that proportionally opens flow control valve T24‐FCV‐0004. Each transformer is equipped with the following instrumentation: 

Temperature switch.



Pressure switch.



Level‐gauge.



Safety valve.



Drain and filler cap.

The treater transformers are controlled and monitored from a stainless steel Panel (IP 66), fully in compliance with Spec SEF 41002 E&I Requirements for package units and suitable for installation in a Class 1, Division 2, Group D classified hazardous area. The control panel provides the following indications and functions for each transformer: 

Ammeter.

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

Voltmeter.



Indicator lamp.



Selector switch.



Main power switch.



Start pushbutton.



Stop pushbutton.

Control circuits within T‐T6203 have built in sensors, which automatically limit full load current in the event of a short circuit on the secondary side, i.e. excess water around the electrodes. The electrostatic dehydrator has been designed to operate at a pressure of up to 15 barg and a temperature of up to 170°C. Incoming fluid will displace gas to the LP separator. Note:The treater vent line connects directly to a top mounted nozzle on the second stage separator. Refer to LP separator pressure control data in para 2.3.5. Fluids pumped from the LP separator via a 14” line enter the dehydrator through an 16” base mounted nozzle. The inlet stream is distributed through a header within the vessel that has off‐takes each fitted with deflection plates for efficient liquid dispersion. The oil and produced water collectors are also manifolds, with opening ports aligned to the particular liquid collected. The vessel operates ‘liquid full’; any gas present is displaced back to the LP separator via 2” top mounted outlets Crude oil leaves the dehydrator from the top of the vessel and flows to the Electrostatic desalter for removing the salt laden waster. Then it enters ‘hot’ side of the crude/crude heat exchanger E‐T6202A/B, where it is cooled against incoming live crude from the wells. Level Control The emulsion of oil and water separates within the lower section of the vessel, between the baffle plates, and will separate to form an interface. Efficient separation at this point will be aided by residence time and the electrostatic electrode action. Oil/water interface liquid levels are monitored at two independent instrument bridles, one comprising a visual gauge and a level transmitter and other have level instrument. Sample ‘try cocks’ are provided on the separator, to allow confirmation of content levels at fixed points. Transmitter T62‐LST‐0020 is a capacitance sensor monitoring the interface (water) liquid level. To prevent the possibility of oil entering the produced water system it will initiate a unit shutdown on sensing a low/low level. This closes the water outlet shutdown valve T62‐SDV‐0020 from the vessel. It will also initiate a shutdown on sensing a high/high level to prevent the water level reaching the electrodes. Transmitter T62‐LT‐0024, a capacitance sensor, monitors the oil/water interface level and automatically sets level control valve T62‐LCV‐0024 proportionally open and MANUAL No.

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closed in order to maintain the level by draining off produced water. Gauge glasses T62‐LG‐0025 also provide operators with visual indications. T62‐LST‐0021 supplied to prevents contact between hydrocarbon gas and the high voltage electrodes by switching off the transformers, should the oil level in the vessel fall to a point (low/low) at which the electrodes may become exposed. Pressure Control Gas flashing off within the dehydrator exits to the LP separator, A low/low pressure sensed within the dehydrator by pressure transmitter T62‐PST‐0020 will initiate a shutdown. A pair of parallel relief valves provide vessel overpressure protection by venting into the HP flare header. Utilities A pair of 24” manways provides access for vessel inspection and cleaning. Note:Vessel draining shall only be carried out under a permit to work when the vessel has been completely isolated both mechanically and electrically, depressured and nitrogen purged. Drain points are flanged to accept a suitable hose connection enabling draining to a hazardous open drain or vessel designed for the purpose. 2.3.8

Electrostatic Desalter V‐T6204 Refer to: DTT62007 – Topsides Electrostatic Desalter P&ID V‐T6204 is an electrostatic desalter, fabricated from carbon steel fitted with transformers T‐T6204A/B. It has been designed to process a maximum oil production of 106,700 bpd of oil plus 5% water carry over from the LP separator. The desalter transformers supply a high voltage, direct current, to electrodes installed inside the vessel. The effect of this voltage is to attract the polarized remaining water molecules, causing entrained water droplets to coalesce and settle out in the lower section of the vessel; from here the water flows under gravity, via T62‐LCV‐0034, to the produced water handling system. Refer to Section 05 Produced Water Handling. Produced water can also be recycled to the V‐T6203 in the event that the water cut is below the 5% required to operate the Electrostatic desalter. This is achieved by manually inputting a bypass flow rate to transmitter T24‐FT‐0003 that proportionally opens flow control valve T24‐FCV‐0003. Each transformer is equipped with the following instrumentation: 

Temperature switch.



Pressure switch.



Level‐gauge.



Safety valve.



Drain and filler cap.

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The treater transformers are controlled and monitored from a stainless steel Panel (IP 66), fully in compliance with Spec SEF 41002 E&I Requirements for package units and suitable for installation in a Class 1, Division 2, Group D classified hazardous area. The control panel provides the following indications and functions for each transformer: 

Ammeter.



Voltmeter.



Indicator lamp.



Selector switch.



Main power switch.



Start pushbutton.



Stop pushbutton.

Control circuits within T‐T6204A/B have built in sensors, which automatically limit full load current in the event of a short circuit on the secondary side, i.e. excess water around the electrodes. The electrostatic desalter has been designed to operate at a pressure of up to 15 barg and a temperature of up to 170°C. Incoming fluid will displace gas to the LP separator. Note:The Desalter vent line connects directly to a top mounted nozzle on the second stage separator. Refer to LP separator pressure control data in para 2.3.5. Crude from the dehydrator via a 14” line enter the desalter through an 16” base mounted nozzle. The inlet stream is distributed through a header within the vessel that has off‐takes each fitted with deflection plates for efficient liquid dispersion. The oil and produced water collectors are also manifolds, with opening ports aligned to the particular liquid collected. The vessel operates ‘liquid full’; any gas present is displaced back to the LP separator via 2” top mounted outlets Crude oil leaves the desalter from the top of the vessel and flows to ‘hot’ side of the crude/crude heat exchanger E‐T6202A/B, where it is cooled against incoming live crude from the wells. Level Control The emulsion of oil and water separates within the lower section of the vessel, between the baffle plates, and will separate to form an interface. Efficient separation at this point will be aided by residence time and the electrostatic electrode action. Oil/water interface liquid levels are monitored at two independent instrument bridles, one comprising a visual gauge and a level transmitter and other have level instrument. Sample ‘try cocks’ are provided on the separator, to allow confirmation of content levels at fixed points. Transmitter T62‐LST‐0030 is a capacitance sensor monitoring the interface (water) liquid level. To prevent the possibility of oil entering the produced water system it MANUAL No.

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will initiate a unit shutdown on sensing a low/low level. This closes the water outlet shutdown valve T62‐SDV‐0030 from the vessel. It will also initiate a shutdown on sensing a high/high level to prevent the water level reaching the electrodes. Transmitter T62‐LT‐0034, a capacitance sensor, monitors the oil/water interface level and automatically sets level control valve T62‐LCV‐0034 proportionally open and closed in order to maintain the level by draining off produced water. Gauge glasses T62‐LG‐0035 also provide operators with visual indications. T62‐LST‐0031 supplied to prevents contact between hydrocarbon gas and the high voltage electrodes by switching off the transformers, should the oil level in the vessel fall to a point (low/low) at which the electrodes may become exposed. Pressure Control Gas flashing off within the desalter exits to the LP separator, A low/low pressure sensed within the desalter by pressure transmitter T62‐PST‐0030 will initiate a shutdown. A pair of parallel relief valves provides vessel overpressure protection by venting into the HP flare header. Utilities A pair of 24” manways provides access for vessel inspection and cleaning. Note:Vessel draining shall only be carried out under a permit to work when the vessel has been completely isolated both mechanically and electrically, depressured and nitrogen purged. Drain points are flanged to accept a suitable hose connection enabling draining to a hazardous open drain or vessel designed for the purpose. 2.3.9

Crude Oil Cooler E‐T6205A/B Refer to:DTT 62003 – Topside Crude Oil Cooler P&ID Stabilized crude oil leaves the crude/crude heat exchanger E‐T6202A/B and is further cooled in the Crude Oil Cooler E‐T6205A/B by giving heat to a counter current flow of Cooling Medium, before flowing to the cargo tanks via the fiscal metering package A‐T6210. This cooler is of plate and gasket construction, a barrier is fitted to contain fluid spray in the event of a leak. The temperature of the crude oil leaving the Crude/Crude Heat Exchanger E‐ T6202A/B, estimated at 92°C, is decreased to 55°C by flowing through this cooler. Cooling of the crude is by indirect contact with a cooling medium (inhibited fresh water). Local indication of differential pressure across the heaters is provided by T62‐PDG‐0120 to monitor for blockage. A hot side heater bypass is also provided, with the bypass valve normally closed.

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Temperature Control Temperature of the crude leaving the cooler is controlled by T62‐TCV‐0007. This controller proportionally increases or decreases the cooling medium flow in response to signals from T62‐TIC‐0007. High temperature protection is provided on the crude oil outlet of the exchanger via T62‐TST‐0008. If pre determined limits are reached the executive action from this device will trip close the Crude Oil Heater heating medium return valve T62‐TCV‐ 0005. Should it be deemed necessary for coarse temperature adjustment or maintenance reasons, it is possible to bypass the hot side of the heater, partially or completely dependent on the perceived problem. CAUTION: THE HEAT EXCHANGER SHALL BE DRAINED UPON BLOCK‐IN TO AVOID OVER‐PRESSURISATION DUE TO THERMAL EXPANSION 2.4

ASSOCIATED SYSTEMS SYSTEM

FUNCTION

V‐T6201 HP Separator Refer to: DTT62008 Topside HP Separator Produced Water System 2400

Produced water from the LP separator drains into produced water flash vessel A‐T2410.

HP Flare System 7600

Gas from relief valves T62‐PSV‐0041A/B/C. Gas from pressure control valve T71‐PCV‐0042 Gas from Blow down valve T62‐BDV‐0040.

Gas Compression System 7100

Flash gas is routed to V‐T7111, the 1st stage suction scrubber of the gas lift compression system. Corrosion inhibitor into flash gas line from injection pumps P‐T2825 A/B (head 2).

Chemical Injection System 2800

Demulsifier from injection pumps P‐T2821 A/B (head 3) is injected downstream of separator. Foam Inhibitor from injection pumps P‐T2822 A/B (head 3) is injected downstream of separator.

HP Fuel Gas System 7700

Condensate from V‐T7701 HP fuel gas scrubber is injected into the crude line upstream of separator.

Test Separator

Crude from the test separator enters the process train downstream of the production separator oil LCV and before the crude/crude exchangers.

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SYSTEM

FUNCTION

E‐T6203A/B Crude Oil Heater Refer to: DTT62002 Topside Crude Oil Heater Heating Medium System 2500

Crude oil is heated by indirect contact with heated freshwater in the plate and gasket heaters (2 x 50%).

V‐T6202 LP Separator Refer to: DTT62009 Topside LP Separator HP/LP Flare System 7600

Vent gas from relief valves T62‐PSV‐0061A/B to HP flare. Excess gas relieved by T71‐PCV‐0061 to LP flare.

Produced Water System 2400

Produced water drains to produced water flash vessel A‐T2410.

Gas Compression System 7100

Flash gas flows to booster compressor suction cooler E‐T7141. Condensate from gas lift compression 1st stage suction scrubbers V‐T7111/21 is re‐injected into crude line upstream of the separator.

V‐T6203 Electrostatic Dehydrator Refer to: DTT62006 Topside Electrostatic Dehydrator Power Supply System 1100

440V supply to transformers T‐T6203.


Produced water from dehydrator send to V‐ T6201

V‐T6204 Electrostatic Desalter Refer to: DTT62007 Topside Electrostatic Desalter Power Supply System 1100

440V supply to transformers T‐T6204A/B.


Produced water from desalter send to V‐T6203

E‐T6205A/B Crude Oil Cooler Refer to: DTT62003 Topside Crude Oil Cooler Cooling Medium System 2500

Crude oil is cooled by indirect contact with cooling medium in the plate and gasket cooler (2 x 50%).

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3 3.1

SYSTEM OPERATION CONTROL PHILOSOPHY DTT 92027&92028 ‐ Topsides Oil Processing System PFD The function of the oil separation system is to process the live crude oil into stable and dry crude oil meeting the product specifications for BS&W, temperature and vapour pressure. This is achieved in the following stages of separation, heating, cooling and processing: HP Separation Stage

3 phase oil, water, and gas separation

LP Separation

3 phase oil, water, and gas separation

Electrostatic Treater Stage

2 phase oil, water separation (gas to vent)

Produced Water Degassing

2 phase water and flash gas separation

During normal operation of the process train, the dead crude discharged to storage will be at a temperature of 45°C and the produced water to overboard at 40°C or less. The horizontally mounted HP and LP separators are each equipped with an internal weir. The oil/water emulsion flows under a natural pressure gradient into each vessel’s reception section and separates to form an interface. Produced water is taken off under local level control whilst the oil flows over the weir into the outlet section of the vessel. Oil collecting in this section is also taken off under local level control. To maintain the temperature and enhance the separation of oil/water/gas, the treated crude leaving the swivels is heated in a heater before entering the first vessel. In the heater the live crude is warmed by a heating medium (treated fresh water). A further two heating stages, crude/crude exchanger and crude oil heater is located before the LP separator. The temperature at the outlet of the heater is controlled by a local temperature control loop that regulates the flow of heating medium through the heater. On entry into each separation vessel the incoming product is subjected to a pressure drop. This reduction in pressure causes entrained gas to flash off. Pressure control loops located in each gas take off header regulate the pressure in the vessel; at times excess gas is automatically vented to the flare system. Flash gas is piped to the compression system for further processing. For well start‐up, test and initial riser de‐watering purposes an additional swivel and separator have been provided, refer to Section 03 Test Train. The final processing stage is carried out in the electrostatic treater. Oil is pumped from the LP separator to the treater that operates ‘liquid full’. Gas above the oil is displaced through two vent lines back to the LP separator. The remaining water separated by the electrostatic coalescer process forms an interface with the oil. This interface level is controlled by a local level control loop that lets water down to the produced water slops tank. MANUAL No.

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In order to maintain the process variables described in the preceding paragraphs the following controls have been provided. 

Pump duty/standby switching controls.



Simple level, pressure and temperature process control loops.

Each of the above are identified and described in the following paragraphs 3.1.1

Duty/Standby Pump Controls The design intent of the duty/standby pump controls is to ensure that failure of a single pump in a set does not result in a significant process upset. On failure or confirmed stop of a duty pump detected by the PCS the standby pump will start automatically. Once the standby pump has started its status changes to ‘Duty Pump’. The previous duty pump can then be changed to ‘Standby’ manually by a pushbutton on the PCS. The suction and discharge valve of all pumps shall normally be open. However, manual start of first pump is normally locally against a blocked discharge valve. A field mounted local control station is provided for each pump with local start/stop selection. The stop is a fixed stop position that can be locked for maintenance, whilst the start has spring return to the control position. If the switch is in the central position it can be started from the PCS. Each pump has an ‘Auto/Manual’ selector on the PCS faceplate details as follows. AUTO

Standby pump will start on failure of the running pump

MANUAL

Either pump may be manually started or stopped via the PCS faceplate

Note: In either MANUAL or AUTO a pump will be tripped automatically by the safety logic. 3.1.2

Simple Control Loops The design intent is to maintain a process variable at a constant pre‐set value. Two modes are available to these simple control loops: AUTO

A set point is required, whereby the control valve will be automatically controlled to achieve the required set point.

MANUAL

When operating in this mode the operator enters a percentage output to the control valve. The actual process variable will be displayed but not automatically acted upon. Unless stated otherwise, all control valves are pneumatically actuated and all control signals are electronic. Set points shown in the following table are for guidance only and have been derived from design parameters. Although these may need to be revised with operational

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experience, changes should not be carried out without prior supervisory discussion and approval. Note: All set point measurements are from the base line of the vessel 3.2

SYSTEM CONTROL LOOPS TAG NO.

SETTING

FUNCTION

HP Separator V‐T6201 Refer to: DTT62008 Topside HP Separator T62‐LIC‐0041*

26%

Controls vessel produced water level in front of weir.

T62‐LIC‐0045*

55%

Controls vessel crude oil level after the weir.

Note*: If downstream equipment is upset by flow disturbances (e.g. slugging) a gap remote setpoint may be required. In this case the setpoint is equal to the measured variable (PV) as long as the measured variable (PV) is between thlow and high setpoints. The setpoint will be equal to the low setpoint if the PV is less than or equal to the low setpoint and equal to the high setpoint if the PV is higher or equal to the high setpoint. The operator enters these low and high settings for the remote setpoint of the controller with values between high and low alarm points. T71‐PIC‐0042 T71‐PT‐005 T71‐PIC‐005

T71‐PT‐006 T71‐PIC‐006

9.0 barg

Vessel pressure control, PCV vents excess gas to HP flare.

8 barg

Gas lift compressor K‐T7111/21 performance control ‐ suction pressure is regulated by Vendor anti‐surge and performance control panels with input from T71‐ PT‐005.

8 barg

Gas lift compressor K‐T7141/51 performance control ‐ suction pressure is regulated by Vendor anti‐surge and performance control panels with input from T71‐ PT‐006.

Crude Oil Heaters E‐T6203A/B Refer to: DTT62002 Topside Crude oil Heater T62‐TIC‐0005

110°C

Crude oil temperature across the heater is controlled by T62‐TT‐0005 in the outlet line from the heater to the LP separator.

LP Separator V‐T6202 Refer to: DTT62009 Topside LP Separator T62‐LIC‐0061

20%

Controls vessel produced water level in front of weir.

MANUAL No.

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TAG NO.

SETTING

T62‐LIC‐00605

62%

T71‐PIC‐0061

1.9 barg

Note:

FUNCTION Controls vessel crude oil level after the weir. Vessel pressure control.

Under normal operating conditions T71‐PIC‐0061 is direct acting. However when the pressure is equal to or greater than 5 barg the valve is kept in a ‘fixed’ position.

Crude Oil Pumps P‐T6201A/B Refer to: DTT62004 Crude Oil Pumps T62‐FT‐0001

400 m3/hr

Minimum flow control loop ‐ controls crude recycling flow.

Electrostatic Dehydrator V‐T6203 Refer to: DTT6206 Topside Electrostatic Dehydrator T62‐LIC‐0024

11%

T62‐FIC‐075

28 m3/hr

Controls vessel water level. Controls flow of recycled water to suction of crude oi pumps.

Crude Oil Coolers E‐T6205A/B Refer to: DTT62003 Topside Crude Oil Cooler T62‐TIC‐0053

35C

Controls crude temperature by cooling medium flow.

MANUAL No.

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3.3

PRE‐START CHECKS STEP

ACTION

CHECK

Prior to starting or restarting the process train it is essential that the following topsides and associated vessel systems are available:

1



Process control and safety monitoring system



Fire and gas detection system



Fire fighting and deluge system



Subsea control system and HPU



Turret systems



Heating medium



Cooling medium



Instrument air



Power generation and distribution



Chemical injection



HP/LP flare and drains



Produced water system



Fiscal metering/BS&W





MDO System



Cargo handling/oil storage

Note: The gas compression system, although desirable for gas lift purposes, is not essential to the running of the process train as gas can initially be flared until the system has totally stabilised

Confirm that the Oil Processing system is mechanically 2 complete and that all associated work permits have been signed off

3

Check that all manually operated valves are positioned as detailed in the Valve Position Checklist. Refer to Section 3.3.1

4

Confirm that all instruments are correctly lined up and operational. Refer to Instrumentation Checklist Section 3.3.3

5

Check that all removable spools and blinds are positioned as detailed in the Blind/Spool Checklist. Refer to Section 3.3.2

Confirm that well(s) are available to flow and that turret 6 flowline and swivel systems are operational. Refer to Turret Manual for details.

MANUAL No.

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STEP

ACTION

CHECK

If the system is to be started following intrusive maintenance, confirm that leak tests were satisfactory, all air has been 7 purged from the equipment and that the system is at a slightly positive nitrogen pressure.

Confirm that a liquid level is present in both sections of each separator. Note: In the absence of a working level it should not be 8 necessary to override low/low level shutdowns as these can be reset progressively as the vessel levels are established.

Confirm that a working liquid/oil level is present in the electrostatic treater V‐T6203, or the vessel is bypassed for start‐up. 9 A LIQUID LEVEL MUST BE ESTABLISHED BEFORE THE TREATER IS SWITCHED ON.

HP Separator V‐T6201 Refer to: DTT62008 Topside HP Separator CAUTION: FOLLOWING ISOLATION OF THE PRODUCTION SEPARATOR FOR MAINTENANCE, BEFORE RESTART ENSURES THAT THE CRUDE INLET VALVE T62‐BL‐1300 IS THE OPEN POSITION BEFORE COMMENCING PRESSURING UP FROM THE TURRET. Confirm that pressure controller T71‐PIC‐0042 is set to ‘Auto’ 10 and that T71‐PCV‐0042 is closed. 11 12

Check oil outlet valve T62‐SDV‐0041 is Open.

Check water outlet valve T62‐SDV‐0040 is Open.

Check position of oil and water level control valves, T62‐LCV‐ 0041 and T62‐LCV‐0045 respectively, relative to the actual 13 levels in vessels. Controllers T62‐LIC‐0041 and T62‐LIC‐0045 should be set to operate in ‘Auto’ mode.

Crude Oil Heater E‐T6203A/B Refer to: DTT62002 Topside Crude Oil Heater Check that T62‐TCV‐0005 in the heating medium outlet header 14 from crude oil heater E‐T6203A/B is open and that controller T62‐TIC‐0005 is set to ‘Auto’. 15

Check that a heating medium supply is available to E‐ T6203A/B.

MANUAL No.

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STEP

ACTION

CHECK

LP Separator V‐T6202 Refer to: DTT62009 Topside LP Separator Confirm that pressure controller T71‐PIC‐0061 is set to ‘Auto’ 16 and that T71‐PCV‐0061 is closed. 17 18

Check oil outlet valve T62‐SDV‐0060 is Open.

Check water outlet valve T24‐SDV‐0060 is Open.

Check position of oil and water level control valves, T62‐LCV‐ 0061 and T62‐LCV‐0065 respectively, relative to the actual levels 19 in vessels. Controllers T62‐LIC‐0061 and T62‐LIC‐0065 should be set to operate in ‘Auto’ mode.

Crude Oil Pumps P‐T6201A/B Refer to: DTT62004 Crude Oil pumps Minimum flow control loop ‐ check flow control valve T62‐FCV‐ 20 0001 is closed and controller T62‐FIC‐0001 is set to ‘Auto’.

Electrostatic Dehydrator V‐T6203 Refer to: DTT62006 Topside Electrostatic Dehydrator Check position of water level control valve T62‐LCV‐0024 relative 21 to the actual level in the vessel. Controller T62‐LIC‐0024 should be set to operate in ‘Auto’ mode. Check recycled water flow control valve T24‐FCV‐0003 is 22 closed, and controller T24‐FIC‐0003 is set to operate in ‘Auto’ mode.

Electrostatic Desalter V‐T6204 Refer to: DTT62007 Topside Electrostatic Desalter Check position of water level control valve T62‐LCV‐0034 relative 23 to the actual level in the vessel. Controller T62‐LIC‐0034 should be set to operate in ‘Auto’ mode.

Crude Oil Cooler E‐T6205A/B Refer to: DTT62003 Topside Crude Oil Cooler Check that T62‐TCV‐0007 in the cooling medium outlet header 24 from crude oil cooler E‐T6205A/B is closed and that controller T62‐TIC‐0007 is set to ‘Auto’.

Check that a cooling medium supply is available to E‐ 25 T6205A/B.

MANUAL No.

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STEP

ACTION

CHECK

Confirm that Oil Fiscal Metering Package A‐T6210 is lined up 26 and functional. 3.3.1

Valve Position Checklist The following checklists should be read in conjunction with the associated Turret Manual and Section 05 Produced Water Handling of this manual. Note: Those instrument isolation valves that are safety critical for the functioning of shutdown systems are itemised and highlighted in red italics in the following tables. TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

The following valve status must be checked prior to initial start‐up and/or following a major shutdown:



Instrument isolation valves



Instrument sensing lines

OPEN OPEN

HP Separator V‐T6201 Refer to: DTT62008 Topside HP Separator

The following valve status must be checked prior to initial start‐up and/or following a major shutdown: 





OPEN OPEN CLOSED AND BLANKED

V‐T6201 drain valve

NORMALLY CLOSED

T62‐BL‐3007 (N5b)


NORMALLY CLOSED

T62‐BL‐3008 (N5c)


NORMALLY CLOSED

T62‐BL‐3009 (N5d)


NORMALLY CLOSED

T62‐BL‐3314

Closed drain header isolation valve

NORMALLY CLOSED

T62‐BL‐3315

Closed drain header drain valve

NORMALLY CLOSED

T62‐BL‐1299 (N8)

Utility connection valve

T62‐BL‐1313 (N5a)

MANUAL No.

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TAG NO.

POSITION

CHECK


NORMALLY CLOSED

K10a

V‐T6201 sample valve

NORMALLY CLOSED

K10b


NORMALLY CLOSED

K10c


NORMALLY CLOSED

K10d


NORMALLY CLOSED

K10e


NORMALLY CLOSED

T62‐BL‐1320

Production fluids inlet from E‐T6206

NORMALLY CLOSED

T62‐BL‐1283

Production fluid drain valve from E‐ T6206

NORMALLY CLOSED

T71‐BL‐2392

Condensate Inlet valve from P‐ T7142A/B

OPEN

T71‐BL‐3587

Condensate inlet line vent valve from P‐ CLOSED AND T7142A/B BLANKED

T62‐BL‐1300

Production fluid inlet valve from Q‐ M6101

LOCKED OPEN

T62‐BL‐2393

Condensate inlet valve from Condensate return header

OPEN

T62‐BL‐3316

VALVE DESCRIPTION

T62‐TCV‐0042

Produced water temperature control valve

AUTO/ CLOSED

T24‐GA‐2396

Produced water T62‐TCV‐0042 inlet block valve

OPEN

T24‐GA‐1318

Produced water T62‐TCV‐0042 outlet block valve

OPEN

T24‐BL‐2398

T62‐TCV‐0042 inlet drain valve

CLOSED AND BLANKED

T24‐BL‐2397

T62‐TCV‐0042 outlet drain valve

CLOSED AND BLANKED

T24‐GL‐2399

Produced water T62‐TCV‐0042 bypass block valve

LOCKED CLOSED

LOCKED OPEN

T62‐BL‐1266& T62‐PSV‐0041A inlet isolation valve T62‐BL‐1319

MANUAL No.

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TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

T62‐BL‐1274

T62‐PSV‐0041A inlet drain valve

CLOSED AND BLANKED

T62‐BL‐1297


NORMALLY CLOSED

T76‐BL‐1287

T62‐PSV‐0041A outlet drain valve

CLOSED AND BLANKED

T76‐BL‐1294

T62‐PSV‐0041A outlet isolation valve

LOCKED OPEN

LOCKED OPEN

T62‐BL‐3648& T62‐PSV‐0041B inlet isolation valve T62‐BL‐1314 T62‐BL‐1286

T62‐PSV‐0041B inlet drain valve

CLOSED AND BLANKED

T62‐BL‐1305


NORMALLY CLOSED

T76‐BL‐1295

T62‐PSV‐0041B outlet drain valve

CLOSED AND BLANKED

T76‐BL‐1292

T62‐PSV‐0041B outlet isolation valve

LOCKED OPEN

LOCKED CLOSED

T62‐BL‐1303& T62‐PSV‐0041C inlet isolation valve T62‐BL‐3005 T62‐BL‐1296

T62‐PSV‐0041C inlet drain valve

CLOSED AND BLANKED

T62‐BL‐2394

T62‐PSV‐0041C inlet drain valve

NORMALLY CLOSED

T62‐BL‐3004

T62‐PSV‐0041C outlet drain valve

CLOSED AND BLANKED

T76‐BL‐3003

T62‐PSV‐0041C outlet isolation valve

LOCKED OPEN

FAIL OPEN

LOCKED OPEN

CLOSED AND BLANKED

OPEN

NORMALLY CLOSED

OPEN

T62‐BDV‐0040 Blow down valve T62‐BL‐1325

Blow down outlet isolation valve

T62‐BL‐3006

Blow down Drain valve

T62‐BL‐1279 T62‐LT‐0041 bridle upper isolation &T62‐BL‐3301 valve T62‐BL‐3303

T62‐LT‐0041 bridle Drain valve

T62‐BL‐1304 T62‐LT‐0041 bridle middle isolation &T62‐BL‐3300 valve MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 38 OF 91


TAG NO. T62‐BL‐3302

VALVE DESCRIPTION T62‐LT‐0041 bridle middle drain valve

T62‐BL‐1328 T62‐LT‐0041 bridle lower isolation valve &T62‐BL‐3304

POSITION

CHECK

NORMALLY CLOSED

OPEN

T62‐BL‐3305

T62‐LT‐0041 bridle lower drain valve

NORMALLY CLOSED

T62‐BL‐1272

T62‐LT‐0041 Standpipe drain valve

NORMALLY CLOSED

T62‐BL‐1269

T62‐LG‐0040 upper isolation valve

OPEN

T62‐BL‐1284

T62‐LG‐0040 lower isolation valve

OPEN

T62‐BL‐1323

T62‐LG‐0040 vent valve

NORMALLY CLOSED

T62‐BL‐1271

T62‐LG‐0040 drain valve

NORMALLY CLOSED

LOCKED OPEN

NORMALLY CLOSED

LOCKED OPEN

NORMALLY CLOSED

LOCKED OPEN

T62‐BL‐1329 T62‐LST‐0042 bridle upper isolation &T62‐BL‐3307 valve T62‐BL‐3308

T62‐LST‐0042 bridle upper drain valve

T62‐BL‐1275 T62‐LST‐0042 bridle middle isolation &T62‐BL‐3306 valve T62‐BL‐3309

T62‐LST‐0042 bridle middle drain valve

T62‐BL‐1268 T62‐LST‐0042 bridle lower isolation &T62‐BL‐3310 valve T62‐BL‐3311

T62‐LST‐0042 bridle lower drain valve

NORMALLY CLOSED

T62‐BL‐1278


NORMALLY CLOSED

T62‐BL‐1309

T62‐LST‐0043 upper isolation valve

LOCKED OPEN

T62‐BL‐1288

T62‐LST‐0043 lower isolation valve

LOCKED OPEN

T62‐BL‐1324


OPEN

T62‐BL‐1317


OPEN

T62‐BL‐1290


NORMALLY CLOSED

T62‐BL‐1307


NORMALLY CLOSED

MANUAL No.

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REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 39 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

T62‐BL‐1322

T62‐LT‐0045 upper isolation valve

OPEN

T62‐BL‐1301

T62‐LT‐0045 lower isolation valve

OPEN

T62‐BL‐1321

T62‐PST‐0040 Pressure switch isolation valve

LOCKED OPEN

T62‐BL‐1280

Spare Nozzle with isolation valve

NORMALLY CLOSED

Produced water outlet safety shut‐off valve

FAIL CLOSED

T24‐BL‐1277

Produced water outlet drain valve

NORMALLY CLOSED

T62‐BL‐3312

Crude oil header drain valve

NORMALLY CLOSED

FAIL CLOSED

NORMALLYC LOSED

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

OPEN

FAIL OPEN

T62‐SDV‐0040

T62‐SDV‐0041 Crude Oil outlet safety shut‐off valve T62‐BL‐1315

Crude oil outlet drain valve

T62‐BL‐1285 T62‐FT‐0042 Crude oil FT Upstream &T62‐BL‐3248 isolation valve T62‐BL‐3249

T62‐FT‐0042 Crude oil FT Upstream drain valve

T62‐BL‐1281 T62‐FT‐0042 Crude oil FT Downstream &T62‐BL‐1267 isolation valve T62‐BL‐1289

T62‐FT‐0042 Crude oil FT downstream drain valve

T62‐BL‐1298 T62‐FT‐0041 Crude oil FT Upstream &T62‐BL‐3250 isolation valve T62‐BL‐3251

T62‐FT‐0041 Crude oil FT Upstream drain valve

T62‐BL‐1321 T62‐FT‐0041 Crude oil FT Downstream &T62‐BL‐1326 isolation valve T62‐BL‐1327 No tag no

T62‐FT‐0041 Crude oil FT downstream drain valve T62‐PT‐0042 Pressure transmitter isolation valve on crude oil line

T62‐LCV‐0045 Crude oil level control valve T62‐BL‐1310

Crude oil T62‐LCV‐0045 inlet block valve

OPEN

T62‐BL‐1293

Crude oil T62‐LCV‐0045 outlet block valve

OPEN

MANUAL No.

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REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 40 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

T62‐BL‐1311

T62‐LCV‐0045 inlet drain valve

NORMALLY CLOSED

T62‐BL‐1291

T62‐LCV‐0045 outlet drain valve

NORMALLY CLOSED

T62‐GL‐1260

Crude oil T62‐LCV‐0045 bypass block valve

NORMALLY CLOSED

T71‐FE‐0040

Flash gas flow meter

T71‐BL‐2401

T71‐FE ‐0040 upstream isolation valve

LOCKED OPEN

T71‐BL‐2403

T71‐FE ‐0040 downstream isolation valve

LOCKED OPEN

T71‐FE‐0041


T71‐BL‐3191

T71‐FE ‐0041 upstream isolation valve

LOCKED CLOSED

T71‐BL‐3192

T71‐FE ‐0041 downstream isolation valve

LOCKED CLOSED

T71‐BL‐1303

Pressure transmitter on flow gas line

T71‐BL‐1303

T71‐BL‐1303 isolation valve

OPEN

AUTO

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

T71‐PCV‐0042 Flash gas vent pressure control valve T71‐BL‐1282

T71‐PCV‐0042 Inlet isolation valve

T71‐BL‐1270

T71‐PCV‐0042 Inlet drain valve

T76‐BL‐1306

T71‐PCV‐0042 outlet isolation valve

T71‐BL‐1270

T71‐PCV‐0042 outlet drain valve

Crude‐Crude Exchanger E‐T6202 A/B Refer to: DTT62005 Topside Crude/Crude Exchanger






OPEN OPEN

EXCHANGER COOL SIDE (‘live’ crude from HP separator) T62‐BL‐1149

Crude inlet line from HP separator to E‐ T6202A

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

OPEN

PAGE 41 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

NORMALLY CLOSED

T62‐BL‐1159

Crude oil inlet drain valve

T62‐BL‐1143

Crude oil inlet line Strainer drain valve

CLOSED AND BLANKED

T62‐BL‐2362

Crude inlet line from HP separator to E‐ T6202B

OPEN

T62‐BL‐1155

Crude oil inlet drain valve

NORMALLY CLOSED

T62‐BL‐1144

Crude oil inlet line Strainer drain valve

CLOSED AND BLANKED

T62‐BL‐1146

Outlet from E‐T6202A to crude oil heater E‐T6203A/B

OPEN

T62‐BL‐1145

Crude outlet vent valve

NORMALLY CLOSED

T62‐BL‐1147

Outlet from E‐T6202B to crude oil heater E‐T6203A/B

OPEN

T62‐BL‐1139

Crude outlet vent valve

NORMALLY CLOSED

T62‐BL‐1160

Cold side bypass valve

NORMALLY CLOSED

OPEN

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

T62‐BL‐1152& Cold side differential pressure gauge T62‐BL‐1158 (T62‐PDG‐0006) isolation valves EXCHANGER HOT SIDE (‘dead’ crude from treater V‐T6204) T62‐BL‐1157

Dead crude inlet to exchanger E‐ T6202A

T62‐BL‐1141

Dead crude inlet vent valve

T62‐BL‐1151

Dead crude inlet to exchanger E‐ T6202B

T62‐BL‐1150

Dead crude inlet vent valve

T62‐BL‐1156

Dead crude outlet from exchanger E‐ T6202A

T62‐BL1137

Dead crude outlet drain valve

T62‐BL‐1148

Dead crude outlet from exchanger E‐ T6202B

T62‐BL‐1153

Dead crude outlet drain valve

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 42 OF 91



VALVE DESCRIPTION Hot side bypass valve

T62‐BL‐1142& Hot side differential pressure gauge T62‐BL‐1138 (T62‐PDG‐0007) isolation valves Crude Oil Heater E‐T6203A/B

POSITION

CHECK

NORMALLY CLOSED

OPEN

Refer to: DTT62002 Topside Crude Oil Heater






OPEN OPEN

COOL SIDE (crude from crude/crude exchanger) T62‐BL‐1085

Crude inlet isolation valve to E‐T6203A

T62‐BL‐1090

Crude inlet drain valve

T62‐BL‐1089

Crude inlet isolation valve to E‐T6203B

T62‐BL‐2368

Crude inlet drain valve

T62‐BA‐1066

Live crude oil bypass valve

T62‐BL‐1083

Crude oil outlet from E‐T6203A isolation valve.

T62‐BL‐1078

Crude oil outlet vent valve

T62‐BL‐1084

Crude oil outlet from E‐T6203B isolation valve.

T62‐BL‐1079

Crude oil outlet vent valve

T62‐BL‐1080 & Crude oil side differential pressure T62‐BL‐1081 gauge (T62‐PDG‐0110) isolation valves

OPEN

CLOSED AND BLANKED

OPEN

CLOSED AND BLANKED

NORMALLY CLOSED

OPEN

CLOSED AND BLANKED

OPEN

CLOSED AND BLANKED

OPEN

OPEN

CLOSED AND BLANKED

HOT SIDE (heating medium) T25‐GA‐1072

E‐T6203A heat medium inlet isolation valve

T25‐GA‐2365

E‐T6203A heat medium inlet vent valve

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 43 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

OPEN

T25‐GA‐1068

E‐T6203B heat medium inlet isolation valve

T25‐GA‐2366

E‐T6203B heat medium inlet vent valve

CLOSED AND BLANKED

T62‐GA‐1064

E‐T6203A heat medium outlet isolation valve

OPEN

T62‐GA‐1071

E‐T6203A heat medium outlet drain valve

CLOSED AND BLANKED

T25‐GA‐1062

E‐T6203B heat medium outlet isolation valve

OPEN

T25‐GA1061

E‐T6203B heat medium outlet drain valve

CLOSED AND BLANKED

FAIL CLOSED

T62‐TCV‐0005 Heater temperature control valve

AUTO

T25‐GA‐1069

T62‐TCV‐0005 inlet isolation valve

OPEN

T25‐GA‐1067


CLOSED AND BLANKED

T25‐GA‐1063


NORMALLY CLOSED

T25‐GA‐1070

T62‐TCV‐0005 outlet isolation valve

AUTO

FAIL CLOSED

T25‐GL‐1060

T62‐TCV‐0005 bypass isolation valve

NORMALLY CLOSED

LP Separator V‐T6202 Refer to: DTT62009 Topside LP Seperator






OPEN OPEN CLOSED AND BLANKED


NORMALLY CLOSED

T62‐BL‐2986


NORMALLY CLOSED

T62‐BL‐2987


NORMALLY CLOSED

T62‐BL‐2867

Utility connection valve

T62‐BL‐2985

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 44 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

T62‐BL‐2988


NORMALLY CLOSED

T62‐BL‐2989


NORMALLY CLOSED

T62‐BL‐3293


NORMALLY CLOSED

T62‐BL‐3296


NORMALLY CLOSED

T62‐BL‐3287


NORMALLY CLOSED

T62‐BL‐3288


NORMALLY CLOSED

K10a


NORMALLY CLOSED

K10b


NORMALLY CLOSED

K10c


NORMALLY CLOSED

K10d


NORMALLY CLOSED

K10e


NORMALLY CLOSED

T62‐BL‐2407

Crude oil from E‐T6203A/B to V‐T6202 isolation valve

LOCKED OPEN

T24‐SDV‐0060

Produced water outlet safety shut‐off valve

FAIL CLOSED

Produced water outlet drain valve

NORMALLY CLOSED

FAIL CLOSED

NORMALLYC LOSED

LOCKED OPEN

T24‐BL‐1375

T62‐SDV‐0060 Crude Oil outlet safety shut‐off valve T62‐BL‐1352

Crude oil outlet drain valve

T62‐BL‐1381& T62‐PSV‐0061A inlet isolation valve T62‐BL‐3272 T62‐BL‐3271


CLOSED AND BLANKED

T62‐BL‐1340


NORMALLY CLOSED

T76‐BL‐1370


CLOSED AND BLANKED

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 45 OF 91



VALVE DESCRIPTION T62‐PSV‐0061A outlet isolation valve

T62‐BL‐1336& T62‐PSV‐0061B inlet isolation valve T62‐BL‐3274

POSITION

CHECK

LOCKED OPEN

LOCKED OPEN

T62‐BL‐3273


CLOSED AND BLANKED

T62‐BL‐1338


NORMALLY CLOSED

T76‐BL‐1380


CLOSED AND BLANKED

T76‐BL‐1341

T62‐PSV‐0061B outlet isolation valve

LOCKED OPEN

T71‐FE‐0060


OPEN

T62‐BL‐2993

T71‐FE‐0060 Upstream isolation valve

OPEN

T62‐BL‐2990

T71‐FE‐0060 Downstream isolation valve

OPEN

T71‐FE‐0062


OPEN

T62‐BL‐2992

T71‐FE‐0060 Upstream isolation valve

NORMALLY CLOSED

T62‐BL‐2991

T71‐FE‐0060 Downstream isolation valve

NORMALLY CLOSED

T62‐BL‐1361

Flow gas pressure transmitter (T71‐PT‐ 0061) isolation valve

OPEN

AUTO

LOCKED OPEN

NORMALLY CLOSED

AUTO

NORMALLY CLOSED

LOCKED OPEN

NORMALLY CLOSED

LOCKED OPEN

T71‐PCV‐0061 Flash gas vent pressure control valve T71‐BL‐1349

T71‐PCV‐0061 outlet to LP Flare

T71‐BL‐1364

T71‐PCV‐0061 outlet to LP Flare vent valve

T71‐SDV‐0060 T71‐BL‐1347

Flare gas safety shutdown valve outlet to E‐T7141 Drain valve

T62‐BL‐1379& T62‐LST‐0062 bridle upper isolation T62‐BL‐3275 valve T62‐BL‐3276

T62‐LST‐0062 bridle Drain valve

T62‐BL‐1374& T62‐LST‐0062 bridle middle isolation T62‐BL‐3277 valve MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 46 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

T62‐BL‐3673


NORMALLY CLOSED

LOCKED OPEN

T62‐BL‐1342& T62‐LST‐0062 bridle lower isolation T62‐BL‐3279 valve T62‐BL‐3280


NORMALLY CLOSED

T62‐BL‐1348

T62‐LST‐0062 Standpipe drain valve

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

LOCKED OPEN

NORMALLY CLOSED

LOCKED OPEN

T62‐BL‐1377& T62‐LT‐0061 bridle upper isolation T62‐BL‐3281 valve T62‐BL‐3282

T62‐LT‐0061 bridle Drain valve

T62‐BL‐1337& T62‐LT‐0061 bridle middle isolation T62‐BL‐3283 valve T62‐BL‐3284

T62‐LT‐0061 bridle middle drain valve

T62‐BL‐1369& T62‐LT‐0061 bridle lower isolation valve T62‐BL‐3285 T62‐BL3286


NORMALLY CLOSED

T62‐BL‐2413


NORMALLY CLOSED

T62‐BL‐1367


OPEN

T62‐BL‐1365


OPEN

T62‐BL‐1363


NORMALLY CLOSED

T62‐BL‐1368


NORMALLY CLOSED

T62‐BL‐1344

T62‐LST‐0063 upper isolation valve

LOCKED OPEN

T62‐BL‐2409

T62‐LST‐0063 lower isolation valve

LOCKED OPEN

T62‐BL‐2408


OPEN

T62‐BL‐2412


OPEN

T62‐BL‐1360


NORMALLY CLOSED

T62‐BL‐2411


NORMALLY CLOSED

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 47 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

T62‐BL‐1354

T62‐LT‐0065 upper isolation valve

OPEN

T62‐BL‐2415

T62‐LT‐0065 lower isolation valve

OPEN

T62‐BL‐1373

T62‐PST‐0060 Isolation valve

LOCKED OPEN

T62‐BL‐1372

V‐T6202 Vent valve

CLOSED AND BLANKED

NROMALLY OPEN

CLOSED AND BLANKED

Crude Oil Pumps P‐T6201A/B Refer to: DTT62004 Crude Oil Pumps T62‐BL‐2335

P‐T6201A suction isolation valve

T62‐BL‐1115

P‐T6201A suction filter drain valve

T62‐BL‐1118

T62‐PST‐0080 suction pressure isolation v/v

LOCKED OPEN

T62‐BL‐1124

T62‐PST‐0081 discharge pressure isolation v/v

LOCKED OPEN

T62‐BL‐1123

P‐T6201A discharge vent valve

CLOSED AND BLANKED

T62‐BL‐1110

P‐T6201A discharge bypass valve

NROMALLY OPEN

T62‐BL‐2336

P‐T6201A discharge isolation valve

NROMALLY OPEN

T62‐BL‐1127

P‐T6201A discharge drain valve

CLOSED AND BLANKED

T62‐BL‐2337

P‐T6201B suction isolation valve

NROMALLY OPEN

T62‐BL‐1125

P‐T6201B suction filter drain valve

CLOSED AND BLANKED

T62‐BL‐1126

T62‐PST‐0090 suction pressure isolation v/v

LOCKED OPEN

T62‐BL‐1128

T62‐PST‐0091 discharge pressure isolation v/v

LOCKED OPEN

T62‐BL‐1122

P‐T6201B discharge vent valve

CLOSED AND BLANKED

T62‐BL‐3254

P‐T6201B discharge bypass valve

NROMALLY OPEN

T62‐BL‐2338

P‐T6201B discharge isolation valve

NROMALLY OPEN

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 48 OF 91


TAG NO.

POSITION

CHECK

CLOSED AND BLANKED

T62‐BL‐1121& T62‐FT‐0001 Isolation valve T62‐BL‐1119

OPEN

T62‐BL‐1111& T62‐FT‐0062 Upstream isolation valve T62‐BL‐2858

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

OPEN

NORMALLY CLOSED

T62‐BL‐1130

T62‐BL‐1112

VALVE DESCRIPTION P‐T6201B discharge drain valve

T62‐FT‐0062 Upstream drain valve

T62‐BL‐1113& T62‐FT‐0062 Downstream isolation T62‐BL‐2861 valve T62‐BL‐2860

T62‐FT‐0062 Downstream drain valve

T62‐BL‐1114& T62‐FT‐0061 Upstream isolation valve T62‐BL‐2862 T62‐BL‐3252

T62‐FT‐0061 Upstream drain valve

T62‐BL‐3253& T62‐FT‐0061 Downstream isolation T62‐BL‐2864 valve T62‐BL‐2863

T62‐FT‐0061 Downstream drain valve

T62‐FCV‐0001

Minimum flow loop – oil to LP separator V‐T6202

AUTO

T62‐BL‐2339

T62‐FCV‐0001 Upstream isolation valve

OPEN

T62‐BL‐1129

T62‐FCV‐0001 Upstream drain valve

NORMALLY CLOSED

T62‐BL‐2340

T62‐FCV‐0001 Downstream isolation valve

OPEN

T62‐BL‐1117

T62‐FCV‐0001 Downstream drain valve

NORMALLY CLOSED

T62‐GL‐1108

T62‐FCV‐0001 Bypass valve

NORMALLY CLOSED


NORMALLY OPEN

Not tagged

Dehydrator Inlet Heater E‐T6204A/B Refer to: DTT62001 Topside Dehydrator inlet Heater The following valve status must be checked prior to initial start‐up and/or following a major shutdown:

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 49 OF 91


TAG NO.

VALVE DESCRIPTION 





POSITION

CHECK

OPEN OPEN

COOL SIDE (crude from P‐T6201A/B T62‐BL‐1044

Heater E‐T6204A Crude oil inlet valve

OPEN

T62‐BL‐1053

Heater E‐T6204A inlet drain valve

NORMALLY CLOSED

T62‐BL‐3186

T62‐PSV‐0010 Upstream isolation valve

LOCKED OPEN

T62‐BL‐2999

T62‐PSV‐0010 Upstream vent valve

CLOSED AND BLANKED

T76‐BL‐2998

T62‐PSV‐0010 Downstream isolation valve

LOCKED OPEN

T76‐BL‐3614

T62‐PSV‐0010 Downstream drain valve

NORMALLY CLOSED

T62‐BL‐2378

Heater E‐T6204A Crude oil outlet valve

OPEN

T62‐BL‐1056

Heater E‐T6204A Outlet drain valve

CLOSED AND BLANKED

T62‐BL‐2857

Heater E‐T6204B Crude oil inlet valve

OPEN

T62‐BL‐2369

Heater E‐T6204B inlet drain valve

CLOSED AND BLANKED

T62‐BL‐3002

T62‐PSV‐0011 Upstream isolation valve

LOCKED OPEN

T62‐BL‐3000

T62‐PSV‐0011 Upstream vent valve

NORMALLY CLOSED

T76‐BL‐3001

T62‐PSV‐0011 Downstream isolation valve

LOCKED OPEN

T76‐BL‐3615

T62‐PSV‐0011 Downstream drain valve

NORMALLY CLOSED

T62‐BL‐1041

Heater E‐T6204B Crude oil outlet valve

OPEN

T62‐BL‐1047

Heater E‐T6204B Outlet drain valve

CLOSED AND BLANKED

T62‐BL‐1039

Crude oil bypass valve

NORMALLY CLOSED

T62‐BL‐1046& Crude oil side differential pressure T62‐BL‐1048 gauge (T62‐PDG‐0100) isolation valves

OPEN

HOT SIDE (heating medium)

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 50 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

OPEN

T25‐GA‐2379

E‐T6204A heat medium inlet isolation valve

T25‐GA‐2856

E‐T6204A heat medium inlet vent valve

CLOSED AND BLANKED

T25‐GA‐2402

E‐T6204A heat medium outlet isolation valve

OPEN

T25‐GA‐1042

E‐T6204A heat medium outlet drain valve

CLOSED AND BLANKED

T25‐GA‐2376

E‐T6204B heat medium inlet isolation valve

OPEN

T25‐GA‐2377

E‐T6204B heat medium inlet vent valve

CLOSED AND BLANKED

T25‐GA‐2370

E‐T6204B heat medium outlet isolation valve

OPEN

T25‐GA‐2371

E‐T6204B heat medium outlet drain valve

CLOSED AND BLANKED

T62‐TCV‐0003 Heater temperature control valve

AUTO

FAIL CLOSED

T25‐GA‐2372


OPEN

T25‐GA‐2373


NORMALLY CLOSED

T25‐GA‐2374


NORMALLY CLOSED

T25‐GA‐2375


OPEN

T25‐GL‐1037


NORMALLY CLOSED

Electrostatic Dehydrator V‐T6203 Refer to: DTT62006 Topside Electrostatic Dehydrator






OPEN OPEN

T62‐CH‐1168

Oil inlet isolation valve from E‐ T6204A/B

NORMALLY OPEN

T24‐GA‐1197

Recycle isolation valve from P‐ T2402A/B

OPEN

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 51 OF 91


TAG NO.

VALVE DESCRIPTION

T62‐GL‐1162

Crude oil Inlet header isolation valve

T62‐BL‐1163


T62‐BL‐3340

Crude oil outlet return to V‐T6203

T62‐BL‐3022

Header drain valve

T62‐BL‐3024& T62‐PDG‐0022 Isolation valves T62‐BL‐3026 T24‐SDV‐0020 Produced water outlet shutdown valve

POSITION

CHECK

OPEN

NORMALLY CLOSED

LOCKED OPEN

NORMALLY CLOSED

OPEN

AUTO/CLOS ED

FAIL CLOSED

T24‐BL‐1181

Produced water drain valve

NORMALLY CLOSED

T24‐BL‐1172


NORMALLY CLOSED

T24‐BL‐3019


NORMALLY CLOSED

T24‐BL‐3020


NORMALLY CLOSED

T24‐BL‐3021


NORMALLY CLOSED

T24‐BL‐1205


NORMALLY CLOSED

T24‐BL‐3349


NORMALLY CLOSED

NORMALLY CLOSED

NORMALLY OPEN

T24‐BL‐3347& Closed drain header drain valve T24‐BL‐3348 T62‐BL‐1166

Crude oil outlet to V‐T6204 isolation valve

T62‐LCV‐0023

Vent gas level control valve

AUTO

FAIL CLOSED

T62‐BL‐2418

T62‐LCV‐0023 Inlet isolation valve

OPEN

T62‐BL‐2417

T62‐LCV‐0023 Inlet drain valve

NORMALLY CLOSED

AUTO

FAIL CLOSED

NORMALLY CLOSED

T62‐SDV‐0022 Vent gas shutdown valve T62‐BL‐1182

Vent gas outlet vent valve

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 52 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

T62‐BL‐1192


OPEN

T62‐BL‐1209


OPEN

T62‐BL‐1187


NORMALLY CLOSED

T62‐BL‐1211


NORMALLY CLOSED

LOCKED OPEN

T62‐BL‐1171& T62‐PSV‐0021A inlet block valve T62‐BL‐3221 T62‐BL‐1176


NORMALLY CLOSED

T62‐BL‐3338


CLOSED AND BLANKED

T76‐BL‐1193


CLOSED AND BLANKED

T76‐BL‐1203

T62‐PSV‐0021A outlet block valve

LOCKED OPEN

LOCKED CLOSED

T62‐BL‐1175& T62‐PSV‐0021B inlet block valve T62‐BL‐3220 T62‐BL‐1186


NORMALLY CLOSED

T62‐BL‐3339


CLOSED AND BLANKED

T76‐BL‐1199


CLOSED AND BLANKED

T62‐BL‐1189

T62‐PSV‐0021B outlet block valve

LOCKED OPEN

T62‐BL‐1177& T62‐LST‐0020 bridle upper isolation T62‐BL‐3226 valve

LOCKED OPEN

T24‐BL‐1179& T62‐LST‐0020 bridle middle isolation T24‐BL‐3227 valve

LOCKED OPEN

T24‐BL‐1202& T62‐LST‐0020 bridle lower isolation T24‐BL‐3228 valve

LOCKED OPEN

T62‐BL‐3341


NORMALLY CLOSED

T24‐BL‐3342


NORMALLY CLOSED

T24‐BL‐3343


NORMALLY CLOSED

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 53 OF 91


TAG NO.

POSITION

CHECK

NORMALLY CLOSED

T62‐BL‐1207& T62‐LT‐0024 bridle upper isolation valve T62‐BL‐3223

LOCKED OPEN

T24‐BL‐1198& T62‐LT‐0024 bridle middle isolation T24‐BL‐3224 valve

LOCKED OPEN

T24‐BL‐1201& T62‐LT‐0024 bridle lower isolation valve T24‐BL‐3225

LOCKED OPEN

T24‐BL‐1174

VALVE DESCRIPTION T62‐LST‐0020 Stand pipe drain valve

T62‐BL‐3344

T62‐LT‐0024 bridle upper drain valve

NORMALLY CLOSED

T24‐BL‐3345


NORMALLY CLOSED

T24‐BL‐3346


NORMALLY CLOSED

T24‐BL‐3346

T62‐LT‐0024 Stand pipe drain valve

NORMALLY CLOSED

T62‐BL‐1204

T62‐LG‐0025 Upper isolation valve

OPEN

T24‐BL‐1185

T62‐LG‐0025 Lower isolation valve

OPEN

T24‐BL‐1200


NORMALLYC LOSED

T62‐BL‐1190


NORMALLY CLOSED

T62‐BL‐2419


LOCKED OPEN

T62‐BL‐1195


NORMALLY CLOSED

T24‐BL‐1196

V‐T6203 Utility connection valve

CLOSED AND BLANKED

T24‐BL‐1206

V‐T6203 Sample valve

NORMALLY CLOSED

T24‐BL‐1210


NORMALLY CLOSED

T24‐BL‐1208


NORMALLY CLOSED

T24‐BL‐1194


NORMALLY CLOSED

T24‐BL‐1183


NORMALLY CLOSED

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 54 OF 91



VALVE DESCRIPTION V‐T6203 sample manifold isolation valve

POSITION

CHECK

NORMALLY CLOSED

Electrostatic Desalter V‐T6204 Refer to: DTT62007 Topside Electrostatic Desalter The following valve status must be checked prior to initial start‐up and/or following a major shutdown:  Instrument isolation valves 


OPEN OPEN

T62‐BL‐1216

Oil inlet isolation valve from V‐T6203

NORMALLY OPEN

T26‐SDV‐0001

Wash water shutdown valve from E‐ T2651

AUTO

FAIL CLOSED

T62‐GL‐1213

Crude oil Inlet header isolation valve

OPEN

T62‐BL‐2420


NORMALLY CLOSED

T62‐BL‐3325


LOCKED OPEN

T62‐BL‐3326


LOCKED OPEN

T62‐BL‐3330

Header drain valve

NORMALLY CLOSED

OPEN

AUTO/CLOS ED

FAIL CLOSED

T62‐BL‐3188& T62‐PDG‐0032 Isolation valves T62‐BL‐3189 T24‐SDV‐0030 Produced water outlet shutdown valve T24‐BL‐1227

Produced water drain valve

NORMALLY CLOSED

T24‐BL‐1220


NORMALLY CLOSED

T24‐BL‐3016


NORMALLY CLOSED

T24‐BL‐3017


NORMALLY CLOSED

T24‐BL‐1251


NORMALLY CLOSED

T24‐BL‐3018


NORMALLY CLOSED

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 55 OF 91


TAG NO.

POSITION

CHECK

NORMALLY CLOSED

T24‐BL‐3335& Closed drain header drain valve T24‐BL‐3337

NORMALLY CLOSED

T62‐BL‐2421

Crude oil outlet to E‐T6202 A/B isolation valve

NORMALLY OPEN

T62‐LCV‐0033

Vent gas level control valve

AUTO

FAIL CLOSED

T62‐BL‐2423

T62‐LCV‐0033 Inlet isolation valve

OPEN

T62‐BL‐2422

T62‐LCV‐0033 Inlet drain valve

NORMALLY CLOSED

AUTO

FAIL CLOSED

NORMALLY CLOSED

T24‐BL‐3336

VALVE DESCRIPTION Closed drain header isolation valve

T62‐SDV‐0032 Vent gas shutdown valve T62‐BL‐1230

Vent gas outlet vent valve

T62‐BL‐1226


OPEN

T62‐BL‐1239


OPEN

T62‐BL‐1258


NORMALLY CLOSED

T62‐BL‐1229


NORMALLY CLOSED

LOCKED OPEN

T62‐BL‐1256& T62‐PSV‐0031A inlet block valve T62‐BL‐3229 T62‐BL‐1222


NORMALLY CLOSED

T62‐BL‐3323


CLOSED AND BLANKED

T76‐BL‐1240


NORMALLY CLOSED

T76‐BL‐1249

T62‐PSV‐0031A outlet block valve

LOCKED OPEN

LOCKED CLOSED

T62‐BL‐1254& T62‐PSV‐0031B inlet block valve T62‐BL‐3230 T62‐BL‐1233


NORMALLY CLOSED

T62‐BL‐3324


CLOSED AND BLANKED

T76‐BL‐1245


NORMALLY

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 56 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

CLOSED LOCKED OPEN

T62‐BL‐1223& T62‐LST‐0030 bridle upper isolation T62‐BL‐3232 valve

LOCKED OPEN

T24‐BL‐1225& T62‐LST‐0030 bridle middle isolation T24‐BL‐3233 valve

LOCKED OPEN

T24‐BL‐1231& T62‐LST‐0030 bridle lower isolation T24‐BL‐3234 valve

LOCKED OPEN

T76‐BL‐1236

T62‐PSV‐0031B outlet block valve

T62‐BL‐3327


NORMALLY CLOSED

T24‐BL‐3328


NORMALLY CLOSED

T62‐BL‐3329


NORMALLY CLOSED

T24‐BL‐1221

T62‐LST‐0030 Stand pipe drain valve

NORMALLY CLOSED

T62‐BL‐1255& T62‐LT‐0034 bridle upper isolation valve T62‐BL‐3235

LOCKED OPEN

T24‐BL‐1244& T62‐LT‐0034 bridle middle isolation T24‐BL‐3236 valve

LOCKED OPEN

T24‐BL‐1248& T62‐LT‐0034 bridle lower isolation valve T24‐BL‐3237

LOCKED OPEN

T62‐BL‐3332

T62‐LT‐0034 bridle upper drain valve

NORMALLY CLOSED

T24‐BL‐3236


NORMALLY CLOSED

T24‐BL‐3334


NORMALLY CLOSED

T24‐BL‐1259

T62‐LT‐0034 Stand pipe drain valve

NORMALLY CLOSED

T62‐BL‐1250

T62‐LG‐0035 Upper isolation valve

OPEN

T24‐BL‐1234

T62‐LG‐0035 Lower isolation valve

OPEN

T24‐BL‐1246


NORMALLYC LOSED

T62‐BL‐1237


NORMALLY CLOSED

T62‐BL‐2424


LOCKED

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 57 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

OPEN CLOSED AND BLANKED

V‐T6204 Utility connection valve

NORMALLY CLOSED

T24‐BL‐1253


NORMALLY CLOSED

T24‐BL‐1257


NORMALLY CLOSED

T24‐BL‐1252


NORMALLY CLOSED

T24‐BL‐1241


NORMALLY CLOSED

T24‐BL‐1243


NORMALLY CLOSED

NORMALLY CLOSED

T62‐BL‐1242


T24‐BL‐2866

V‐T6204 sample manifold isolation valve Crude Oil Cooler E‐T6205 A/B T24‐BL‐1232

Refer to: DTT62003 Topside Crude Oil Cooler






OPEN OPEN

HOT SIDE (crude from heat exchanger E‐T6202A/B) T62‐BL‐1100

Cooler E‐T6205A oil inlet valve

OPEN

T62‐BL‐1107

Cooler E‐T6205A oil inlet vent valve

NORMALLY CLOSED

T62‐BL‐1104

Cooler E‐T6205A oil outlet valve

OPEN

T62‐BL‐1101

Cooler E‐T620A oil outlet valve

NORMALLY CLOSED

T62‐BL‐2300

Cooler E‐T6205B oil inlet valve

OPEN

T62‐BL‐2387

Cooler E‐T6205B oil inlet vent valve

NORMALLY CLOSED

T62‐BL‐2296

Cooler E‐T6205B oil outlet valve

OPEN

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 58 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

T62‐BL‐2297

Cooler E‐T620B oil outlet valve

NORMALLY CLOSED

T62‐BL‐2298

Cooler oil bypass line valve

NORMALLY CLOSED

NORMALLY OPEN

OPEN

CLOSED AND BLANKED

OPEN

CLOSED AND BLANKED

LOCKED OPEN

CLOSED AND BLANKED

OPEN

CLOSED AND BLANKED

OPEN

CLOSED AND BLANKED

LOCKED OPEN

CLOSED AND BLANKED

T62‐TCV‐0007 Cooler outlet temperature control v/v

AUTO

FAIL OPEN

T25‐GA‐1097


OPEN

T25‐GA‐2764


CLOSED AND BLANKED

T25‐GA‐2384


CLOSED AND BLANKED

T62‐BL‐1103& T62‐PDG‐0120 Isolation valve T62‐BL‐1106 COOL SIDE (cooling medium) T25‐GA‐1096

E‐T6205 A cooling medium inlet isolation valve

T25‐GA‐2380

E‐T6205A cooling medium inlet drain valve

T62‐GA‐2385

E‐T6205A cooling medium outlet isolation valve

T62‐GA‐2386

E‐T6205A cooling medium outlet vent valve

T25‐GA‐1098

T62‐PSV‐0017 Inlet isolation valve

T25‐GA‐1092

T62‐PSV‐0017 Inlet drain valve

T25‐GA‐2382

E‐T6205 B cooling medium inlet isolation valve

T25‐GA‐2383

E‐T6205 B cooling medium inlet drain valve

T62‐GA‐1095

E‐T6205 B cooling medium outlet isolation valve

T62‐GA‐2388

E‐T6205 B cooling medium outlet vent valve

T25‐GA‐1093

T62‐PSV‐0018 Inlet isolation valve

T25‐GA‐2381

T62‐PSV‐0018 Inlet drain valve

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 59 OF 91


TAG NO.

VALVE DESCRIPTION

POSITION

CHECK

T25‐GA‐1094


OPEN

T25‐GL‐1091


NORMALLY CLOSED

T25‐GA‐3384

T62‐TCV‐0007 vent valve

CLOSED AND BLANKED

Oil Fiscal Metering Package A‐T6210 Refer to: DTT62010 Topsides Oil Fiscal Metering Package T62‐SDV‐0010

Oil outlet safety shut‐off valve

AUTO/CLOS ED

FAIL CLOSED

T62‐BL‐1385

T62‐LCV‐0065 inlet block valve

OPEN

T62‐BL‐1386

T25‐LCV‐0065 inlet drain valve

CLOSED AND BLANKED

T62‐BL‐1383

T25‐LCV‐0065 outlet drain valve

CLOSED AND BLANKED

T62‐BL‐1384

T62‐LCV‐0065 outlet block valve

OPEN

T62‐GL‐1382

T62‐LCV‐0065 bypass block valve

NORMALLY CLOSED

T13‐BL‐3580

A‐T6210 Drain valve

NORMALLY CLOSED

3.3.2

Spectacle Blind/Spool Piece Checklist LOCATION

POSITION

CHECK

HP Separator V‐T6201 Refer to: DTT62008 Topside HP Separator 18” relief line spool

INSTALLED

16” flash gas outlet line spool

INSTALLED

12”Live crude oil inlet &Outline line spool (4)

INSTALLED

12”X8” Dead Crude oil inlet line spool(2)

INSTALLED

8”X12” Dead Crude oil outlet line spool(2)

INSTALLED

Crude Heat Exchanger E‐T6202A/B Refer to: DTT62005 Topside Crude/Crude Exchanger

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 60 OF 91


LOCATION

POSITION

CHECK

Crude Oil Heater E‐T6203A/B Refer to: : DTT62002 Topside Crude Oil Heater 12” crude oil inlet &Outline line spool (4)

INSTALLED

12”X8” Heating medium inlet line spool(2)

INSTALLED

8”X12” Heating medium outlet line spool(2)

INSTALLED

6” relief line to flare spool

INSTALLED

14” flash gas outlet line spool

INSTALLED

20” crude oil outlet spool

INSTALLED

20”X12” Pump inlet spool (2)

INSTALLED

10”X14” Pump outlet spool(2)

INSTALLED

10”X12” Crude oil inlet line Spool(2)

INSTALLED

12”X10” Crude oil Outlet line Spool(2)

INSTALLED

12”X8” Heating medium inlet line spool(2)

INSTALLED

8”X12” Heating medium outlet line spool(2)

INSTALLED

INSTALLED

OPEN

INSTALLED

OPEN

LP Separator V‐6202 Refer to: DTT62009 Topside LP Separator

Crude Oil Pumps P‐T6201A/B Refer to: DTT62004 Crude Oil Pumps

Dehydrator Inlet Heater E‐T6204A/B Refer to: DTT62001 Dehydrator Inlet Heater

Electrostatic Dehydrator V‐T6203 Refer to: DTT62006 Topside Electrostatic Dehydrator gas outlets to LP separator spools gas outlets to LP separator Spectacle blind 6” relief valve line spool 8” produced water outlets spectacle blinds

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 61 OF 91


LOCATION

POSITION

Electrostatic Desalter V‐T6204 Refer to: DTT62007 Topside Electrostatic Desalter

CHECK

OPEN

INSTALLED

OPEN

8”X12” Crude oil inlet line Spool(2)

INSTALLED

12”X8” Crude oil outlet line Spool(2)

INSTALLED

12”X8” Cooling medium inlet line Spool(2)

INSTALLED

8”X12” Cooling medium out let line Spool(2)

INSTALLED

2 x 8” Cooling medium inlet and outlet

INSTALLED

gas outlets to LP separator Spectacle blind 6” relief valve line spool 4” produced water outlets spectacle blinds Crude Oil Cooler E‐T6205A/B Refer to: DTT DTT62003 Topside Crude Oil Cooler

Oil Fical Metering Package A‐T6210 Refer to: DTT62010 Topside Oil Fical Metering Package Spools not fitted

MANUAL No.

ISSUE No: 01

REVISION No:

REF NUMBER:


REVISION DATE:

PAGE 62 OF 91


3.3.3

Instrument Checklist Check the line‐up of the following instruments: INSTRUMENT

LOCATION

CHECK

HP Separator V‐T6201 Refer to: DTT62008 Topside HP Separator T62‐LG‐0040

Oil/water interface level gauge upstream of weir

T62‐LT‐0041

Oil/water interface level transmitter upstream of weir to control the produced water outlet

T62‐TT‐0042

Temperature transmitter to monitor the liquid temperature

T62‐LST‐0042

Interface liquid level to initiate shutdown signal

T62‐PST‐0040

Pressure safety transmitter to monitor the vessel pressure

T62‐LST‐0043

High High & Low Low safety transmitter to monitor the level in oil section downstream of weir

T62‐LG‐0044

Level gauge in oil section downstream of weir

T62‐LT‐0045

Level transmitter in oil section downstream of weir to control the crude oil outlet

T62‐FT‐0041

Flow transmitter in crude oil outlet line

T62‐FT‐0042

Flow transmitter in crude oil outlet line

T24‐FT‐0040

Flow transmitter in produced water outline

T71‐PT‐0042

Outlet gas pressure transmitter

T71‐FE‐0040

Outlet gas flow monitoring transmitter

T71‐FE‐0041


Crude/Crude Exchanger E‐T6202A/B Refer to: DTT62005 Topside Crude/Crude Exchanger T62‐TG‐0010

Cool side inlet temperature gauge

T62‐TG‐0017

Cool side inlet temperature gauge

T62‐TG‐0016

Cool side outlet temperature gauge

T62‐TG‐0012

Cool side outlet temperature gauge

T62‐TG‐0011

Hot side inlet temperature gauge

T62‐TT‐0009

Hot side outlet temperature transmitter

MANUAL No.

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INSTRUMENT

LOCATION

CHECK

T62‐PDG‐0006

Cool side differential pressure gauge across the exchanger

T62‐PDG‐0007

Hot side differential pressure gauge across the exchanger

Crude Oil Heater E‐T6203A/B Refer to: DTT62002 Topside Crude Oil Heater T62‐TT‐0005

Cold side outlet temperature transmitter

T62‐TST‐0018

Cold side safety temperature transmitter

T62‐TG‐0012

Hot side outlet temperature gauge

T62‐TIC‐0005

Hot side outlet temperature indicator control

T62‐PDG‐0110


LP Separator V‐T6202 Refer to: DTT62009 Topside LP Separator T62‐LST‐00062

Interface liquid level safety transmitter to initiate shutdown signal

T62‐LT‐0061

Oil/water interface level transmitter upstream of weir to control the produced water

T62‐LG‐0060

Oil/water interface level gauge upstream of weir

T62‐LST‐0063

High High & Low Low safety transmitter to monitor the level in oil section downstream of weir

T62‐LG‐0064

Level gauge in oil section downstream of weir

T62‐LT‐0065

Level transmitter in oil section downstream of weir to control the crude oil outlet

T62‐PST‐0060

Pressure safety transmitter to monitor the vessel pressure

T62‐TG‐0060

Temperature gauge to monitor the liquid temperature

T71‐PT‐0061

Outlet gas pressure transmitter

T71‐FE‐0060


T71‐FE‐0062


Crude Oil Pumps P‐T6201A/B Refer to: DTT 62004 Crude Oil Pumps T62‐PST‐0080

Pump inlet pressure safety transmitter

T62‐PST‐0090

Pump inlet pressure safety transmitter

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INSTRUMENT

LOCATION

CHECK

T62‐PST‐0081

Pump outlet pressure safety transmitter

T62‐PST‐0091

Pump outlet pressure safety transmitter

T62‐FT‐0001

Crude pumps discharge recycle to LP separator minimum flow control transmitter and controller

T62‐FT‐0061

Crude oil outlet flow transmitter to dehydrator inlet heater

T62‐FT‐0062

Crude oil outlet flow transmitter to dehydrator inlet heater

T62‐PT‐0061

Common discharge line pressure transmitter

T62‐TT‐0061

Common discharge line temperature transmitter

Dehydrator Inlet Heater E‐T6204A/B Refer to: DTT 62001 Topside Dehydrator Inlet Heater T62‐TG‐0001

Crude oil inlet temperature gauge

T62‐TST‐0015

Crude oil outlet temperature safety transmitter

T62‐TT‐0003

Crude oil outlet temperature transmitter

T62‐TG‐0051

Heating medium inlet temperature gauge

T62TG‐0050

Heating medium outlet temperature gauge

T62‐TIC‐0003

Heating medium outlet temperature indicator control

T62‐PDG‐0100


Electrostatic Dehydrator V‐T6203 Refer to: DTT 62006 Topside Electrostatic Dehydrator T62‐LST‐0020

Interface (water) liquid level to initiate shutdown signal

T62‐LT‐0024

Oil/water interface level transmitter to control the produced water outlet

T62‐LG‐0025

Oil/water interface level gauge

T62‐LST‐0021

Level transmitter with trip to prevent the contact between hydrocarbon gas & high voltage electrodes

T62‐PST‐0020

Vessel pressure safety transmitter

T62‐TT‐0022

Liquid temperature transmitter

T62‐LG‐0022

Flash gas outlet pot level gauge

T62‐LT‐0023

Flash gas outlet pot level transmitter

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INSTRUMENT

LOCATION

CHECK

T62‐LIC‐0023

Flash gas level indicator controller

T62‐PDG‐0022

Differential pressure gauge in crude oil side across the exchanger

Electrostatic Desalter V‐T6204 Refer to: DTT 62007 Topside Electrostatic Desalter T62‐LST‐0030

Interface (water) liquid level to initiate shutdown signal

T62‐LT‐0034

Oil/water interface level transmitter to control the produced water outlet

T62‐LG‐0035

Oil/water interface level gauge

T62‐LST‐0031

Level transmitter with trip to prevent the contact between hydrocarbon gas & high voltage electrodes

T62‐PST‐0030


T62‐TT‐0032


T62‐LG‐0032

Flash gas outlet pot level gauge

T62‐LT‐0033

Flash gas outlet pot level transmitter

T62‐LIC‐0033

Flash gas level indicator controller

T62‐PDG‐0032

Differential pressure gauge in crude oil side across the exchanger

Crude Oil Cooler E‐6205A/B Refer to: DTT 62003 Topside Crude Oil Cooler T62‐TG‐0006

Crude oil Inlet temperature gauge

T62‐TT‐0007

Crude oil outlet temperature transmitter

T62‐TST‐0008

Crude oil outlet temperature safety transmitter

T62‐TG‐0053

Cooling medium outlet temperature gauge

T62‐TIC‐0007

Cooling medium temperature indicator control

T62‐PDG‐0120

Crude oil side differential pressure gauge across the exchanger

Oil Fiscal Metering Package A‐T6210 Refer to: DTT 62010 Topside Oil Fiscal Metering T62‐LCV‐0065 A‐T6210

LP separator oil level control valve (CCR)

Check metering package is fully functional

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3.4

SYSTEM START‐UP STEP

ACTION

CHECK

General Process

1

Ensure that all pre‐start checks have been carried out. Refer to section 3.3

2

Confirm well(s) are available to flow. Refer to Turret manual.

3

Check HP separator, LP separator, and electrostatic treater oil / water levels/interfaces. Override low/low level trips as required to enable the process ESD system to be reset.

4

Check process train vessel pressures and override low/low pressure trips as required to reset the process.

5

Reset process shutdowns then re‐open SDVs. Confirm that a flow path is lined up to a Cargo tank.

6

Commence flowing into process train. Refer to Turret procedures for details of flowing live crude from risers to swivels.

7

Start injection of demulsifier and anti‐foaming chemicals into production inlet header between swivels and the crude oil inlet heater. Refer to Chemical Injection Section 15 of this manual.

Production Separator V‐T6201 Refer to: DTT62009 Topside HP Separator 8

Locally monitor separator pressure and confirm T71‐PIC‐0042 is maintaining control via T71‐PCV‐0042. Check that a gas flow indication is available from the vessel via T71‐FT‐0041&T71‐FT‐ 0040.

9

Start corrosion inhibitor injection into gas outlet from vessel.

10

Locally monitor rising oil level and check for corresponding increase in level in oil section of vessel as oil flows over the weir. Check function of oil level controller T62‐LIC‐0045 and control valve T62‐LCV‐0045.

11

Locally monitor the oil/water interface level and confirm the correct operation of produced water level controller T62‐LIC‐ 0041 and control valve T62‐LCV‐0041.

12

Monitor produced water flows from the separator.T24‐FT‐0045

13

Monitor crude oil flows from the separator.T62‐FT‐0041&T62‐ FT‐0042

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STEP

ACTION

CHECK

Crude Oil Heaters E‐T6203A/B Refer to: : DTT62002 Topside Crude Oil Heater 14

Switch T62‐TIC‐0005 to ‘Manual’ and slowly raise the set point, checking T62‐TCV‐0005 opens to establish heating medium flow through the heater. Switch to ‘Auto’ when normal temperatures are reached.

Note: Flow must be established through the tube side of the heater to ensure a ‘live’ temperature indication. LP Separator V‐T6202 Refer to: : DTT62009 Topside LP Separator 15

Locally monitor separator pressure and confirm T71‐PIC‐0061 is maintaining control via T71‐PCV‐0061.

16

Monitor rising oil level and check for corresponding increase in level in oil section of vessel as oil flows over the weir. Check function of oil level controller T62‐LIC‐0065 and control valve T62‐LCV‐0065.

Note: The level control valve is located in the outlet header from the oil fiscal metering package A‐T6210. 17

Locally monitor the oil/water interface level and confirm the correct operation of produced water level controller T62‐LIC‐ 0061 and control valve T62‐LCV‐0061.

Crude Pumps P‐T6201A/B Refer to: : DTT62004 Topside Crude Pumps 18

Check that the each pump suction and discharge valve is open then start selected pump. Check discharge pressure and visually confirm pump is operating correctly, i.e. without leaks, excessive vibration, or cavitation.

19

Check that an offline pump is available, lined up and set to ‘Auto’ start.

20

Monitor oil flow using T62‐FIC‐0001, confirm low flow recycle valve T62‐FCV‐0001 is operating correctly. A preset low flow reading from T62‐FIC‐0001 will cause T62‐FCV‐0001 to open in order to recycle crude back into the LP separator V‐T6202. Note: Should a valve closure or other downstream blockage restrict the pump discharge flow, this recycle valve will open to relieve the back‐pressure and thus protect the pump(s).

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STEP

ACTION

CHECK

Dehydrator Inlet Heater E‐T6204A/B Refer to: : DTT62001 Topside Crude Pumps 21

Switch T62‐TIC‐0003 to ‘Manual’ and slowly raise the set point, checking T62‐TCV‐0003 opens to establish heating medium flow through the heater. Switch to ‘Auto’ when normal temperatures are reached. Note: Flow must be established through the tube side of the heater to ensure a ‘live’ temperature indication.

Electrostatic Dehydrator V‐T6203 Refer to: : DTT62006 Topside Electrostatic Dehydrator Note: Under low water cut conditions or during maintenance the crude flow from the LP separator can bypass the treater by opening line valve T62‐BL‐1143. Operators must also be aware that the treater requires a minimum crude flow water content – see note below. 22

Monitor level in treater ensuring the vessel is kept ‘liquid full’. Note: In order to prevent hydrocarbon gas contacting the high voltage electrodes, trip T62‐LST‐0021 activates if the vessel is not ‘liquid full’. Additional switches T62‐LS‐101/201 will automatically switch off the transformer T‐T6203.

23

Using local level gauges confirm that an oil/water interface has been established in the vessel. It may take several hours before an interface is visible, so monitoring at regular intervals is advised.

24

When the interface level is stable, establish a power supply (440V) to the treater transformers T‐T6203 from the main switchboard.

25

At the local panel, press the ‘Start’ pushbutton to energise the transformers, check ammeter and voltmeter readings. At start‐ up the electrical loading may be slightly higher than in normal operation. Note: Should the crude contain less water than the minimum necessary to run the Electrostatic Treater, i.e. under low water cut conditions, water can be recycled to the crude oil pumps suction at a fixed rate by flow recycle loop controller T24‐FIC‐0004. 5 % water content is the minimum normally required for operation.

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STEP

ACTION

CHECK

Electrostatic Desalter V‐T6204 Refer to: : DTT62007 Topside Electrostatic Desalter Note: Under low water cut conditions or during maintenance the crude flow from the LP separator can bypass the treater by opening line valve T62‐BL‐2420. Operators must also be aware that the treater requires a minimum crude flow water content – see note below. 26

Monitor level in treater ensuring the vessel is kept ‘liquid full’.

Note: In order to prevent hydrocarbon gas contacting the high voltage electrodes, trip T62‐LST‐0031 activates if the vessel is not ‘liquid full’. Additional switches T62‐LS‐101/201 will automatically switch off the transformer T‐T6204A/Bs.

Using local level gauges confirm that an oil/water interface has been established in the vessel. It may take several hours before an interface is visible, so monitoring at regular intervals is advised.

When the interface level is stable, establish a power supply (440V) to the treater transformers T‐T6204A/B from the main switchboard.

At the local panel, press the ‘Start’ pushbutton to energise the transformers, check ammeter and voltmeter readings. At start‐ up the electrical loading may be slightly higher than in normal operation. Note: Should the crude contain less water than the minimum necessary to run the Electrostatic Treater, i.e. under low water cut conditions, water can be recycled to the crude oil pumps suction at a fixed rate by flow recycle loop controller T24‐FIC‐0003. 5 % water content is the minimum normally required for operation.

Crude Oil Cooler E‐T6205A/B Refer to: : DTT62003 Topside Crude Oil Coolers 26

Switch T62‐TIC‐0007 to ‘Manual’ and slowly raise the set point, checking T62‐TCV‐0007 opens to establish a cooling medium flow through the coolers. Switch to ‘Auto’ when normal temperatures are reached.

Note: A hot dead crude flow must be established through the cooler to ensure a ‘live’ temperature indication.

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STEP

ACTION

CHECK

Overall Process 27

Continue checking vessel flows, levels, pressures and temperatures until entire process has stabilised.

28

Check that the start‐up overrides have ‘timed out’ as the vessel levels and pressures stabilise to within normal operating parameters. If any maintenance inhibits were used, confirm that these are now healthy and remove them.

29

After the process has stabilised, check the BS&W monitor reading for the oil leaving the fiscal metering package A‐T6210. Note: To assess the effectiveness of the separation process and the chemical injection, stabilised crude samples will need to be taken from dedicated sample points for analysis using BS&W tubes and a laboratory centrifuging procedure. In addition, produced water samples should be analysed to assess the oil content of the water before discharge overboard.

3.5

30

Visually check the entire system for leaks; particularly heaters and coolers where slugging or thermal expansion may have taken place following a cold start.

31

Prepare to ignite flare in accordance with Flare System section 9 of this manual.

32

Start gas compression as required when gas flow has stabilised.

33

Check produced water flow and handling system. Refer to Section 05 of this manual,

34

Check metering systems are functioning correctly and flow streams are not ‘gassing’ up. Refer to Section 04 of this manual.

SYSTEM SHUTDOWN A short duration controlled shutdown of the process train under normal operating circumstances can be carried out from the CCR. Closure of flowing wells and flow lines is followed by progressive closure of LCVs and PCVs to hold the train ready for a ‘hot’ start. Vessel levels are maintained by LCVs and pressures by PCVs. The anti‐ foam, demulsifier and corrosion inhibitor chemical injection pumps should also be stopped and injection lines manually isolated. In the case of a longer duration shut down for maintenance or other reasons it will also be necessary to close the SDVs. For a prolonged shutdown it is advisable to close process vessels’ outlet block valves to provide double isolation. This will ensure that liquid levels are contained and gas

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cannot leak past into the slop tanks should any of the SDV/LCVs prove not to have a 100% seal. The fuel gas supply used as a purge supply to the HP and LP flare headers should be maintained for a short term shutdown. An exception to this is highlighted in the following caution. CAUTION: PROCESS SYSTEMS AND VENT HEADERS MUST BE SHUTDOWN, VENTED AND PURGED FOR AT LEAST 48 HOURS IN THE EVENT OF ANY MAINTENANCE ON THE FLARE. For reasons of safety for both personnel and plant, process upsets will automatically close down and isolate the oil process train. These are categorized as follows: 

Level 1 shutdown (unit shutdown or USD)



Level 2 shutdown (process shutdown or PSD).



Level 3 shutdown (F&G or marine/CCR pushbutton initiated ESD).



Level 4 shutdown (PESD manual pushbutton).

The actions initiated by levels 1 and 2 shutdowns are detailed in the following paragraphs. Note: Shutdown levels of seriousness range from the lowest level 1 to the highest level 4. Refer to Section 16 for details of level 4. 3.5.1

Level 1 Shutdown (USD) The effects of this level of shutdown are local to the equipment concerned and usually involve closure of a downstream shutdown valve. Refer to para. 3.6 System Trips.

3.5.2

Level 2 Shutdown (PSD) A crude oil separation system shutdown will automatically be caused or cascaded by one or more of the following: 

ESD Level 3 from F&G system.



PSD field pushbuttons modules 01, 02, 03, 04, 05,14.



PSD manual CCR pushbutton.



PSD from Turret SIS.



Instrument air low/low pressure (2oo3 voted).



HP and LP flare knock‐out drums high/high level (2oo3 voted).

The effects of a level 2 PSD specific to the oil process train are as follows: 

Production chemical injection shutdown to utility SIS:  Shutdown chemical injection to water injection  Shutdown production chemical injection  Shutdown ethanol injection to Turret

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      

Production shutdown on gas SIS:  Shutdown gas lift compressors A and B  Shutdown gas dehydration  Shutdown HP fuel gas  Shutdown booster compression  Close booster suction cooler inlet valve T71‐SDV‐052  Stop booster compressor condensate pumps P‐T7101A and B  Close pumps P‐T7101A/B condensate discharge valve T72‐SDV‐053  Close TEG inlet separator V‐T7201 cond. outlet valve T72‐SDV‐001.             

3.6

Shutdown scale inhibitor to Turret Stop produced water clarifier tank mixer. Stop corrosion inhibitor tank mixer Stop foam inhibitor tank mixer Stop ethanol injection pumps P‐T2812A/B Stop ethanol injection to subsea pumps P‐T2811A/B.

Close HP separator water outlet shutdown valve T62‐SDV‐001. Close HP separator oil outlet shutdown valve T62‐SDV‐002. Close E‐T6201 crude inlet heater heat medium outlet valve T62‐TCV‐ 068. Close LP separator water outlet shutdown valve T62‐SDV‐008. Close E‐T6203 crude oil heater heat medium outlet valve T62‐TCV‐013. Stop crude oil pumps P‐T6201A/B. Isolate electrostatic treater transformers T‐T6203A/B. Close electrostatic treater water outlet shutdown valve T62‐SDV‐011. Close oil fiscal metering dead crude valve to cargo tank T62‐SDV‐004. Close test separator vessel water outlet shutdown valve T62‐SDV‐020. Close test separator oil outlet shutdown valve T62‐SDV‐021. Close E‐T6204 test heater heat medium outlet valve T62‐TCV‐053. Close produced water outlet from Flash vessel T24‐SDV‐002.

BLOWDOWN AND MANUAL VENTING The following table identifies the oil process train vessels that are equipped with valves with blowdown capability by venting into a flare header, along with the valve tag numbers. PROCESS VESSEL HP Separator V‐T6201

VALVE TAG NO.

HEADER REF.

T62‐BDV‐0040

To HP flare

Note: The above BDV’s will fail open in the event of a shutdown thus venting the gas inventory from the HP separators into the HP flare header. MANUAL No.

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3.6.1

Blowdown A blowdown signal shall be preceded by a total process shutdown. Immediate activation of a total blowdown is a manual intervention activity that is available to the OIM, or his delegate.

3.6.2

Manual Venting A manually operated blowdown valve facility has not been provided.

3.7

SYSTEM TRIPS Control and Safeguarding Systems are provided to protect against un‐safe operation of the process facilities and to perform automatic corrective or suppressive actions in case of hazardous conditions on the FPSO. The philosophy behind these systems is based upon the requirement to shutdown the process facilities under defined abnormal process conditions, fire or gas detection, or executive action. For each input signal received, the Control and Safeguarding Systems initiate a corresponding group of output signals. The relationship between these input and output signals is shown in the cause and effect charts. The cause and effects listed in the following table are all classified as Level 1 Unit Shutdowns. TRIP

SETTING

EFFECTS

HP Separator V‐T6201 Refer to: DTT62002 Topside HP Separator

T62‐PSLL‐001 Vessel low pressure

3 barg

CCR HMI alarm. Initiate PSD to Turret SIS (refer to Turret manual). Close oil outlet valve T62‐SDV‐002 from production separator V‐T6201. Close water outlet valve T62‐SDV‐001 from production separator V‐T6201. Close condensate outlet valve T72‐SDV‐001 from TEG inlet separator V‐T7201. Close condensate outlet valve T77‐SDV‐001 from fuel gas scrubber V‐T7701. Close heat medium return outlet valve T25‐TCV‐068 from oil inlet heater E‐T6201.

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TRIP T62‐PSHH‐001 Vessel high pressure

SETTING

EFFECTS

14.5 barg

T62‐LSLL‐002 Water level

7%

CCR HMI alarm. Close water outlet valve T62‐SDV‐001 from production separator V‐T6201.

T62‐LSLL‐004 Oil level

33%

CCR HMI alarm. Close oil outlet valve T62‐SDV‐002 from production separator V‐T6201.

94%

CCR HMI alarm. Initiate PSD to Turret SIS (refer to Turret manual). Close oil outlet valve T62‐SDV‐002 from production separator V‐T6201. Close water outlet valve T62‐SDV‐001 from production separator V‐T6201. Close condensate outlet valve T72‐SDV‐001 from TEG inlet separator V‐T7201. Close condensate outlet valve T77‐SDV‐001 from fuel gas scrubber V‐T7701. Close heat medium return outlet valve T25‐TCV‐068 from oil pre‐heater E‐T6201.

T62‐LSHH‐004 Oil level

Crude Oil Heater E‐T6203A/B Refer to: DTT62004 Topside Crude Oil Heater T62‐TSHH‐009 High fluid temperature

95°C

CCR HMI alarm. Close heat medium outlet valve T62‐TCV‐013.

LP Separator V‐T6202 Refer to: DTT62005 Topside LP Separator T62‐PSHH‐005 Vessel pressure

7.5 barg

T62‐LSLL‐010 Water level

6%

T62‐LSLL‐012 Oil level

42%

T62‐LSHH‐012 Oil level

83%

Level 2 PSD ‐ Production shutdown on oil SIS. Refer to para 3.5.2 above for details. CCR alarm. Close water outlet valve T62‐SDV‐008. CCR alarm. Stop crude pumps P‐T6201A/B. Close valve T62‐SDV‐004, dead crude oil from fiscal metering to cargo tanks. Level 2 PSD ‐ Production shutdown on oil SIS. Refer to para 3.5.2 above for details.

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TRIP

SETTING

EFFECTS

Crude Oil Heater E‐T6203A/B Refer to: DTT62004 Topside Crude Oil Heater T62‐PSHH‐006 T62‐PSLL‐006 High and low discharge pressures

16 barg 3 barg

CCR alarm. Stop crude pump P‐T6201A.

T62‐PSHH‐008 T62‐PSLL‐008 High and low discharge pressures

16 barg 3 barg

CCR alarm. Stop crude pump P‐T6201B.

Electrostatic Treater V‐T6203 Refer to: DTT62007 Topside Electrostatic Treater CCR alarm. T62‐LSLL‐014 1% Close treater water outlet valve T62‐SDV‐011. Water level CCR alarm. T62‐LSHH‐014 30% Isolate electric transformers X‐T6203A/B. Water level CCR alarm. T62‐LSLL‐101 N/A Isolate electric transformers X‐T6203A. Oil level CCR alarm. T62‐LSLL‐201 N/A Isolate electric transformers X‐T6203B. Oil level Note: The above level switches T62‐LSLL‐101 and 201 are directly connected to the transformers of the treater (Vendor supply). 3.8

ROUTINE CHECKS Checks listed in the following table are intended to provide guidance to process personnel to monitor trends within the separation process. Refer to OSX2 and Production Contractors operational procedures and routines for further details specific to this operation. It is expected that the majority of process parameters listed in the following table will be monitored continuously from the CCR. However, it is important that each item of equipment is also visually checked and monitored at least once per shift both to ensure that the remote instrumentation is operating correctly and to confirm that no abnormalities are present (excess heat, noise, vibration, leaks, etc.). Frequency of checks to be determined by safety and operational needs. EQUIPMENT

ACTION

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FREQUENCY

PAGE 76 OF 91


EQUIPMENT

ACTION

FREQUENCY

Process Train General

Sample and check crude BS&W Check levels are clearly visible in sight glasses Check vessel levels visually to ensure they are similar to those indicated remotely Check control valves for stem leakage Sample and check oil content of produced water.

Each shift

V‐T6201 HP Separator

Check vessel pressure Check product temperature Check oil/water interface level Check crude oil levels Check crude oil flow and cumulative flow Check gas flow rate, pressure and temperature Check flash gas cumulative flow Check produced water flow rate Check produced water cumulative flow.

Each shift

E‐T6202A/B Crude/Crude Exchanger

Check pressure drop across heat exchangers Check crude inlet and outlet pressures Check crude inlet and outlet temperatures Carry out visual leak check.

Each shift

E‐T6203A/B Crude Oil Heater

Check pressure drop across heaters Check crude inlet and outlet temperatures Check heating medium inlet and outlet temperatures Carry out visual leak check.

Each shift

V‐T6202 LP Separator

Check vessel pressure Check product temperature Check oil/water interface level Check crude oil levels Check flash gas pressure and temperature Check flash gas cumulative flow.

Each shift

P‐T6201A/B Crude Pumps

Check oil suction pressure Check oil discharge pressure Check mechanical seal for leaks Check pump for high vibration and noise levels Check flow rate Check lube oil level.

Each shift

Check pressure drop across heaters E‐T6204A/B Check crude inlet and outlet temperatures Dehydrator Inlet Check heating medium inlet and outlet Heater temperatures Carry out visual leak check.

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EQUIPMENT

ACTION

FREQUENCY

V‐T6203 Electrostatic Dehydrator

Check crude oil level Check oil/water interface level Check vessel pressure Check produced water recycle flow to crude pumps Check crude oil flow and cumulative flow to cargo tanks Check transformer current readings.

Each shift

V‐T6204 Electrostatic Desalter

Check crude oil level Check oil/water interface level Check vessel pressure Check produced water recycle flow to crude pumps Check crude oil flow and cumulative flow to cargo tanks Check transformer current readings.

Each shift

E‐T6205A/B Crude Oil Cooler

Check pressure drop across cooler Check crude inlet and outlet temperatures Check cooling medium inlet and outlet temperatures Carry out visual leak check.

Each shift

3.9

OIL, WATER AND GAS SAMPLING During normal production it is essential that that both crude and produced water flows are regularly sampled in order to establish the efficiency of the process and chemical injection. Gas sampling will be less frequent but equally important. A gas chromatograph will be available for these tests, refer to vendor data for procedure. Dedicated liquid sample points have been provided at the locations detailed in the following table. A diagram of each type of sample point is shown in Figs. 4. 5 and 6 overleaf. VESSEL

LOCATION

VALVE TAG NO.

HP Separator V‐T6201

Crude outlet header Produced water outlet header Gas outlet header

SC‐06 SC‐06 SC‐07

LP Separator V‐T6202

Crude outlet header Produced water outlet header Gas outlet header

SC‐06 SC‐06 SC‐07

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Crude outlet header Produced water outlet header

SC‐06 SC‐06

Electrostatic Desalter Crude outlet header V‐T6204 Produced water outlet header

SC‐06 SC‐06

Electrostatic Dehydrator V‐T6203

Note: In order to obtain a representative sample of the fluid stream, only approved test points shall be used and each test point shall be flushed to vent or the hazardous drain prior to sampling. 3.9.1

Sample Points Figure 3

Sample Point ‐ Liquid with Cooling

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Figure 4

Sample Point ‐ High Pressure Gas

Figure 5

Sample Point – Low Pressure Liquids

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CAUTIONS: ALL SAMPLING MUST BE CARRIED OUT USING DESIGNATED SAMPLE POINTS AND APPROVED SAMPLE CONTAINERS. OPERATIONAL CONTROLS AND THE USE OF COMPETENT AND TRAINED PERSONNEL SHALL MINIMIZE THE LIKELIHOOD OF ERRORS WHEN SAMPLING.

THE SAMPLE POINTS LISTED ABOVE HAVE BEEN DESIGNED TO PROVIDE A REPRESENTATIVE SAMPLE OF FLUIDS IN THE FLOW STREAM. SAMPLING FROM OTHER SOURCES IS NOT RECOMMENDED AS THE RESULTS MAY NOT PROVIDE A TRUE AND STABLE REPRESENTATION OF THE FLOW STREAM CHARACTERISTICS.

WARNING:

DURING SAMPLING ACTIVITIES CARE SHALL BE TAKEN TO PREVENT OIL SPILLAGE AND MINIMISE THE RELEASE OF HYDROCARBON GAS TO ATMOSPHERE.

3.10 TROUBLESHOOTING PROBLEM

POSSIBLE CAUSES

Oil Processing System Unstable interface level in separators caused by one or more of the following:  Instrumentation malfunction

High train outlet BS&W readings and/or oil carryover into produced water

Shutdown on high/high liquid levels



Blocked level sensing bridle valve



Demulsifier injection failure



Anti‐foaming injection failure or excess



Chemical injection pump(s) failure



Chem. Injection pump flow setting incorrect



Chemical tote tank(s) empty



Separator temperatures low



Slugging of incoming production flow



Faulty BS&W analyser



Electrostatic treater electrical failure

‘Slug’ control system (SCS) ineffective (Turret) Level control system unstable or failed Insufficient control over pigging operations (Turret) Liquid surge caused by opening incoming crude line too quickly Separator vessel oil outlet blocked (high level trip)

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PROBLEM

POSSIBLE CAUSES

Liquid carry‐over into gas outlet

Failed exit nozzle vane pack Surging separator levels Lack of, or excess of anti‐foaming chemical Level control failure Vessel internal vane packs are inefficient at low flow rates, typically if gas flow is less than 30% of design flow rate

Separator temperatures low

Heating medium failure or blocked heater matrix Temperature control system malfunction High flow of cold crude exceeds heater capacities Failure to recycle dead crude before well start up Low heating medium temperature

Pressure instrumentation malfunction Pressure control valve malfunction Separator pressures unstable Gas compressor problem ’Slugging’ of incoming well fluids Note: This is possible but unlikely in the case of E‐6203A/B as the heating medium pressure is higher than the crude oil operating pressure. Crude pump cavitation

Blocked suction line or strainer Blocked outlet from LP separator

Crude pump high discharge pressure

Discharge valve closed

Inefficient crude heat exchangers and/or heaters High p across exchangers and/or heaters

Internal blockages or deposits ’Cold’ crude flow too high Highly viscous or waxy crude

Inefficient separation in treater

Transformer or power failure Low water cut – treater requires a minimum of 5% water to operate satisfactorily

Instrument problems

‘Wet’ instrument air supply

Leaking plate/gasket heaters or heat exchangers

Gasket/seal failure possibly caused by high pressure/temperature differentials distorting the matrix or gaskets becoming brittle with age

Level instruments fail to respond to changes in level

Sand, wax or debris blocking instrument lower bridle connections Closed bridle valves Transmitter failure

MANUAL No.

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4

OPERATING DATA OIL PROCESSING DESIGN FLOW Design Oil Production:

100,000 bopd

Design Gas Processing:

53 MMscfd

Design Produced Water Capacity:

50,000 bwpd

Water Injection System Capacity

150,000 bwpd

HP SEPARATOR V‐T6201 Refer to: DTT62008 Topside HP Separator Type

3‐phase wit weir

Size (ID x length T/T)

4700 mm x 18000 mm

Design pressure

FV / 15 barg

Design temperature

110 ºC

Operating pressure range

9.0 barg

Operating temperature

72 ºC

CRUDE‐CRUDE EXCHANGER E‐T6202A/B Refer to: DTT62005 Topside Crude‐Crude Exchanger Type

Plate and gasket

Service

2 X 100%

Design Duty

18400 kW

Hot shell side (dead crude) Design pressure

FV/15 barg

Design temperature

‐15/160 ºC

Operating pressure

6.0 barg


140 /92 ºC

Cold shell side (live crude) Design pressure

FV/15 barg

Design temperature

‐15/160 ºC

Operating pressure

4.9 barg


72 /93 ºC

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CRUDE OIL HEATERS E‐T6203A/B Refer to: DTT62002 Topside Crude Oil Heater Type

Plate and gasket

Service

2 X 50%

Design Duty

26400 kW

Hot shell side (heating medium)

Design pressure

15.0 barg

Design temperature

‐15/170 ºC

Operating pressure

9.5 barg


150 /125 ºC

Cold shell side (crude oil) Design pressure

15.0 barg

Design temperature

‐15/170 ºC

Operating pressure

3.9 barg


83 /110 ºC

LP SEPARATOR V‐T6202 Refer to: DTT62009 Topside LP Separator Type

3‐phase wit weir

Size (ID x length T/T)

4500 mm x 16000 mm

Design pressure

FV / 15 barg

Design temperature

‐15/140 ºC

Operating pressure range

2.4/2.9 barg


110 ºC

CRUDE OIL PUMPS P‐T6201A/B Refer to: DTT62004 Crude Oil Pumps Type

Centrifugal

Service

2 x 100%

Driver

Electric Motor

Design pressure

15 barg

Design temperature

140°C

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Design Capacity

879 m3/hr

Differential Head

100 mlc

DEHYDRATOR INLET HEATER‐T6204A/B Refer to: DTT62001 Topside Dehydrator Inlet Heater Type

Plate and gasket

Service

2 X 50%

Design Duty

17180 kW

Hot shell side (heating medium)

Design pressure

FV/15.0 barg

Design temperature

‐15/170 ºC

Operating pressure

8.5 barg


150 /125 ºC

Cold shell side (crude oil)

Design pressure

FV/15.0 barg

Design temperature

‐15/170 ºC

Operating pressure

9.5 barg


140 /110 ºC

ELECTROSTATIC DEHYDRATOR V‐T6203 Refer to: DTT62006 Topside Electrostatic Dehydrator Type:

Electrostatic coalescer

Size (ID x length T/T):

3,900 mm x 15,000 mm

Design Pressure:

FV / 15 barg

Design Temperature:

‐15 to 170°C

Operating Pressure Range:

8.5 barg

Operating Temperature

140°C

Transformer T‐T6203 Rating Service:

1 x 100%

Voltage:

440V / 60Hz / 1Ph /170A

Power

35 KW

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ELECTROSTATIC DESALTER V‐T6204 Refer to: DTT62007 Topside Electrostatic Desalter Type:

Electrostatic coalescer

Size (ID x length T/T):

4,300 mm x 21,400 mm

Design Pressure:

FV / 15 barg

Design Temperature:

‐15 to 170°C

Operating Pressure Range:

6.3 barg

Operating Temperature

139°C

Transformer T‐T6204A/B Rating

Service:

2 x 50%

Voltage:

440V / 60Hz / 1Ph /170A

Power

60 KW

CRUDE OIL COOLER E‐T6205A/B Refer to: DTT62003 Topside Crude Oil Cooler Type

Plate and gasket

Service

2 X 50%

Hot shell side (Crude Oil Design pressure

FV/15 barg

Design temperature

‐15/160 ºC

Operating pressure

5.0 barg


92/55ºC

Cold tube Side (Cooling Medium)

4.1.1

Design pressure

FV/15 barg

Design temperature

‐15/160 ºC

Operating pressure

9.0 barg


35 to 55 ºC

Separator Vessel Internals 

Cyclone inlet device to discourage foaming.



Inlet diffuser.



Vane packs arrangement at gas outlet.

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4.1.2



‘Wing’ type weir plate with adjustment if needed.



Removable vortex breakers for oil and water outlets.



316L stainless steel nuts, bolting and gaskets.

Electrostatic Treater Internals Refer to Figure 8 at the end of this section for the internal layout of a typical treater.

5 5.1



Inlet feed (oil/water) distributor.



Oil outlet collector with removable outlet vortex breakers.



Water outlet collection pipe work complete with removable vortex breakers.



Anti‐surge plates to damp liquid movement.



Stainless steel electrode grid assemblies.



Sand wash facility complete with internal piping, headers, nozzles, etc.



Low level transformer shut off arrangement.



316L stainless steel nuts, bolting and gaskets

REFERENCES REFERENCE DOCUMENTS DOCUMENT NUMBER DTT 67008

Topsides Early Life – Min. BS&W Heat & Mass Balance

SKT 62013

Topsides Separator Internals Design Specification

STT 62014

Topsides Oil System Vessels Functional Specification

STT 92065

Topsides Process Control & Safeguarding Narrative

VME Process 5.2

DESCRIPTION

Vendor ‐ Separator Operating Parameters

REFERENCE DRAWINGS DRAWING NUMBER

DESCRIPTION

DTT 92027&92028

Oil Processing System – PFD

DTT 62008

Topsides HP Separator P&ID

DTT 62005

Topsides Crude/Crude Exchanger P&ID

MANUAL No.

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DTT 62002

Topsides Crude Oil Heater P&ID

DTT 62009

Topsides LP Separator P&ID

DTT 62004

Crude Oil Pumps P&ID

DTT62001

Dehydrator Inlet Heater

DTT 62006

Topsides Electrostatic Dehydrator

DTT 62007

Topsides Electrostatic Desalter

DTT 62003

Topsides Crude Oil Cooler P&ID

DTT 62010

Topsides Oil Fiscal Metering Package P&ID

DJF 52001

FPSO Hierarchical Shutdown Levels Diagram

DJT 52001

Topsides Cause and Effect Diagram

MANUAL No.

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CAPIXABA OPERATIONS MANUAL PART 3 – PROCESS TOP SIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM

Figure 6

System Schematic

MANUAL No. 25.07.10.OPS3

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Figure 7

Equipment Locations


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Figure 8

Typical Internals for Electrostatic Treater


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Section 3 Oil Processing System

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