HBNS-01-PUL-OP-PRC-2005-A3 Operating Procedure PDF
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2022
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Summary
This document is an operating procedure for the Train 2 Separation system, including the Inlet Separator, Feed Preheat Exchanger, and HP Separator. It provides definitions, safety information, and procedures for start-up, normal operation, troubleshooting, and shutdown. The document is a comprehensive guide for industrial operations and maintenance personnel.
Full Transcript
PROJECT NAME: HBNS – CPF OPERATING PROCEDURES UPDATE CONTRACT NO.: SC/4032016/20 PETROFAC PROJECT NO.: 10137 OPERATING PROCEDURE TRAIN 2 SEPARATION (In...
PROJECT NAME: HBNS – CPF OPERATING PROCEDURES UPDATE CONTRACT NO.: SC/4032016/20 PETROFAC PROJECT NO.: 10137 OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO: HBNS-01-PUL-OP-PRC-2005-A3 A3 Approved for use 18-03-2022 RS TKS BM A2 Approved for use 07-12-2021 RS TKS BM A1 Issued for Approval 11-05-2021 RS TKS BM R3 Re-Issued for Review 22-03-2021 RS TKS BM R2 Re-Issued for Review 25-02-2021 RS TKS BM R1 Issued for Review 14-12-2020 NMR TKS BM Rev. Description Date Originator Reviewed by Approved by Contractor Document Ref. No.: Client Document Ref. No.: HBNS-01-PUL-OP-PRC-2005 OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 2 of 59 Hold List: Revision Section Description of Hold OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 3 of 59 CONTENTS 1.0 INTRODUCTION...................................................................................................................... 4 1.1 Purpose........................................................................................................................ 4 2.0 DEFINITIONS, ABBREVIATIONS, SYMBOLS AND UNITS OF MEASUREMENT................. 5 2.1 Definitions.................................................................................................................... 5 2.2 Abbreviations............................................................................................................... 6 2.3 Symbols........................................................................................................................ 8 2.4 Units of Measurement.................................................................................................. 8 3.0 REFERENCE DOCUMENTS & DRAWINGS........................................................................... 9 3.1 Reference Documents................................................................................................. 9 3.2 Reference Drawings..................................................................................................... 9 4.0 HEALTH, SAFETY AND ENVIRONMENTAL ISSUES........................................................... 10 4.1 Chemicals................................................................................................................... 10 4.2 Personal Protective Equipment (PPE)...................................................................... 10 4.3 Hazardous Area Classification.................................................................................. 10 5.0 SAFETY SYSTEMS............................................................................................................... 11 6.0 MAJOR ACCIDENT HAZARDS............................................................................................. 13 7.0 RESPONSIBILITIES.............................................................................................................. 15 7.1 Supervisor.................................................................................................................. 15 7.2 Operators.................................................................................................................... 15 8.0 EQUIPMENT SPECIFICATION.............................................................................................. 16 9.0 PROCESS/SYSTEM DESCRIPTION..................................................................................... 17 9.1 Inlet Separator............................................................................................................ 19 9.2 Feed Preheat Exchanger........................................................................................... 20 9.3 HP Separator.............................................................................................................. 22 9.4 Interconnection of Train-2 Separation System........................................................ 24 10.0 OPERATING PHASES........................................................................................................... 25 10.1 Startup after Maintenance Phase.............................................................................. 25 10.2 Normal Start-up Phase............................................................................................... 32 10.3 Normal Operations Phase......................................................................................... 34 10.4 Temporary Operations Phase................................................................................... 35 10.5 Emergency Shutdown Phase.................................................................................... 36 10.6 Emergency Operations Phase................................................................................... 39 10.7 Normal Shutdown Phase........................................................................................... 39 11.0 NORMAL OPERATING CONDITIONS AND OPERATING LIMITS....................................... 48 12.0 TROUBLESHOOTING........................................................................................................... 49 12.1 Methodology............................................................................................................... 49 12.2 Inlet Separator............................................................................................................ 51 12.3 Feed Preheater Exchanger........................................................................................ 55 12.4 HP Separator.............................................................................................................. 56 OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 4 of 59 1.0 INTRODUCTION 1.1 Purpose The purpose of this procedure is to guide the Operators on the start-up, normal operation, troubleshooting, normal shutdown, and emergency shutdown of the Train 2 Separation system (namely the Inlet Separator ⟨V2-101⟩, Feed Preheat Exchanger ⟨E2-102⟩, and the HP Separator ⟨V2-102⟩). This procedure contains the key information to carry out the actions described in a safe and efficient manner. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 5 of 59 2.0 DEFINITIONS, ABBREVIATIONS, SYMBOLS AND UNITS OF MEASUREMENT 2.1 Definitions Term Definition Authorized person A person assessed as having sufficient technical knowledge and authorized by Groupement Berkine (GB) in writing to carry out specific work on any systems, apparatus and equipment. Battery Limit Confines of a plant (which normally includes all processing equipment) signifying the end of one processing facility and the start of another. Danger Notice A notice attached to the apparatus when live, calling attention to the danger of approach to, or interference with such apparatus. Downstream A term used to determine the relationship of one piece of equipment to another. For example, if a pipeline incorporates a valve and a spool piece, and the direction of flow in the pipeline is first through the valve and then through the spool piece, the spool piece is said to be ‘downstream’ of the valve. Inhibitor A chemical additive that reduces the rate of a chemical reaction. For instance, corrosion inhibitor reduces the rate of corrosion. Knock out Drum A vessel through which a gas stream is passed to remove any accompanying liquid. Procedure A sequence of operations undertaken in a specific order. Removable Spool A short section of pipe, flanged at each end, which can be inserted Piece into, or removed from, a pipeline to render that pipeline operational or non-operational. Retention time The time a fluid remains within a settling or separation tank or vessel. A fluid mixture requires a minimum retention time for efficient separation to take place. Spectacle Blind A plate shaped with a hole through one of the lobes, which is installed between flanges in a pipeline. By removing all but one of the flange bolts, the spectacle blind can be swung from the open position (the lobe with the hole in the pipeline) to the closed position or from the closed position to the open position. The hole in the lobe is of the same diameter as the pipeline. The absence or presence of a hole in the exposed lobe gives a clear indication of the status of the spectacle blind. Upstream A term used to determine the relationship of one piece of equipment to another. For example, if a pipeline incorporates a valve and a spool piece, and the direction of flow in the pipeline is first through the valve and then through the spool piece, the valve is said to be ‘upstream’ of the spool piece. (See also downstream). OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 6 of 59 2.2 Abbreviations Abbreviation Description ATEX European certification given to equipment tested and approved to be safe BDV Blow Down Valve CCR Central Control Room CPF Central Processing Facility CS Carbon Steel DCS Distributed Control System ESD Emergency Shutdown F&G Fire & Gas FC Flow Controller FIC Flow Indicator Controller FSV Fail Safe Valve (Check valve) FV Flow Control Valve GB Groupement Berkine GT Gas Turbine HP High Pressure HS Hand Switch HSE Health Safety Environment JSA Job Safety Analysis KO Knock Out (Vessel, Pot, etc.) LAH Level Alarm High LAHH Level Alarm High-high LAL Level Alarm Low LALL Level Alarm Low-Low LEL Lower Explosive Limit LG Level Glass LIC Level Indicator Controller LOTO Lock Out/Tag Out LP Low Pressure LSHH Level Switch High-High LSLL Level Switch Low-Low LT Level Transmitter LV Level Control valve MOS Maintenance Override Switch OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 7 of 59 Abbreviation Description MP Medium Pressure MSDS Material Safety Data Sheet OWS Oil Water Sewer P&ID Piping and Instrumentation Diagram PA/GA Public Address/General Alarm PAHH Pressure Alarm High-high PALL Pressure Alarm Low-Low PFD Process Flow Diagram PI Pressure Indicator PIC Pressure Indicator Controller PPE Personal Protective Equipment PSD Plantwide Shutdown PSHH Pressure Switch High-High PSLL Pressure Switch Low-Low PSSR Pre-Startup Safety Review PSV Pressure Safety Valve PTW Permit to Work PV Pressure Control Valve RPM Revolutions Per Minute SDV Shutdown Valve TEMA Tubular Exchanger Manufacturers Association TI Temperature Indicator TIC Temperature Indicator Controller TV Temperature Control Valve USD Unit Shutdown OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 8 of 59 2.3 Symbols WARNING: A warning is used to indicate a risk of death or significant injury or danger and/or mandatory action. CAUTION: Risk of significant damage to equipment and/or the environment. NOTE: Includes information that is helpful, but not part of the action described in the step. 2.4 Units of Measurement Dimensions mm, m, km Flow rate (liquids) BPD Flow rate (mass) kg/h Flow rate (volume) m³/h Heat kcal, MM kcal Heat Transfer Coefficient kcal/(m²°Ch) Molar flow kg mole/h Power kW, MW Pressure bara (absolute), barg (gauge) Standard flow rate (gases) MMSCFD, Sm³/d Standard flow rate (liquids) STm³/d, STBPD (stabilized dead oil at 20°C) Standard Volume (gases) Sm³ (ideal gas at 1.01325 bara and 15°C) Temperature °C Velocity m/s Volume m³ Weight kg OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 9 of 59 3.0 REFERENCE DOCUMENTS & DRAWINGS 3.1 Reference Documents Sl. No. Document Description Document No. 1. Cause and Effect HBNS2-IC-2008-Z0 Diagram 2. Hazard Report DNV GL - Report No. 1UC5MKV-9-CTR2, Rev-1 (02 Feb 16) 3. Operation Manual of Sonatrach / Anadarko Algeria Corporation Process Safety system Hassi Berkine – CPF Expansion section-19. (27 March 2002) 4. Operating Procedure HBNS11-Section 5.1 – Train 2 Gas & Water Separation 5. HBNS & ELM Plant GBF-03-PRC-0003 Safety System Bypass Procedure 3.2 Reference Drawings Sl. No. Document Description Document No. 1. PFD HBNS2-PR-1020-2/4 Rev. 0 (18-April-01); CPF– Flowlines and Manifolds Train-2 HBNS2-PR-1020-2/4 Rev. 0; (25 April 01) CPF – Oil Separation and Desalters 2. P&IDs HBNS2-PR-1233-1/1 Rev. Z2; (22 April 19) CPF - Inlet Separator - Train 2 HBNS2-PR-1234-1/1 Rev. Z1. (21 Jan 19) CPF - Feed Preheat Exchanger - Train 2 HBNS2-PR-1235-1/1 Rev. Z2. (22 April 19) CPF - HP Separator - Train 2 OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 10 of 59 4.0 HEALTH, SAFETY AND ENVIRONMENTAL ISSUES 4.1 Chemicals The chemicals that are used in the Separation system are Defoamer and Demulsifier. When an operator is exposed to a chemical, the chemical must be removed by washing off the exposed areas of the body at safety showers and eyewashes which are strategically located at possible contamination points. Contaminated clothing and safety apparel must be removed as soon as it is practicable to do so. Refer to MSDS of Defoamer and Demulsifier for more details. 4.2 Personal Protective Equipment (PPE) All personnel involved in work are required to wear the mandatory Personal Protective Equipment (PPE). The operator shall adhere to the PPE requirements as identified in the Job Safety Analysis (JSA) and site PPE Hazard Assessment. Some of the mandatory PPE required for the safe execution of work are listed below: 1. Hard Hat 2. Safety Boots 3. Fire Retardant Coverall 4. Selected Respiratory Protection Equipment 5. Safety Goggles 6. Hand Protection 4.3 Hazardous Area Classification All plant areas associated with the Train 2 Separation system are classified as Hazardous Area Zone 1 & Zone 2. This is due to the potential presence of hydrocarbon gases in the area and therefore, ALL ignition sources shall be avoided. All portable electronic equipment that may be required for daily operation shall be ATEX Certified. The use of personal mobile phones at any plant location is strictly prohibited. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 11 of 59 5.0 SAFETY SYSTEMS The Safety system of the Train 2 Separation covers Personnel, Environmental, and Equipment safety. Overriding of Safety devices is only permitted for short durations during maintenance activities and start-up situations. Overriding of any Safety Critical device shall be in accordance with the approved GB procedure: HBNS & ELM Plant Safety System Bypass Procedure - GBF-03-PRC- 0003. The safety devices for the Train-2 Separation system are listed in the table below: Setpoint information Safety Systems Low-Low Low High High-High Alarm & Trip Alarm Alarm Alarm & Trip Inlet Separator high-high pressure - - - 49.5 barg (PSHH-V2-101-11) Inlet Separator low-low pressure 32.0 barg - - - (PSLL-V2-101-10) Inlet Separator high-high oil level - - - 1.9m (LSHH-V2-101-20) Inlet Separator high oil level - - 90% - (LAH-V2-101-23B) Inlet Separator low-low oil level 0.356m, - - - (LSLL-V2-101-21, 22) 0.305m Inlet Separator low oil level - 10% - - (LAL-V2-101-23A) Inlet Separator high-high interface - - - 90% level (LAHH-V2-101-24) Inlet Separator high interface level - - 58% - (LAH-V2-101-24) Inlet Separator low interface level - 40% - - (LAL-V2-101-24) Inlet Separator low-low interface 0.150m - - - level (LSLL-V2-101-23) HP Separator high-high pressure - - - 24.6 barg (PSHH-V2-102-4) HP Separator low-low pressure 15 barg - - - (PSLL-V2-102-3) HP Separator high-high oil level - - - 2.4m (LSHH-V2-102-10) HP Separator low-low oil level 0.36m - - - (LSLL-V2-102-11) HP Separator high oil level - - 60% - (LAH-V2-102-13) OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 12 of 59 Setpoint information Safety Systems Low-Low Low High High-High Alarm & Trip Alarm Alarm Alarm & Trip HP Separator low oil level - 10% - - (LAL-V2-102-13) HP Separator high interface level - - 80% - (LAH-V2-102-14) HP Separator low interface level - 10% - - (LAL-V2-102-14) HP Separator low-low interface 0.36m - - - level (LSLL-V2-102-12) PSV Setpoints Inlet Separator 76 barg PSV-V2-101-5A / PSV-V2-101-5B Feed Preheat Exchanger 76 barg PSV-E2-102-1 (tube-side) Feed Preheat Exchanger 11.9 barg PSV-E2-102-2 (shell-side) HP Separator 31.4 barg PSV-V2-102-1A / PSV-V2-102-1B OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 13 of 59 6.0 MAJOR ACCIDENT HAZARDS All Operation activities are carried out under Health, Safety, and Environmental Regulations as per GB policy. All personnel involved in the execution of Operation activities must be familiar with the process, equipment, operating procedures and parameters, and hazards that are associated with the process and/or operation to avoid unwanted circumstances. Ensure any changes carried out during Operation is not compromising HSE requirement. Major Risk Hazards Major hazards associated with the Operation of Separation system have been identified in the table below. These items shall be considered when preparing the risk assessment for the Operation activity. Major Accident Consequence Preventive Controls Mitigation Hazard Failure of Equipment Inlet Separator V2-101 Equipment Failure of the At high pressure, Reduce the oil Overpressure Vessel leading to PCV-V2-101-9 flow to the Hydrocarbon opens to HP Flare. Inlet leakage High-High pressure Separator. Fire or explosion alarm PSHH-V2- Awareness of 101-11 activates the Operation closing the SDV’s Procedures according to cause and effect charts. Pressure safety valves PSV-V2-101- 5A/5B are provided to take care at the design pressure HP Separator V2-102 Equipment Failure of the At high pressure, Reduce the oil Overpressure Vessel leading to PCV-V2-102-2B flow to the HP Hydrocarbon opens to HP Flare. Separator. leakage High-High pressure Awareness of Fire or explosion alarm PSHH-V2- the Operation 102-4 activates Procedures closing the SDV’s according to cause and effect charts. Pressure safety valves PSV-V2-102- 1A/1B are provided to take care at the design pressure OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 14 of 59 Major Accident Consequence Preventive Controls Mitigation Hazard Crude / Gas Line Leak Corrosion Release of Piping designed to Isolate the line Hydrocarbon liquid / API standard with for Gas corrosion maintenance. Escalating to Operation and Maintenance team’s intervention Gas detection leading to plant shutdown Failure of a flange Release of Pressure test before Isolate the line gasket or rupture Hydrocarbon start-up allows for of a pipe liquid/Gas visualization of maintenance possible leaks Operator The presence of training / operators within the Operating CPF during their procedures rounds Gas detection leading to plant shutdown OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 15 of 59 7.0 RESPONSIBILITIES NOTE: Only trained and competent operators will perform the steps in this operating procedure in an unsupervised manner. Other personnel may perform steps in this operating procedure only under the direct supervision of a trained and competent operator. Operation Teams involved in this Procedure Sl. No. Discipline 1. HBNS-Chef Sce Exploitation Gis. (Traitement) 2. HBNS-Chef Sce Exploitation Reinjection 3. HBNS-Superviseur de Quart 4. HBNS-Contremaître Exploitation 5. HBNS-Ing Exploitation 6. HBNS-Ing Exploitation 2 7. HBNS-Ing Exploitation 3 8. HBNS-Ing Exploitation 4 9. HBNS-Ing Exploitation 5 10. HBNS- Panel operator 7.1 Supervisor The Supervisor shall ensure that a suitable number of trained and competent operators are selected to perform the work. 7.2 Operators Only trained and competent operators shall perform the steps in this operating procedure in an unsupervised manner. Other personnel may perform steps in this operating procedure when under the direct supervision of a trained and competent operator (e.g., during on-the-job training). OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 16 of 59 8.0 EQUIPMENT SPECIFICATION The specification of Process Equipment in the Train 2 Separation system is given below: Equipment Tag No. V2-101 - Equipment Name Inlet Separator - Type 3 Phase Separator Vessel - Horizontal - Description Value Unit Design Temperature 93 °C Design Pressure 76 barg Operating Temperature 15-50 °C Operating Pressure 40 barg Material of Construction CS with glass flake coating Equipment Tag No. E2-102 - Equipment Name Feed Preheat Exchanger - Duty 18.1 Mkcal/hr. Type TEMA BEU - Description Value Unit Design Temperature Shell-side 225 °C Design Pressure Shell-side 11.9 barg Design Temperature Tube-side 225 °C Design Pressure Tube-side 76 barg Operating Temperature 10.5 / 57.8 (Tube-side) °C (Inlet/Outlet) 131.7 / 56.0 (Shell-side) Operating Pressure (Inlet/Outlet) 24.0 / 23.1 (Tube-side) barg 5.2 / 4.5 (Shell-side) Material of Construction Shell - SA-516-70/Tube SA-249-316L Equipment Tag No. V2-102 - Equipment Name HP Separator - Type 3 Phase Separator Vessel - Horizontal - Description Value Unit Design Temperature 93 °C Design Pressure 31.4 barg Operating Temperature 60 °C Operating Pressure 21.4 barg Material of Construction CS with glass flake coating OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 17 of 59 9.0 PROCESS/SYSTEM DESCRIPTION The purpose of the Separation system for Train-2 is to separate the gas and produced water from the crude oil. The Train-2 Separation system consists of an Inlet Separator (V2-101), Feed Preheat Exchanger (E2-102), and an HP Separator (V2-102) to separate the associated gas and produced water from the crude oil at 2 different stages. The oil from the Separation system is routed to the Desalters for the removal of dissolved salts. An overview of the Train-2 Separation system is indicated in Figure 9.1. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 18 of 59 HP Flare PV-V2-101-9 Production Manifold Gas Dehydration FV-V2-101-12 2nd Stage Desalter TIC V2-101 E2-102 Inlet Separator Feed Preheat Exchanger Split Feed Exchangers LY-V2-101-24 TV-V2-111B-26 HS FT-V2-101-15 FT-V2-101-13 LV-V2-101-24 Rundown Coolers LV-V2-101-23B FV-V2-101-13 Rerun KO Drum HP Flare PV-V2-102-2B Train-1 HP Separator Temporary Mode Mode-2 Process Gas Compressor PV-V2-102-2A Desalter Blanket Gas 25-100% O-75% LY-V2-102-14 V2-102 HP Separator Produced Water Desalters Header LV-V2-102-14 FT-V2-102-20 LV-V2-101-13 Legend Oil Gas Oil+Water Produced Water Stabilized oil Figure 9.1 - Overview diagram of Train-2 Separation system OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 19 of 59 9.1 Inlet Separator The Inlet Separator (V2-101) is a three-phase vessel that separates the gas and produced water from the crude oil. The Inlet Separator is equipped with a proprietary inlet flow device to help in the separation of the gas and liquids. The separated gas goes overhead through a vane pack demister to remove entrained liquids then flows to the Gas Dehydration system for dehydration. The flow from the production manifold to the Inlet Separator is manually controlled by FC-V2- 101-12. The flow control valve FV-V2-101-12 is used to regulate the flow of the oil from the Production Manifold during any upset in the Train-2 Separation System. The Inlet Separator pressure normally runs on the gas injection header pressure which is controlled below 42.5 barg. The excess gas is vented to the HP Flare by PIC-V2-101-9 set at 46.2 barg. The oil level in the Inlet Separator is controlled by the level indicator controller LIC-V2-101-23A. This controller resets the flow indicator controller FIC-V2-101-13 on the Inlet Separator oil outlet line. A second level indicating controller, LIC-V2-101-23B control the oil level separately. LIC-V2-101-23B diverts oil to the Rerun KO Drum when the oil level is above the setpoint until the level returns to normal. The Inlet Separator oil outlet total flow is metered and displayed. The interface level in the Inlet Separator is measured by the level transmitter (LT-V2-101-24) and provides the process variable to the level controller (LIC-V2-101-24). The level controller (LIC-V2-101-24) output is sent to the high selector. The produced water flow from the Inlet Separator is measured by the flow transmitter (FT-V2-101-15) and provides the process variable to the flow controller (FIC-V2-101-15). The flow controller (FIC-V2-101-15) output is sent to the high selector. The level controller (LIC-V2-101-24) output is compared with the flow controller (FIC-V2-101-15) output in the high selector. The high select output throttles LV-V2- 101-24 to regulate the produced water flow from the Inlet Separator to the header. The HP Separator interface level controller (LIC-V2-102-14) output (25% - 100%) is cascaded with the flow controller (FIC-V2-101-15). The image of the Inlet Separator V2-101 is shown below in Figure 9.2: Figure 9.2 - Image of Inlet Separator OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 20 of 59 The DCS Graphics of the Inlet Separator is shown below in Figure 9.3: Figure 9.3 - DCS Graphics of Inlet Separator 9.2 Feed Preheat Exchanger The separated oil from the Inlet Separator flows on the tube side of the Feed Preheat Exchanger (E2-102). The oil is heated on the shell side by the Stabilizer product oil from the Split Feed Exchangers (E2-101A/B). The Feed Preheat Exchanger ensures the oil to the Desalters is above the minimum temperature for effective Desalter operation. The stabilized oil leaves the shell side to Rundown Cooler (A2-101A~F). The oil outlet temperature controller TIC-E2-101-12 regulates the three-way valve TV-V2-111B- 26. The three-way control valve TV-V2-111B-26 splits the Stabilized oil flow through the shell side of Feed Preheat Exchanger and through Feed Preheat Exchanger bypass to maintain the temperature of the oil leaving the tube side to the HP Separator (V2-102). The oil temperature to the HP Separator is maintained by TIC-E2-102-12 run on cascade mode and is reset by TIC V2-111B-26 to maintain 49°C at 2nd Stage Desalter V2-111B. During the turndown conditions of Oil Train-1, there is a provision to route the oil flow from the HP Separator V1-102 oil outlet to the inlet of Train-2 Feed Pre-heat Exchanger E2-102. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 21 of 59 The image of the Feed Preheat Exchanger E2-102 is shown below in Figure 9.4: Figure 9.4 - Image of Feed Preheat Exchanger The DCS Graphics of the Feed Preheat Exchanger is shown below in Figure 9.5: Figure 9.5 - DCS Graphics of Feed Preheat Exchanger OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 22 of 59 9.3 HP Separator The heated oil from the Feed Preheat Exchanger flows to the HP Separator (V2-102) where the gas and produced water are separated from the oil. The separated gas flows through a vane pack demister to remove the entrained liquid and flows to the HP Suction KO Drum (V2-202) of the Process Gas Compressor. The Separator is sized to limit gas velocity to prevent liquid entrainment and provide sufficient residence time for gas/liquid separation. The HP Separator pressure is controlled by two pressure indicating controllers, PIC-V2-102-2A and PIC-V2-102-2B. PIC-V2-102-2A is set at 21.4 barg and controls the pressure of the HP Separator at the desired value. On high-pressure surges, PIC-V2-102-2B which is set at 23.3 barg vents excess gas to the HP Flare. The HP Separator has a weir that divides the vessel liquid volume into two sections. On the upstream side of the weir, the higher density water separates from the oil and the lighter oil flows over the top of the weir. The HP Separator (V2-102) Interface level is measured by the level transmitter (LT-V2-102-14) and provides the process variable to the split range level controller (LIC-V2-102-14). The level controller (LIC-V2-102-14) output (0-75%) throttles the control valve LV-V2-102-14 to regulate the produced water flow to the produced water header. The level controller (LIC-V2-102-14) output (25%-100%) is cascaded with the flow controller (FIC-V2-101-15). LIC-V2-102-13 controls the oil level on the downstream side of the weir with oil to the 1st Stage Desalter (V2-111A). The DCS image of the HP Separator V2-102 is shown below in Figure 9.6: Figure 9.6 - Image of HP Separator OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 23 of 59 The DCS Graphics of the HP Separator is shown below in Figure 9.7: Figure 9.7 - DCS Graphics of HP Separator OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 24 of 59 9.4 Interconnection of Train-2 Separation System The Interconnection of the Separation system with other systems of CPF is given below in Figure 9.8: Gas vent to HP Flare Oil from Production Manifold Gas to Process Gas Chemical Injection - Inlet Separator V2-101 Compressor Defoamer Chemical Injection - Demulsifier Stabilized Oil from Split Oil to Rundown Coolers Feed Exchangers Feed Preheat Exchanger E2-102 Gas to Dehydration system Gas to Desalter Liquid from Dehydration Blanket Gas Inlet KO Drum Produced Water to Produced Water Header Liquid from HP Filter Separator HP Separator, V2-102 Oil to Rerun system Liquid from HP Discharge Drum (Process Gas Oil to Desalters Compressor) Power Utilities (Instrument Air/ Nitrogen) Oil drain to Closed Oily water drain to Drain system Open Drain system Figure 9.8 - Interconnection of Train-2 Separation System OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 25 of 59 10.0 OPERATING PHASES In this section, the following start-up scenarios are described: Start-up following Planned Maintenance Phase (Cold Start) In this scenario, the equipment may be restarted after being idle or out of service for an extended period such as after maintenance or after total plant shutdown when normal operating parameters related to pressure, flow, and temperature are lost. Additional checks are performed under these conditions to verify that the valves and equipment are properly lined up for a smooth and safe start-up. During this start-up, it is assumed that valves have been repositioned differently from when the equipment is in normal operation mode. Hence, checks shall be performed to verify valve alignment. Normal Start-up Phase (Start-up from Standby) Normal Start-up is done immediately after a plant trip such as after a total blackout, one train trip, or emergency shutdown. Once conditions for the unit are returned to normal, the unit can be started up again after identifying and rectifying the trip cause. In this kind of situation, valves are not repositioned, and it may be restoring electrical power, any action of interlock, or even swapping a train to re-establish process flows back to normal. Levels and temperatures are not changed in most cases and the plant remains in normal conditions. 10.1 Startup after Maintenance Phase This section covers the start-up of the Train 2 Separation system after maintenance. Prerequisites The following prerequisite activities are to be carried out with due attention to the safety of plant equipment and personnel. Ensure the following activities are completed before commencing the Nitrogen purging of the hydrocarbon system: 1. ENSURE all maintenance activities are completed. 2. CLOSE out all PTW issued for each activity and ENSURE readiness for use, properly. 3. ENSURE completion of gross air leak test, if joints are open for inspection. 4. ENSURE all the instruments in the system are lined up. 5. ENSURE the position of valves as per Table 10.1. 6. CONFIRM safety & firefighting equipment are in place, operational, and ready to use. 7. Ensure fire and gas detection system is in service and not bypassed. 8. ENSURE PSSR (Pre-Startup Safety Review) is completed and all points are CLOSED. 9. CONFIRM Lock Out/Tag Out (LOTO) is removed from all required systems. 10. ENSURE PSV’s are calibrated and are installed (if removed for calibration). 11. ENSURE prior to opening any of the SDVs, the manual valve alignment and controller setpoints are verified. 12. ENSURE communications are established with the control room. 13. ENSURE all drains valves and vents are closed. 14. INFORM all operators of the start-up within toolbox talks. 15. STOP all work close to the Train-2 Area during Start-up. 16. ENSURE that the area near Train-2 is clean. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 26 of 59 17. USE the radio for all work communications. 18. FOLLOW supervisor’s orders for the start-up. 19. ENSURE communication is established with EP (Exploitation & Production) Service. 20. Use your STOP WORK AUTHORITY, if necessary. Nitrogen Purging ENSURE the entire hydrocarbon system is purged with Nitrogen and ready for ‘Start-up’. Status of Equipment prior to Start-up The status of various equipment in the Separation Facility is given below: Inlet Separator (V2-101), Feed Preheat Exchanger (E2-102), and HP Separator (V2-102) are under Nitrogen pressure (0.5 barg). Inlet Manifold is lined up and supplying oil to Train-2. The normal status of other units is given below: ENSURE all utilities are available - HP Flare, LP Flare, and AP Flare, Fuel Gas System, Re-run and Produced Water System. ENSURE the inlet reception, chemical injection system is operating and feeding to other Separation Facility. ENSURE Train-2 Desalters are purged and ready for start-up. ENSURE the Gas Compressors are Nitrogen purged and ready for operation. Valve Line-up ENSURE the position of valves is as per Table 10.1 below. Table 10.1 Sl. No. Location Valve Position Remarks P&ID No. HBNS2-PR-1233-1/1 Rev. Z2 – Inlet Separator 1. 4” block valve on inlet of PSV-V2-101-5B Lock Close 2. Both 2” block valves on the PSV-V2-101-5A/B Close bypass line 3. 4” block valve on inlet of PSV-V2-101-5A Lock Open 4. 6” block valve on outlet of PSV-V2-101-5A Lock Open 5. 6” block valve on outlet of PSV-V2-101-5B Lock Open 6. 16” SDV-V2-101-1 on the oil inlet line Close 7. 2” block valve on oil feed bypass line Close 8. 2” HV-V2-101-25 on oil feed bypass line Close 9. Three 3” block valves on the closed drain lines Close 10. 14” SDV-V2-101-4 on normal gas outlet line Close 11. 12” SDV-V2-101-2 on normal oil outlet line Close 12. 12” SDV-V2-101-3 on rerun oil outlet line Close 13. 8” SDV-V2-101-5 on the produced water line Close OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 27 of 59 Sl. No. Location Valve Position Remarks 14. 3” valve on oil inlet line from JT fuel gas-liquid Close conditioning skid 15. 1” block valve on Defoamer tubing line Close 16. 2” block valve on Demulsifier line Close 17. 12” block valve upstream of PV-V2-101-9 Lock Open 18. 12” block valve downstream of PV-V2-101-9 Lock Open 19. 14” block valve upstream of SDV-V2-101-4 Open 20. 16” block valve on oil outlet line Open 21. 12” block valve upstream of FV-V2-101-13 Open 22. 12” block valve upstream of LV-V2-101-23B Open 23. 8” block valve upstream of LV-V2-101-24 Open 24. 8” block valve downstream of LV-V2-101-24 Open 25. 6” bypass valve of LV-V2-101-24 Close P&ID No. HBNS2-PR-1234-1/1 Rev. Z1. Feed Preheat Exchanger 26. Three 3” block valves on the closed drain lines Close 27. 16” block valve on tube-side bypass line Close 28. 1” block valve on Demulsifier injection line Close 29. 4” block valve on outlet of PSV-E2-102-2 Lock Open 30. 3” Block valve on inlet of PSV-E2-102-2 Lock Open 31. 4” Block valve on outlet of PSV-E2-102-1 Lock Open 32. 3” Block valve on inlet of PSV-E2-102-1 Lock Open 33. 16” block valve on tube-side inlet line Lock Open 34. 16” block valve on the tube-side outlet line Lock Open 35. 16” block valve on shell-side inlet line Open 36. 16” block valve on the shell-side outlet line Open 37. 16” block valve on shell-side inlet line upstream Open of TV-V2-111B-26 38. 16” block valve on shell-side bypass line Open downstream of TV-V2-111B-26 P&ID No. HBNS2-PR-1235-1/1 Rev. Z2 HP Separator 39. 6” block valve on inlet of PSV-V2-102-1B Lock Close 40. Both 2” block valves on PSV-V2-102-1B Close bypass line 41. 6” block valve on inlet of PSV-V2-102-1A Lock Open 42. 8” block valve on outlet of PSV-V2-102-1A Lock Open 43. 8” block valve on outlet of PSV-V2-102-1B Lock Open OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 28 of 59 Sl. No. Location Valve Position Remarks 44. Three 2” block valves on the closed drain lines Close 45. 10” block valve upstream of PV-V2-102-2A Open 46. 12” SDV-V2-102-8 on oil outlet line Close 47. 8” SDV-V2-102-9 on the produced water line Close 48. 3” block valve from Dehydration inlet KO Drum Close to HP Separator 49. 6” block valve from HP Discharge Drum to Close HP Separator 50. 2” block valve from HP Filter Separator to Close HP Separator 51. 8” block valve downstream of PV-V2-102-2B Open 52. 8” block valve upstream of PV-V2-102-2B Open 53. 10” block valve downstream of PV-V2-102-2A Open 54. 12” block valve upstream of LV-V2-102-13 Open 55. 12” block valve downstream of SDV-V2-102-8 Open 56. 8” block valve upstream of LV-V2-102-14 Open Sequence of Start-up These are the main steps in the Start-up of Separation Train-2. LINING up of Inlet Separator (V2-101), Feed Preheat Exchanger (E2-102), and HP Separator (V2-102) PRESSURIZATION of Inlet Separator (V2-101) / Start-up START-UP of Feed Preheat Exchanger (E2-102) PRESSURIZATION of HP Separator (V2-102) / Start-up OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 29 of 59 Introduction of Hydrocarbons Sl. # Steps Check Box 1. Inlet Separator (V2-101) 1.1 PLACE the pressure controller PIC-V2-101-9 in MANUAL mode and CLOSE the pressure control valve PCV-V2-101-9. 1.2 PLACE the flow controller FC-V2-101-12 in MANUAL mode and CLOSE the flow control valve FV-V2-101-12. 1.3 PLACE the level controller LIC-V2-101-23A in MANUAL mode. 1.4 PLACE the level controller LIC-V2-101-23B in MANUAL mode and CLOSE the level control valve LV-V2-101-23B. 1.5 PLACE the flow controller FIC-V2-101-13 in MANUAL mode and CLOSE the flow control valve FV-V2-101-13. 1.6 PLACE the level controller LIC-V2-101-24 in MANUAL mode and CLOSE the level control valve LV-V2-101-24. 2. Feed Preheat Exchanger (E2-102) 2.1 PLACE the temperature controller TIC-E2-102-12 in MANUAL mode and fully open the valve to the shell side bypass line and fully close the valve to the shell side inlet line. 3. HP Separator (V2-102) 3.1 PLACE the pressure controller PIC-V2-102-2B in MANUAL and CLOSE the pressure control valve PCV-V2-102-2B. 3.2 PLACE the pressure controller PIC-V2-102-2A in MANUAL and CLOSE the pressure control valve PCV-V2-102-2A. 3.3 PLACE the level controller LIC-V2-102-13 in MANUAL mode and CLOSE the level control valve LV-V2-102-13. 3.4 PLACE the level controller LIC-V2-102-14 in MANUAL mode and CLOSE the level control valve LV-V2-102-14. 4. SELECT the Inlet Separator “Safety System Reset” HS-V2-101-1S from DCS. 5. OPEN the 2” block valve on the oil feed bypass line. 6. Slowly OPEN the 2” hand valve (HV-V2-101-25) on the oil feed bypass line to equalize the pressure around SDV-V2-101-1. 7. Slowly OPEN 12” FV-V2-101-12 on oil inlet line to 20% to START oil flow to the Inlet Separator. 8. PUT PIC-V2-101-9 in AUTO mode with a set point of 46.2 barg. NOTE: The gas flows to the HP Flare through PV-V2-101-9 once the Inlet Separator pressure reaches 46.2 barg. 9. OPEN 14” SDV-V2-101-4 on normal gas outlet line to START gas flow to the gas distribution header. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 30 of 59 Sl. # Steps Check Box NOTE: The opening of the SDV-V2-101-4, need more attention to avoid water hammer. There are two situations: 1. Low or no pressure in gas distribution header – In this case open SDV-V2-101-4 first, before opening FV-V2-101-12. 2. Gas Distribution Header under operating pressure around 42 barg- In this case open SDV-V2-101-4 when the Inlet Separator pressure is equal to the gas distribution header pressure to avoid any unexpected situation if there is malfunction or passing of check valve FSV-V2-101-17. 10. START Defoamer injection to the oil flow to Inlet Separator. 11. START Demulsifier injection to the oil flow to Inlet Separator. 12. INCREASE the opening of FV-V2-101-12 in manual mode gradually to feed 350 m3/h to the Inlet Separator. 13. ENSURE PALL-V2-101-10 trip resets as the pressure of the Inlet Separator PIC-V2-101-9 increases more than 32.0 barg 14. CONFIRM Inlet Separator pressure PIC-V2-101-9 reaches the setpoint of 46.2barg. 15. Reset and OPEN 16” SDV-V2-101-1 on oil inlet line when the pressure around SDV-V2-101-1 is equalised. 16. CLOSE the 2” block valve and hand valve (HV-V2-101-25) on the oil feed bypass line. ENSURE the valve is set lock closed. 17. CHECK for interface level rise in LIC-V2-101-24. 18. OBSERVE that the interface level increases, and the low-low interface level alarm trip (LALL-V2-101-23) is reset. 19. RESET and OPEN 8” SDV-V2-101-5 on the produced water outlet line when the low-low interface level trip LSLL-V2-101-23 is reset. 20. PLACE the flow controller FIC-V2-101-15 in cascade mode. NOTE: The level controller (LIC-V2-101-24) output is compared with the Flow controller (FIC-V2-101-15) output in the high selector. The high select output throttles LV-V2-101-24 to regulate the produced water flow to the header. 21. CHECK oil level indicated at LIC-V2-101-23A as more oil is separated. 22. SELECT the HP Separator “Safety System Reset” HS-V2-102-1S from DCS. 23. PUT PIC-V2-102-2B in AUTO mode with a set point of 23.3 barg to control the pressure of HP Separator V2-102. NOTE: The gas flows to HP Flare through PV-V2-102-2B once the HP Separator pressure reaches 23.3 barg. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 31 of 59 Sl. # Steps Check Box 24. RESET and OPEN 12” SDV-V2-101-2 on the normal oil outlet line, when the interface trip LSLL-V2-101-21&LSLL-V2-101-22 Clear 25. RESET and OPEN 12” SDV-V2-101-3 on rerun oil outlet line. 26. CHECK that the oil low-level alarm (LAL-V2-101-23A) is cleared as the oil level increases to 10% in Inlet Separator. 27. START oil feed to the Feed Preheat Exchanger and the HP Separator by slowly OPENING FV-V2-101-13 to about 25%. NOTE: The Feed Preheat Exchanger shell-side has no oil flow through it until the Stabilizer comes into operation 28. SET LIC-V2-101-23A in AUTO mode with a set point of 30%. 29. SET LIC-V2-101-23B in AUTO mode with a set point of 10%. 30. CHANGE FIC-V2-101-13 to CASCADE mode. NOTE: The control valves FV-V2-101-13 and LV-V2-101-23B control independently to handle surge events. At a high liquid level in LIC-V2-101- 23A, the flow controller FIC-V2-101-13 allows FV-V2-101-13 to increase flow to ease the surge. LIC-V2-101-23B diverts oil to the Rerun KO Drum when the oil level is above the setpoint (10%) until the level returns to normal. 31. MONITOR the increase of LIC-V2-102-14 and pressure PIC-V2-102-2B in HP Separator. 32. CONFIRM the pressure PIC-V2-102-2A reaches a set point of 21.4 barg in HP Separator. 33. CHANGE PIC-V2-102-2A to AUTO mode with a set point of 21.4 barg. NOTE: To start gas flow to the Process Gas Compressors and supply blanket Gas for the Desalters. 34. CHECK for interface level build up in LIC-V2-102-14. 35. OBSERVE that the interface low-low level trip LALL-V2-102-12 is reset. 36. RESET and OPEN 8” SDV-V2-102-9 on produced water line from HP Separator when the interface trip LSLL-V2-102-12 is reset. 37. CHECK that the oil low-level alarm (LAL-V2-102-13) is cleared as the oil level increases to 10% in HP Separator. 38. SET LIC-V2-102-14 in AUTO mode with a set point of 86%. when the interface level is stabilized. 39. CHECK oil level indicated at LIC-V2-102-13 as more oil is separated. 40. OBSERVE that the low-low oil level trip (LALL-V2-102-11) is reset. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 32 of 59 Sl. # Steps Check Box 41. RESET and OPEN 12” SDV-V2-102-8 on oil outlet line from HP Separator when the oil low-low level trip LSLL-V2-102-11 is reset. NOTE: 1st stage desalter PSLL-V2-111A-6 prevent the permissive to open the SDV-V2-102-8 42. CHANGE LIC-V2-102-13 to AUTO mode with a setpoint of 45%. NOTE: When the oil level reaches the setpoint, the oil will flow to the 1st Stage Desalter. 43. INCREASE the opening of FV-V2-101-12 in manual mode to increase the oil flow to the Inlet Separator V2-101. 44. LINE UP Condensate from the HP Discharge KO Drums and the HP Filter- Separators to the HP Separator. 45. CHANGE TIC-E2-102-12 to Cascade mode after the 2nd Stage Desalter V2-111B is started. NOTE: TIC-E2-102-12 is reset by the 2nd Stage Desalter (V2-111B) oil outlet TIC V2-111B-26 that is set at 49ºC. Ramp up of Feed Flow Sl. # Steps Check Box 1. ENSURE oil feed rate to the Train-2 is raised after the Desalters and Stabilizer are in service. 2. ADJUST FV-V2-101-12 to balance the liquid flow rate from the Inlet Separator to the other Trains. 10.2 Normal Start-up Phase Status prior to start-up The equipment in the Train-2 Separation System is in pressurized condition and isolated by the following: SDV-V2-101-1 on the Inlet Separator V2-101 - inlet line. SDV-V2-101-5 on the Inlet Separator produced water outlet line. SDV-V2-101-4 on the Inlet Separator to the Gas distribution header. SDV-V2-101-2 on the Inlet Separator oil outlet line. SDV-V2-102-9 on the HP Separator produced water outlet line. SDV-V2-102-8 on the HP Separator oil outlet line. SDV-V2-101-3 on rerun oil outlet line. Oil inlet flow control valve FV-V2-101-12 to the Inlet Separator V2-101 closed in manual mode. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 33 of 59 Inlet Separator pressure controller PIC-V2-101-9 in Auto mode. Inlet Separator level controllers LIC-V2-101-23A & LIC-V2-101-23B are in Manual mode and level control valve LV-V2-101-23B is closed. Inlet Separator flow controller FIC-V2-101-13 in Manual mode and flow control valve FV-V2-101-13 closed. Inlet Separator interface level controller LIC-V2-101-24 in Manual mode and control valve LV-V2-101-24 closed. HP Separator Pressure controller PIC-V2-102-2A & PIC-V2-102-2B in Auto mode. HP Separator Level controllers LIC-V2-102-14 and LIC-V2-102-13 in Manual mode and level control valves LV-V2-102-14 & LV-V2-102-13 closed. Sl. # Steps Check Box 1. ENSURE the cause for Shutdown is identified and attended. 2. CHECK the reset position of SDV at the field. 3. SELECT the Inlet Separator “Safety System Reset” HS-V2-101-1S from DCS. 4. SELECT the HP Separator “Safety System Reset” HS-V2-102-1S from DCS. 5. RESET and OPEN 12” SDV-V2-101-3 on rerun oil outlet line. 6. OPEN the 2” block valve on the oil feed bypass line. 7. Slowly OPEN the 2” hand valve on the oil feed bypass line to equalize the pressure around SDV-V2-101-1. 8. Slowly OPEN 12” FV-V2-101-12 on oil inlet line to 20% to START oil flow to the Inlet Separator. 9. START Defoamer injection to the oil flow to Inlet Separator. 10. START Demulsifier injection to the oil flow to Inlet Separator. 11. OPEN 14” SDV-V2-101-4 on normal gas outlet line to START gas flow to the gas distribution header. NOTE: The opening of the SDV-V2-101-4, need more attention to avoid water hammer. There are two situations: 1. Low or no pressure in gas distribution header – In this case open SDV-V2-101-4 first, before opening FV-V2-101-12. 2. Gas Distribution Header under operating pressure around 42 barg- In this case open SDV-V2-101-4 when the Inlet Separator pressure is equal to the gas distribution header pressure to avoid any unexpected situation if there is malfunction or passing of check valve FSV-V2-101-17. 12. CONFIRM Inlet Separator pressure PIC-V2-101-9 reaches the setpoint of 46.2barg. 13. RESET and OPEN 16” SDV-V2-101-1 on oil inlet line once the pressure is equalised. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 34 of 59 Sl. # Steps Check Box 14. CLOSE the 2” block and hand valves on the oil feed bypass line. ENSURE the valve is set lock closed. 15. RESET and OPEN 12” SDV-V2-101-2 on the normal oil outlet line from the Inlet Separator V2-101. 16. RESET and OPEN 12” SDV-V2-101-3 on rerun oil outlet line from the Inlet Separator V2-101. 17. RESET and OPEN 8” SDV-V2-101-5 on the produced water outlet line from the Inlet Separator V2-101. 18. PLACE the flow controller FIC-V2-101-15 in cascade mode. NOTE: The level controller (LIC-V2-101-24) output is compared with the Flow controller (FIC-V2-101-15) output in the high selector. The high select output throttles LV-V2-101-24 to regulate the produced water flow to the header. 19. SET the level controller LIC-V2-101-23A in AUTO with a set point of 30%. 20. PLACE the flow controller FIC-V2-101-13 in CASCADE mode. 21. SET the level controller LIC-V2-101-23B in AUTO with a set point of 10%. 22. MONITOR the level and pressure in HP Separator. 23. ENSURE gas flows through PV-V2-102-2A to HP Suction KO Drum, when the pressure increases above 21.4 barg 24. RESET and OPEN 12” SDV-V2-102-8 on oil outlet line from HP Separator. 25. CHANGE LIC-V2-102-13 to AUTO mode with a setpoint of 45%. 26. RESET and OPEN 8” SDV-V2-102-9 on produced water line from HP Separator. 27. CHANGE LIC-V2-102-14 into the AUTO mode with a set point of 85%. 10.3 Normal Operations Phase This section covers the monitoring of the Train 2 Separation system when the process/system has been started up and is running within its normal operating limits. Sl. # Steps Check Box 1. MONITOR and RECORD Inlet Separator feed oil flow at FC-V2-101-12. NOTE: If any Train shuts down, slowly start closing FV-V2-101-12 to prevent an increased flow to the Inlet Separator. 2. MONITOR and RECORD Inlet Separator pressure at PIC-V2-101-9. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 35 of 59 Sl. # Steps Check Box 3. CHECK Inlet Separator levels LIC-V2-101-23A - normal level LIC-V2-101-23B - high level LIC-V2-101-24 - produced water level 4. MONITOR and RECORD Feed Preheat Exchanger outlet oil temperature TIC-E2-102-12. 5. MONITOR and RECORD HP Separator pressure in PIC-V2-102-2A. 6. CHECK levels in HP Separator LIC-V2-102-14 - interface Level LIC-V2-102-13 - oil Level 7. PERIODICALLY check the Inlet Separator PSV-V2-101-5A/5B outlet bleed valves for any hydrate formation in the flare header. 10.4 Temporary Operations Phase During the turndown conditions of Oil Train-1, the oil flow from Train-1 HP Separator V1-102 is routed to Train-2 Feed Pre-Heat Exchanger E2-102. Sl. # Steps Check Box Changeover of Train-1 HP Separator oil outlet to Train-1 Desalters (Mode-1 to Mode-2 Operation) 1. ENSURE a valid work permit is in place. 2. REMOVE the Car seal on the 12” block valves in the HP Separator oil outlet line towards Train-2 Feed Pre-heat Exchanger E2-102. 3. REMOVE the Car seal on the 12” block valves in the HP Separator oil outlet line towards Train-1 Desalters. 4. SWITCH the HP Separator to Mode-2 Operation using the selector switch “HS-Train1_Train2_MC” from DCS 5. INCREASE the setpoint of PIC-V1-102-1A to 1 bar above the Train-2 HP Separators operating pressure. 6. OPEN the 12” block valves (DB&B) in the HP Separator oil outlet line towards Train-2 Feed Pre-heat Exchanger E2-102. INSTALL Car Seal on the 12” valves. (CSO) 7. ENSURE there is oil flow from Train-1 to Oil Train-2. NOTE: If there is no oil flow, increase the setpoint of PIC-V1-102-1A in steps of 0.5 bar until the flow is established. 8. MONITOR the increase in level of HP Separator V2-102 at LIC-V2-102-14. 9. CLOSE the 12” block valves (DB&B) in the Train-1 HP Separator oil outlet line towards Train-1 Desalter. INSTALL the Car Seal on the 12” Valves (CSC). OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 36 of 59 Sl. # Steps Check Box Changeover of Train-1 HP Separator oil outlet to Train-1 Desalters (Mode-2 to Mode-1 Operation) 10. ENSURE a valid work permit is in place. 11. REMOVE the Car seal on the two 12” block valves in the HP Separator oil outlet line towards Train-1 Desalters. 12. OPEN the 12” block valves (DB&B) in the HP Separator oil outlet line towards Train-1 Desalters. CAUTION: In case the Train-1 Desalter is depressurized the block valves should be opened slowly to allow pressurization of the Desalter vessel. 13. SWITCH the HP Separator to Mode-2 Operation using the selector switch “HS-Train1_Train2_MC” from DCS. 14. INSTALL Car Seal on the 12” valves. (CSO) on the line to the Train-1 Desalter. 15. CLOSE the 12” block valves (DB&B) in the HP Separator oil outlet line towards Train-2 Feed Pre-heat Exchanger E2-102. INSTALL the Car Seal on the 12” Valves (CSC). 16. NORMALISE the setpoints of Train-1 PIC-V1-102-1A and PIC-V1-102-1B. Refer to Train-1 Operating Procedure HBNS-01-PUL-OP-PRC-2001 for details. 10.5 Emergency Shutdown Phase In Groupement Berkine CPF facilities, there are 5 different levels of an Emergency shutdown and they occur under the following conditions: Emergency Shutdown (ESD) – Level 1 Plantwide Shutdown (PSD) – Level 2 Train Specific Shutdown – Level 3 Process / Utility, Unit Shutdown (USD) Equipment Protection OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 37 of 59 EMERGENCY: INITIATING CONDITION: Sl. # Steps Check Box 1. Level 1 Shutdown Level-1 shutdown is the manual initiation of ESD pushbutton in CCR and ESD pushbuttons at other strategic locations within the CPF. Pushbuttons locations are listed below: ESD PB located in the CCR HS-ESD0270 ESD Pushbutton located in the Separation area HS-ESDP221 Level-1 shutdown is also initiated automatically by: 1.1 CONFIRMED Fire detection in a Hydrocarbon area. 1.2 CONFIRMED high-level gas detection 1.3 Total LOSS of Instrument Air 1.4 TOTAL POWER FAILURE (Failure of grid power & GT generators not running) resulting in total shutdown and automatic depressurization of the CPF. 2. Level 2 Shutdown It is initiated by a manual pushbutton (HS-PSDO270) provided at CCR in an emergency to prevent or mitigate a possible hazard event or cascading from a Level-1 shutdown. The Level-2 shutdown is also initiated by a high-high level in HP and/or LP Flare KO Drum shutting down the entire plant. Process equipment remains pressurized. CPF Plantwide Shutdown shuts all SDV’s, BDV’s, pumps, and motors except Flare Drum and Firewater Pumps. The CPF inlet SDV’s, gas injection manifold SDV’s, GT generators, common areas are closed. A blowdown is an operator option. 3. Level 3 Shutdown Train 2 SHUTDOWN Pushbutton located in the CCR (HS-TSDO270-2) is initiated by the control room operator to shutdown Train-2 individually or cascading from L2 shutdown. 3.1 SHUTDOWN all process equipment associated with train 2 3.2 CLOSURE of Train 2 Inlet Separator valve 3.3 An automatic delayed depressurizing (Blowdown) is initiated by opening all Train 2 associated compressor BDV’s (Blowdown valves) after 45 minutes. However, the operator can initiate a train blowdown by pushing the train BLOWDOWN pushbutton located on the ESD Panel in the CCR, provided that the blowdown permissive is received from the safety system. 3.4 The chemical injection pumps are MANUALLY SHUTDOWN. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 38 of 59 Sl. # Steps Check Box 3.5 Common process equipment is not affected by a “TRAIN SHUTDOWN” 3.5.1 Flare Drum/Pump, Rerun system and CPF utilities. 3.5.2 Common areas are operational. 4. Level 4 Shutdown Tripping of an individual process or utility systems or subsystems initiated automatically from the Safety system is Unit Shutdown or cascading from the higher-level shutdown. This will place a unit in a safe state. No manual unit trips are implemented. ISOLATION of the following systems is covered in this Operating Procedure. 4.1 Separation Train-2 (Inlet Separator V2-101, HP Separator V2-102) 4.2 Feed Preheat Exchanger Inlet Separator 4.3 Inlet separator high-high pressure (PSHH-V2-101-11), low- low pressure (PSLL-V2-101-10) and high-high Level (LSHH-V2-101-20) CLOSES the Inlet separator liquid inlet and gas outlet. 4.4 Low-low level in inlet separator (LSLL-V2-101-21, 22) CLOSES Inlet Separator normal liquid outlet and Re-Run liquid outlet. 4.5 Whereas the low-low interface level (LSLL-V2-101-23) CLOSES Inlet Separator water outlet. HP Separator 4.6 HP Separator high-high pressure (PSHH-V2-102-4), low-low level (PSLL-V2-102-3), high-high level (LSHH-V2-102-10) CLOSES HP Discharge KO Drum liquid outlet, HP Filter Separator liquid outlet to HP Separator, Dehydration Inlet KO Drum liquid outlet to HP Separator, HP Discharge KO Drum liquid outlet, Inlet Separator Normal liquid outlet, Train 2 HP Separator condensate inlet from MP KO Drums. 4.7 Low-low level (oil) LSLL-V2-102-11 CLOSES the HP Separator oil outlet and low-low level (interface) LSLL-V2-102-12 HP Separator water outlet. 5. Level 5 Shutdown Equipment Protection Shutdown solely trips and/or isolates the equipment that they protect, typically rotating machines or vessels. Automatic initiation results from a higher-level shutdown. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 39 of 59 10.6 Emergency Operations Phase Sl. # Steps Check Box 1. In Case of an Emergency in the Train 2 Separation system, ACTIVATE the ESD Pushbutton Panel in the Central Control Room of the Separation Area (HS-ESD-P221) and ENSURE the following valves are CLOSED. SDV-V2-101-1 (Inlet Separator oil inlet) SDV-V2-101-2 (Inlet Separator normal oil outlet) SDV-V2-101-3 (Inlet Separator re-run oil outlet) SDV-V2-101-5 (Inlet Separator produced water outlet) SDV-V2-101-4 (Inlet Separator normal gas outlet) SDV-V2-102-8 (HP Separator oil outlet line) SDV-V2-102-9 (HP Separator produced water) CAUTION: Confirm that the SDVs are closed on the HMI. Failure to close can lead to a hazardous situation. 2. ENSURE oil flow to the Separation system is STOPPED. 3. ENSURE gas flow to the Process Gas Compressors and supply blanket gas for the Desalters is STOPPED. 4. STOP Defoamer and Demulsifier injection. 10.7 Normal Shutdown Phase The shutdown of the Train 2 Separation system will reduce the load of production wells. The process conditions are to be monitored at a reduced load. The Separation system is taken for shutdown during the planned and scheduled maintenance of the CPF or the Field production areas. This could require the system to be isolated, depressurized, drained, flushed, purged and vented to allow safe work to proceed. The steps to be followed during the shutdown of the Separation system is given below: Sl. # Steps Check Box 1. Upon notification of a Normal scheduled SHUTDOWN, the CCR shall begin to GRADUALLY reduce the output of the flow controller FC-V2-101-12-to the Inlet Separator V2-101. 2. As the minimum turndown is approached (approximate flow of 20,000 STBPD, or 25% of design), the oil flow from the Separation system will continue for the cooldown of the Stabilizer. 3. MAINTAIN level and pressure in the Inlet Separator and HP Separator. 4. MONITOR the pressure of the entire Separation Train-2 and ISOLATION of the systems shall begin as required by the planned activities of the shutdown. 5. CLOSE the SDV-V2-101-1 on the oil inlet line. 6. CLOSE FV-V2-101-12 on oil inlet line to Inlet Separator. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 40 of 59 Sl. # Steps Check Box 7. CLOSE 3” valve on oil inlet line from JT fuel gas-liquid conditioning skid to Inlet Separator. 8. ENSURE oil flow to the Inlet Separator is STOPPED. 9. STOP Defoamer and Demulsifier flow to the oil. 10. ENSURE SDV-V2-101-2 on the oil outlet line is CLOSED when the oil level reaches a low-low level. 11. CLOSE SDV-V2-101-4 on normal gas outlet line of Inlet Separator. 12. ENSURE SDV-V2-101-5 on the produced water outlet line is CLOSED when the interface level reaches a low-low level. 13. SELECT TIC-E2-102-12 in MANUAL mode and CLOSE the TV-V2-102-12 in Feed Preheat Exchanger. 14. ISOLATE condensate from the HP Discharge KO Drums and the HP Filter- Separators to HP Separator. 15. SELECT PIC-V2-102-2A in MANUAL mode and CLOSE the PV-V2-102-2A. 16. ENSURE gas flow to the Process Gas Compressors and supply blanket gas for the Desalters is STOPPED. 17. ENSURE SDV-V2-102-8 on the oil outlet line of HP Separator is CLOSED when the oil level reaches a low-low level. 18. ENSURE SDV-V2-102-9 on the produced water line of HP Separator is CLOSED when interface level reaches low-low level. 19. DRAINING the oil in the Inlet Separator and the HP Separator can be actioned if required. Shutdown Maintenance Shutdown maintenance for the Separation system is carried out as per the GB maintenance schedule. If the Inlet Separator (V2-101), Feed Preheat Exchanger (E2-102) and the HP Separator (V2-102) are isolated for any maintenance activity, it is necessary to depressurize, drain and flush the vessels and piping for safe execution of activities as detailed below. 20. Depressurization and Draining of Inlet Separator (V2-101) 20.1 Gradually OPEN PV-V2-101-9 and depressurize the Inlet Separator up to 2 barg. CAUTION: Depressurization shall be done gradually. Avoid sudden depressurization. 20.2 CLOSE PV-V2-101-9 depressurizing valve of Inlet Separator 20.3 ENSURE the level of oil in the Closed Drain Drum (V1-801) is low and ready to receive the drained liquid from Inlet Separator. 20.4 ENSURE drain valves in the oil line from Inlet Separator are in the CLOSED position. 20.5 CONNECT a hose from ¾” bleed valve on the Inlet Separator drain line and route to the Oily Water system. OPERATING PROCEDURE TRAIN 2 SEPARATION (Inlet Separator, Feed Pre-heat Exchanger and HP Separator) DOCUMENT NO. HBNS-01-PUL-OP-PRC-2005 Revision A3 Date: 18-03-2022 Ref. Page 41 of 59 Sl. # Steps Check Box 20.6 OPEN the ¾” bleed valve to the Oily Water System to release any residual pressure. 20.7 CLOSE the ¾” bleed valve on the drain line. 20.8 ROTATE the spectacle blind to the OPEN position in the Closed Drain system. CAUTION: Ensure that the upstream system is depressurized before rotating the blind to open position. 20.9 OPEN the 3” drain valves (Ball valves) on the oil drain line from the Inlet separator to Closed Drain Drum to empty the Vessel. 20.10 OPEN the 3” globe valve on the common oil drain line and control the flow to Closed Drain Drum. 20.11 MONITOR Closed Drain Drum (V1-801) level at field and DCS. 20.12 On completion of draining, CLOSE the 3” globe valve on oil drain line from the Inlet separator to the Closed Drain Drum (V1-801). 20.13 OPEN the ¾” bleed valve in the Oil drain line from the Inlet separator. 20.14 CHECK that no flow of hydrocarbon fluid to the Oily Water System from the vessel and this confirms the draining is completed. 20.15 CLOSE the ¾” bleed valve on the drain line. 20.16 CLOSE 3” drain valves (Ball valves) on the oil drain line of the Inlet separator. 20.17 DIS CONNECT the hose from ¾” bleed valve. 20.18 ROTATE the spectacle blind to CLOSE position on the Closed Drain. CAUTION: Ensure that the spectacle blind is returned to the closed position before the system is put back into service due to HP/LP interface. Draining of oil from the oil side of V2-101 20.19 APPLY Maintenance bypass for LSLL-V2-101-21 and LSLL-V2-101-22.
