OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
SECTION 3 OIL PROCESSING SYSTEM
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OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
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
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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
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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
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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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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 System 2400
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 System 2400
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.
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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
35C
Controls crude temperature by cooling medium flow.
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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.
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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.
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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.
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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:
Instrument isolation valves
Instrument sensing lines
OPEN OPEN CLOSED AND BLANKED
V‐T6201 drain valve
NORMALLY CLOSED
T62‐BL‐3007 (N5b)
V‐T6201 drain valve
NORMALLY CLOSED
T62‐BL‐3008 (N5c)
V‐T6201 drain valve
NORMALLY CLOSED
T62‐BL‐3009 (N5d)
V‐T6201 drain valve
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)
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TAG NO.
POSITION
CHECK
Closed drain header drain valve
NORMALLY CLOSED
K10a
V‐T6201 sample valve
NORMALLY CLOSED
K10b
V‐T6201 sample valve
NORMALLY CLOSED
K10c
V‐T6201 sample valve
NORMALLY CLOSED
K10d
V‐T6201 sample valve
NORMALLY CLOSED
K10e
V‐T6201 sample valve
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
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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
T62‐PSV‐0041A inlet drain valve
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
T62‐PSV‐0041B inlet drain valve
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.
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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
T62‐LT‐0042 Standpipe drain valve
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
T62‐LG‐0044 upper isolation valve
OPEN
T62‐BL‐1317
T62‐LG‐0044 lower isolation valve
OPEN
T62‐BL‐1290
T62‐LG‐0044 vent valve
NORMALLY CLOSED
T62‐BL‐1307
T62‐LG‐0044 drain valve
NORMALLY CLOSED
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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
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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
Flash gas flow meter
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
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
EXCHANGER COOL SIDE (‘live’ crude from HP separator) T62‐BL‐1149
Crude inlet line from HP separator to E‐ T6202A
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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:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 42 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
TAG NO. T62‐BL‐2363
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
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
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:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 43 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
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
T62‐TCV‐0005 inlet drain valve
CLOSED AND BLANKED
T25‐GA‐1063
T62‐TCV‐0005 outlet drain valve
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
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 CLOSED AND BLANKED
V‐T6202 drain valve
NORMALLY CLOSED
T62‐BL‐2986
V‐T6202 drain valve
NORMALLY CLOSED
T62‐BL‐2987
V‐T6202 drain valve
NORMALLY CLOSED
T62‐BL‐2867
Utility connection valve
T62‐BL‐2985
MANUAL No.
ISSUE No: 01
REVISION No:
REF NUMBER:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 44 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
TAG NO.
VALVE DESCRIPTION
POSITION
CHECK
T62‐BL‐2988
V‐T6202 drain valve
NORMALLY CLOSED
T62‐BL‐2989
V‐T6202 drain valve
NORMALLY CLOSED
T62‐BL‐3293
V‐T6202 drain valve
NORMALLY CLOSED
T62‐BL‐3296
Closed drain header isolation valve
NORMALLY CLOSED
T62‐BL‐3287
Closed drain header drain valve
NORMALLY CLOSED
T62‐BL‐3288
Closed drain header drain valve
NORMALLY CLOSED
K10a
V‐T6201 sample valve
NORMALLY CLOSED
K10b
V‐T6201 sample valve
NORMALLY CLOSED
K10c
V‐T6201 sample valve
NORMALLY CLOSED
K10d
V‐T6201 sample valve
NORMALLY CLOSED
K10e
V‐T6201 sample valve
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
T62‐PSV‐0061A inlet drain valve
CLOSED AND BLANKED
T62‐BL‐1340
T62‐PSV‐0061A inlet drain valve
NORMALLY CLOSED
T76‐BL‐1370
T62‐PSV‐0061A outlet drain valve
CLOSED AND BLANKED
MANUAL No.
ISSUE No: 01
REVISION No:
REF NUMBER:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 45 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
TAG NO. T76‐BL‐1378
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
T62‐PSV‐0061B inlet drain valve
CLOSED AND BLANKED
T62‐BL‐1338
T62‐PSV‐0061B inlet drain valve
NORMALLY CLOSED
T76‐BL‐1380
T62‐PSV‐0061B outlet drain valve
CLOSED AND BLANKED
T76‐BL‐1341
T62‐PSV‐0061B outlet isolation valve
LOCKED OPEN
T71‐FE‐0060
Flash gas flow meter
OPEN
T62‐BL‐2993
T71‐FE‐0060 Upstream isolation valve
OPEN
T62‐BL‐2990
T71‐FE‐0060 Downstream isolation valve
OPEN
T71‐FE‐0062
Flash gas flow meter
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:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 46 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
TAG NO.
VALVE DESCRIPTION
POSITION
CHECK
T62‐BL‐3673
T62‐LST‐0062 bridle middle drain valve
NORMALLY CLOSED
LOCKED OPEN
T62‐BL‐1342& T62‐LST‐0062 bridle lower isolation T62‐BL‐3279 valve T62‐BL‐3280
T62‐LST‐0062 bridle lower drain valve
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
T62‐LT‐0061 bridle lower drain valve
NORMALLY CLOSED
T62‐BL‐2413
T62‐LT‐0061 Standpipe drain valve
NORMALLY CLOSED
T62‐BL‐1367
T62‐LG‐0060 upper isolation valve
OPEN
T62‐BL‐1365
T62‐LG‐0060 lower isolation valve
OPEN
T62‐BL‐1363
T62‐LG‐0060 vent valve
NORMALLY CLOSED
T62‐BL‐1368
T62‐LG‐0060 drain valve
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
T62‐LG‐0064 upper isolation valve
OPEN
T62‐BL‐2412
T62‐LG‐0064 lower isolation valve
OPEN
T62‐BL‐1360
T62‐LG‐0064 vent valve
NORMALLY CLOSED
T62‐BL‐2411
T62‐LG‐0064 drain valve
NORMALLY CLOSED
MANUAL No.
ISSUE No: 01
REVISION No:
REF NUMBER:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 47 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
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:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 48 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
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
T62‐PST‐0061 Isolation valve
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:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 49 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
TAG NO.
VALVE DESCRIPTION
Instrument isolation valves
Instrument sensing lines
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:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 50 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
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
T62‐TCV‐0003 inlet isolation valve
OPEN
T25‐GA‐2373
T62‐TCV‐0003 inlet drain valve
NORMALLY CLOSED
T25‐GA‐2374
T62‐TCV‐0003 outlet drain valve
NORMALLY CLOSED
T25‐GA‐2375
T62‐TCV‐0003 outlet isolation valve
OPEN
T25‐GL‐1037
T62‐TCV‐0003 bypass isolation valve
NORMALLY CLOSED
Electrostatic Dehydrator V‐T6203 Refer to: DTT62006 Topside Electrostatic Dehydrator
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
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:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 51 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
TAG NO.
VALVE DESCRIPTION
T62‐GL‐1162
Crude oil Inlet header isolation valve
T62‐BL‐1163
Crude oil bypass valve
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
V‐T6203 drain valve
NORMALLY CLOSED
T24‐BL‐3019
V‐T6203 drain valve
NORMALLY CLOSED
T24‐BL‐3020
V‐T6203 drain valve
NORMALLY CLOSED
T24‐BL‐3021
V‐T6203 drain valve
NORMALLY CLOSED
T24‐BL‐1205
V‐T6203 drain valve
NORMALLY CLOSED
T24‐BL‐3349
Closed drain header isolation valve
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:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 52 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
TAG NO.
VALVE DESCRIPTION
POSITION
CHECK
T62‐BL‐1192
T62‐LG‐0022 upper isolation valve
OPEN
T62‐BL‐1209
T62‐LG‐0022 lower isolation valve
OPEN
T62‐BL‐1187
T62‐LG‐0022 drain valve
NORMALLY CLOSED
T62‐BL‐1211
T62‐LG‐0022 vent valve
NORMALLY CLOSED
LOCKED OPEN
T62‐BL‐1171& T62‐PSV‐0021A inlet block valve T62‐BL‐3221 T62‐BL‐1176
T62‐PSV‐0021A inlet drain valve
NORMALLY CLOSED
T62‐BL‐3338
T62‐PSV‐0021A inlet drain valve
CLOSED AND BLANKED
T76‐BL‐1193
T62‐PSV‐0021A outlet drain valve
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
T62‐PSV‐0021B inlet drain valve
NORMALLY CLOSED
T62‐BL‐3339
T62‐PSV‐0021B inlet drain valve
CLOSED AND BLANKED
T76‐BL‐1199
T62‐PSV‐0021B outlet drain valve
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
T62‐LST‐0020 bridle upper drain valve
NORMALLY CLOSED
T24‐BL‐3342
T62‐LST‐0020 bridle middle drain valve
NORMALLY CLOSED
T24‐BL‐3343
T62‐LST‐0020 bridle lower drain valve
NORMALLY CLOSED
MANUAL No.
ISSUE No: 01
REVISION No:
REF NUMBER:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 53 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
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
T62‐LT‐0024 bridle middle drain valve
NORMALLY CLOSED
T24‐BL‐3346
T62‐LT‐0024 bridle lower drain valve
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
T62‐LG‐0025 drain valve
NORMALLYC LOSED
T62‐BL‐1190
T62‐LG‐0025 vent valve
NORMALLY CLOSED
T62‐BL‐2419
T62‐PST‐0020 Isolation valve
LOCKED OPEN
T62‐BL‐1195
V‐T6203 Vent valve
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
V‐T6203 Sample valve
NORMALLY CLOSED
T24‐BL‐1208
V‐T6203 Sample valve
NORMALLY CLOSED
T24‐BL‐1194
V‐T6203 Sample valve
NORMALLY CLOSED
T24‐BL‐1183
V‐T6203 Sample valve
NORMALLY CLOSED
MANUAL No.
ISSUE No: 01
REVISION No:
REF NUMBER:
ISSUE DATE: 27/05/13
REVISION DATE:
PAGE 54 OF 91
OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
TAG NO. T24‐BL‐184
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
Instrument sensing lines
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
Crude oil bypass valve
NORMALLY CLOSED
T62‐BL‐3325
Crude oil outlet return to V‐T6204
LOCKED OPEN
T62‐BL‐3326
Crude oil outlet return to V‐T6204
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
V‐T6204 drain valve
NORMALLY CLOSED
T24‐BL‐3016
V‐T6204 drain valve
NORMALLY CLOSED
T24‐BL‐3017
V‐T6204 drain valve
NORMALLY CLOSED
T24‐BL‐1251
V‐T6204 drain valve
NORMALLY CLOSED
T24‐BL‐3018
V‐T6204 drain valve
NORMALLY CLOSED
MANUAL No.
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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
T62‐LG‐0032 upper isolation valve
OPEN
T62‐BL‐1239
T62‐LG‐0032 lower isolation valve
OPEN
T62‐BL‐1258
T62‐LG‐0032 drain valve
NORMALLY CLOSED
T62‐BL‐1229
T62‐LG‐0032 vent valve
NORMALLY CLOSED
LOCKED OPEN
T62‐BL‐1256& T62‐PSV‐0031A inlet block valve T62‐BL‐3229 T62‐BL‐1222
T62‐PSV‐0031A inlet drain valve
NORMALLY CLOSED
T62‐BL‐3323
T62‐PSV‐0031A inlet drain valve
CLOSED AND BLANKED
T76‐BL‐1240
T62‐PSV‐0031A outlet drain valve
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
T62‐PSV‐0031B inlet drain valve
NORMALLY CLOSED
T62‐BL‐3324
T62‐PSV‐0031B inlet drain valve
CLOSED AND BLANKED
T76‐BL‐1245
T62‐PSV‐0031B outlet drain valve
NORMALLY
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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
T62‐LST‐0030 bridle upper drain valve
NORMALLY CLOSED
T24‐BL‐3328
T62‐LST‐0030 bridle middle drain valve
NORMALLY CLOSED
T62‐BL‐3329
T62‐LST‐0030 bridle lower drain valve
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
T62‐LT‐0034 bridle middle drain valve
NORMALLY CLOSED
T24‐BL‐3334
T62‐LT‐0034 bridle lower drain valve
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
T62‐LG‐0035 drain valve
NORMALLYC LOSED
T62‐BL‐1237
T62‐LG‐0035 vent valve
NORMALLY CLOSED
T62‐BL‐2424
T62‐PST‐0030 Isolation valve
LOCKED
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TAG NO.
VALVE DESCRIPTION
POSITION
CHECK
OPEN CLOSED AND BLANKED
V‐T6204 Utility connection valve
NORMALLY CLOSED
T24‐BL‐1253
V‐T6204 Sample valve
NORMALLY CLOSED
T24‐BL‐1257
V‐T6204 Sample valve
NORMALLY CLOSED
T24‐BL‐1252
V‐T6204 Sample valve
NORMALLY CLOSED
T24‐BL‐1241
V‐T6204 Sample valve
NORMALLY CLOSED
T24‐BL‐1243
V‐T6204 Sample valve
NORMALLY CLOSED
NORMALLY CLOSED
T62‐BL‐1242
V‐T6204 Vent valve
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
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
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
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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
T62‐TCV‐0007 inlet isolation valve
OPEN
T25‐GA‐2764
T62‐TCV‐0007 inlet drain valve
CLOSED AND BLANKED
T25‐GA‐2384
T62‐TCV‐0007 outlet drain valve
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
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TAG NO.
VALVE DESCRIPTION
POSITION
CHECK
T25‐GA‐1094
T62‐TCV‐0007 outlet isolation valve
OPEN
T25‐GL‐1091
T62‐TCV‐0007 bypass isolation valve
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
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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
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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
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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
Outlet gas flow monitoring transmitter
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
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OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
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
Cool side differential pressure gauge across the exchanger
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
Outlet gas flow monitoring transmitter
T71‐FE‐0062
Outlet gas flow monitoring transmitter
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
Cool side differential pressure gauge across the exchanger
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
Vessel pressure safety transmitter
T62‐TT‐0032
Vessel pressure safety transmitter
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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OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
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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OSX2 OPERATIONS MANUAL PART 3 – PROCESS TOPSIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
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
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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
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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
Operating temperature
140 /92 ºC
Cold shell side (live crude) Design pressure
FV/15 barg
Design temperature
‐15/160 ºC
Operating pressure
4.9 barg
Operating temperature
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
Operating temperature
150 /125 ºC
Cold shell side (crude oil) Design pressure
15.0 barg
Design temperature
‐15/170 ºC
Operating pressure
3.9 barg
Operating temperature
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
Operating temperature
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
Operating temperature
150 /125 ºC
Cold shell side (crude oil)
Design pressure
FV/15.0 barg
Design temperature
‐15/170 ºC
Operating pressure
9.5 barg
Operating temperature
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
Operating temperature
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
Operating temperature
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
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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.
ISSUE No: 01
REVISION No:
REF NUMBER:
ISSUE DATE: 27/05/13
REVISION DATE:
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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
ISSUE No: 01
REVISION No:
REF NUMBER: MTF 94003 A1
ISSUE DATE: 27/03/06
REVISION DATE:
PAGE 89 OF 91
CAPIXABA OPERATIONS MANUAL PART 3 – PROCESS TOP SIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
Figure 7
Equipment Locations
MANUAL No. 25.07.10.OPS3
ISSUE No: 01
REVISION No:
REF NUMBER: MTF 94003 A1
ISSUE DATE: 27/03/06
REVISION DATE:
PAGE 90 OF 91
CAPIXABA OPERATIONS MANUAL PART 3 – PROCESS TOP SIDE SYSTEMS SECTION 3:OIL PROCESSING SYSTEM
Figure 8
Typical Internals for Electrostatic Treater
MANUAL No. 25.07.10.OPS3
ISSUE No: 01
REVISION No:
REF NUMBER: MTF 94003 A1
ISSUE DATE: 27/03/06
REVISION DATE:
PAGE 91 OF 91