Oil Manual Rev 01

Petrofac International Ltd.
Elf Petroleum Iran

JI-163 Dorood Project Onshore Facilities & e! Plant
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,tart u- and O-eratin. /anual
Oil Processin. Facilities
,tartu- and
O-eratin. /anual
For
Dorood Onshore Facilities & e! Plant
0har. Island
Elf Petroleum Iran
Doc o.1 I" #$ %11 &$$ %%$$$ P"' ($1)
Pre-ared 23
Petrofac International Ltd.
JI-163

"e+ o. Date Pre-ared 23 'erified 23 %--ro+ed 23
01 Feb. 2004 PFI G.Faber P.L. dHaussy
Page 1 of 149
Petrofac International Ltd. Elf Petroleum Iran
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4%5LE OF 6O4E4,
1 I4"OD764IO............................................................................................................ 8
1.1 Project ,co-e......................................................................................................... 9
1.: ;eneral Descri-tion of the Facilit3.......................................................................)
1.2.1 Plant Capactes................................................................................................ 9
1.2.2 !ns"ore Ppelnes............................................................................................ 9
1.2.# !l $reat%ent.................................................................................................. 10
1.2.4 Gas $reat%ent and Co%presson...................................................................11
1.2.& 'ea(ater $reat%ent and In)ecton..................................................................11
1.2.* Produced +ater $reat%ent.............................................................................12
1.2., Flarng 'yste%s.............................................................................................. 12
1.2.- Fuel Gas 'yste%............................................................................................ 12
1.2.9 !t"er .tltes (t"n /e( Plant.......................................................................12
1.2.10 0uldngs......................................................................................................... 1#
1.3 5asis of Desi.n.................................................................................................... 1#
1.#.1 1esgn 0ass for 1orood #..............................................................................14
1.#.2 Flo( 2ates...................................................................................................... 14
1.# Fluid 6om-osition............................................................................................... 16
1.4.1 Producton Flud.............................................................................................. 1*
1.4.2 In)ecton Gas................................................................................................... 1*
1.4.# 'ea(ater........................................................................................................ 1,
1.4.4 Produced +ater.............................................................................................. 1-
1.( ,ite and /eteorolo.ical Data..............................................................................1)
1.&.1 !ns"ore 1esgn Condtons............................................................................19
1.&.2 !ffs"ore 1esgn Condtons............................................................................19
1.&.# Cl%atc Condton........................................................................................... 20
: P"O6E,, DE,6"IP4IO OF OIL P"O6E,,I; ,<,4E/,....................................:1
:.1 O+er+ie!............................................................................................................... :1
:.: Oil Producer =ellheads and Production /anifolds..........................................:1
2.2.1 Introducton on !l Producton.........................................................................21
2.2.2 +ell"eads....................................................................................................... 22
2.2.# Gat"erng 'yste%........................................................................................... 2#
2.2.4 Control 3 4ontorng....................................................................................... 2&
:.3 ,e-arator section................................................................................................ :9
2.#.1 Prncple of 'eparaton of +ater fro% !l n 'eparators..................................2-
2.#.2 1
st
'tage 'eparator......................................................................................... ##
2.#.# $est 'eparator................................................................................................ #,
2.#.4 LP 'eparator Feed Pre"eater5 6C7#1# 8909C91.............................................40
2.#.& 'econd 'tage 'eparator5 1'7#02...................................................................41
2.#.* !l 0ooster Pu%ps5 G: #10 890.....................................................................44
:.# Desalter ,ection................................................................................................... #6
2.4.1 Prncple of operaton...................................................................................... 4*
2.4.2 1esalters5 1' #20 890....................................................................................49
2.4.# +ater Crculaton Pu%ps5 G: #20 890............................................................&2
:.( ,ta2ili>er ,ection................................................................................................. ((
2.&.1 'tabl;er colu%n5 C8 #10...............................................................................&&
2.&.2 'tabl;er 2eboler5 6C #10.............................................................................&*
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:.6 Product crude -um-in.?coolin..........................................................................()
2.*.1 'tabl;ed !l Pu%ps5 G: #11 890..................................................................&9
2.*.2 Feed 9 0otto%s 6<c"anger5 6C #1# 8909C91..................................................&9
2.*.# 'tabl;ed !l cooler5 60 #11 8909C91.............................................................&9
2.*.4 'tabl;ed !l $r% Cooler5 6C #12..................................................................*0
2.*.& !FF 'P6C Pu%ps5 G: #12 890.....................................................................*1
2.*.* !l 6<port lne................................................................................................. *2
:.8 Oil3 =ater 4reatment ,ection.............................................................................6(
:.9 @3drate miti.ation............................................................................................... 8$
2.-.1 Hydrate $endency........................................................................................... ,0
2.-.2 4n%u% Flo( for Producton Lnes................................................................,0
2.-.# 4n%u% Flo( for $est Lnes..........................................................................,#
2.-.4 '"utdo(n Condtons......................................................................................,*
:.) 6hemical Injection for Oil ,3stem......................................................................89
:.1$ @3drod3namic 6onsideration for the Pi-elines and the e! -lant.............91
2.10.1 Hydrodyna%c sluggng..................................................................................-1
2.10.2 '"utdo(n and 2estart....................................................................................-1
3 P"O6E,, 6O4"OL.................................................................................................. 93
3.1 6ontrol ,3stem Descri-tion................................................................................93
#.1.1 Process =producton> Control Functons =PC'>...............................................-#
#.1.2 Process =producton> '"utdo(n Functons =P''>...........................................-#
#.1.# PC'9P'' 'yste% General descrpton...........................................................-#
#.1.4 ''' '.0 '?'$64....................................................................................... -&
#.1.& FI26 3 G8' '.0 '?'$64. =FG'>................................................................-&
#.1.* 6lectrcal /et(or@ 4anage%ent 'yste%........................................................-*
#.1., 1C' $ranng '%ulator..................................................................................-*
#.1.- Aetty PC'9P''............................................................................................... -*
#.1.9 4an 4ac"ne Interface...................................................................................-,
3.: Process 6ontrol arrati+e...................................................................................99
#.2.1 Producton +ell"eads5 Flo( lnes and 4anfolds............................................--
#.2.2 'eparator 'ecton........................................................................................... -9
#.2.# 1esalter.......................................................................................................... 92
#.2.4 'tabl;er......................................................................................................... 94
#.2.& Product pu%png9coolng................................................................................9&
#.2.* !ly +ater $reat%ent 'yste%.........................................................................9*
# %L%"/,* 4"IP,* E,D %D EA7IP/E4 P"O4E64IO..........................................)8
#.1 P6, %larm ,et Point............................................................................................ )8
#.: E,D 4ri- %larm ,et Point..................................................................................1$1
#.3 Fire &;as ,3stem.............................................................................................. 1$(
#.# "elief 'al+es....................................................................................................... 1$6
#.( 5lo! do!n 'al+es.............................................................................................. 1$6
#.6 Emer.enc3 ,hutdo!n 'al+es...........................................................................1$8
( ,%FE4<..................................................................................................................... 1$9
(.1 Plant La3out....................................................................................................... 1$9
(.: Emer.enc3 ,hutdo!n ,3stem..........................................................................11$
&.2.1 !b)ectBe....................................................................................................... 110
&.2.2 'yste% 8rc"tecture...................................................................................... 110
&.2.# General Prncples......................................................................................... 110
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&.2.4 6'1 Control Logc........................................................................................ 112
&.2.& Process '"utdo(n Logc...............................................................................112
&.2.* Cluster '"utdo(n Logc................................................................................114
(.3 Fire & ;as ,3stem............................................................................................. 11(
&.#.1 !b)ectBe....................................................................................................... 11&
&.#.2 F3G 'ub7'yste% 1escrpton.......................................................................11&
&.#.# $"e 'electon and Locaton of F3G 1etectors..............................................11*
&.#.4 Cotng Logc and 8ctons...............................................................................11-
(.# "elief and De-ressurisation ,3stems..............................................................11)
(.( Flare ,3stems..................................................................................................... 11)
(.6 Draina.e and ,-ill 6ontainment.......................................................................11)
(.8 Fire Protection ,3stem...................................................................................... 1:$
&.,.1 8ctBe Fre Protecton....................................................................................120
&.,.2 PassBe Fre Protecton.................................................................................120
(.9 Emer.enc3* E+acuation and "escue BEE"C Philoso-h3.................................1:1
&.-.1 Goals............................................................................................................ 121
&.-.2 6scape 2outes............................................................................................. 121
&.-.# 4uster 8rea.................................................................................................. 122
(.) "adio 6ommunication and P%;% ,3stem.......................................................1:3
&.9.1 General prncples......................................................................................... 12#
&.9.2 $ypes of 8lar%s............................................................................................ 124
&.9.# ProBsons at !ff7stes...................................................................................12&
(.1$ ,afet3 ,i.ns & Personnel Protection...........................................................1:(
&.10.1 'afety 'gns................................................................................................. 12&
&.10.2 Personnel Protecton.................................................................................... 12&
(.11 Emer.enc3 Po!er ,3stem............................................................................1:8
(.1: Li.htin............................................................................................................ 1:9
(.13 oise............................................................................................................... 1:9
6 ,4%"4 7P P"O6ED7"E,........................................................................................ 1:)
8 OPE"%4I; P"O6ED7"E,.....................................................................................13$
9 ,@74DO= P"O6ED7"E,.....................................................................................131
) 4"O75LE,@OO4I;............................................................................................... 13:
).1 /anifolds............................................................................................................ 13:
).: ,e-arators.......................................................................................................... 133
).3 Desalter.............................................................................................................. 13(
1$ %PPEDI6E,......................................................................................................... 138
1$.1 Effluent =ater 5alance..................................................................................138
1$.: ,3stem P&IDs................................................................................................. 139
1$.3 PacDa.e P&IDs............................................................................................... 13)
1$.# ,hut Do!n Lo.ic Dia.ram.............................................................................1#$
1$.( ,%FE 6harts................................................................................................... 1#1
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;lossar3 of 4erms
01C 0lo( 1o(n CalBe
0!P1 0arrels of !l per 1ay
0P1 0arrels per 1ay
0'+ 0asc 'ed%ents and +ater
0+ 0ac@ +as"
0+2! 0rac@s" (ater 2eBerse !s%oss
CIP
100 1ouble 0loc@ and 0leed
1C' 1strbuted Control 'yste%
d9s do(nstrea%
61G 6%ergency 1esel Generator
6'1 6%ergency '"ut 1o(n
FG' Fre 3 Gas 'yste%
F2P Fberglass 2enforced Plastc
F+ Fre +ater
G!2 Gas to !l 2ato
G2P Glass renforced Plastc
G$G Gas $urbne Generator
HP Hg" Pressure
D! Dnoc@ !ut
L8$ Lo(est 8strono%cal $de
LC Loc@ed Closed
L! Loc@ed !pen
LP Lo( Pressure
40+P1 $"ousand 0arrels of +ater per 1ay
4CC 4otor Control Center
%g9l %llgra%s per lter
44I 4an 4ac"ne Interface
44'CF1 4llon 'tandard Cubc Feet per 1ay
4P 4edu% Pressure
/6 /ort" 6ast
/P'H /et PostBe 'ucton Head
/+ /ort" +est
!C' !perator Control 'taton
!2P
PC' Process Control 'yste%
PLC Progra%%able Logc 1agra%
ppb Parts per 0llon
pp% Parts per 4llon =eEuBalent to %g9lt>
P'' Process '"utdo(n 'yste%
P'C Pressure 'afety CalBe
ptb Pounds per $"ousand barrels
2! 2estrcton !rfce
2!C 2e%ote7!perated CalBe
rp% 2eBoluton per 4nute
'1C '"ut 1o(n CalBe
'' 'uspended 'olds
''' 'afety '"utdo(n 'yste%
'+ 'ea +ater
'+2! 'ea(ater 2eBerse !s%oss
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$6G $r76t"ylene Glycol
$'' $otal 'uspended 'olds
.CP .nt Control Panel
.P' .nnterrupted Po(er 'upply
u9s .pstrea%
C1. Csual 1splay .nt

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1 I4"OD764IO
$"e ob)ectBe of t"s docu%ent s to proBde 1orood !lfeld process and eEup%ent
descrpton5 plant protecton and control5 safety gudelnes5 ntal and nor%al start up
procedures5 nor%al and e%ergency s"utdo(n procedures.
$"s %anual s prepared (t" t"e use of pro)ect 9 Bendor docu%ents 9 dra(ngs aBalable at
t"e t%e of preparaton. $"s procedures 9 nstructons proBded n t"s %anual are
consdered as a base docu%ent and s"all be reBe(ed 9 %odfed at ste as dee%ed
necessary to reflect t"e as7bult dra(ngs 9 docu%ents =ncludng Bendor %anuals> and
operatng e<perence ganed durng t"e start up 9 s"utdo(ns and routne operaton.
$"e nstructons 9 procedures descrbed n t"s %anual 1! /!$ supersede t"e Bendor
reco%%ended procedures. Hence Bendor %anuals s"all be cross7referred ("ereBer
reEured.
It s assu%ed t"at t"e facltes are operated and %antaned by Eualfed and traned
personnel of approprate calber. It s reco%%ended t"at all t"e operatng and %antenance
personnel are fa%lar (t" t"e process and operaton before t"ey are actually assgned to
t"e )ob.
6Bery effort "as been ta@en to coBer all possble e%ergences and operatng condtons
reEured n %antanng safe and relable operaton of t"e facltes. Ho(eBer5 t"s %anual
%ay not coBer eac" and eBery step to be ta@en durng nor%al operaton 9 start up 9
s"utdo(n or coBer all possble contngences or e%ergences ("c" %ay occur. $"erefore5
so%e of t"e procedures and operatng condtons stated "ere %ay reEure %odfcaton to
%eet unusual or ot"er e%ergences.
!peratng condtons5 process Barables5 co%poston of nter%edate and product strea%s n
t"e desgn docu%ents 9 dra(ngs of 1orood !lfelds Pro)ect are based upon t"e results of
process desgn for ("c" t s ntended. 8ctual opt%u% operatng condtons5 as deter%ned
by operatng e<perence %ay Bary so%e("at fro% t"e desgn para%eters due to Baratons
n t"e feedstoc@ Eualtes and nnu%erable Barables nBolBed.
,tructure of /anual
8 bref descrpton of Barous sectons of t"e %anual s gBen belo(F
8n oBerBe( of t"e facltes and ts desgn fgures s gBen n secton 1.
1etaled descrpton of all syste%s s gBen n secton 2. 1escrptons of control and
safeguardng aspects are coBered as (ell. Per syste% are also gBen t"e lstngs of
all nstru%ents fro% !peratons Condtons %ontorng
1escrpton of t"e plant control syste%5 44I and Process control narratBes are gBen
n secton #.15#.2 and #.# respectBely
Lstng of all alar% and trp set ponts n PC'5 6'1 and F3G syste%s and of P'Cs
are gBen n secton 4
1escrpton of 'afety P"losop"y and all safety syste%s s gBen n secton &
'tart7up procedures per syste% are gBen n secton *. Procedures are proBded for
ntal start7up5 /or%al start7up5 'tart7up after GP'1 and 'tart7up after 6'1. $"e
oBerall 1orood7# facltes start7up seEuence s gBen at t"e start of t"e secton *.
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!peratons procedures per syste% are gBen n secton ,.
Lstng (t" nor%al operatng Balues and settngs for all nstru%entaton per syste%
are ncluded n t"e operatons procedures n secton ,.
'"utdo(n procedures per syste% are gBen n secton -. $"e oBerall 1orood7#
facltes s"utdo(n seEuence s gBen at t"e start of t"e secton -.
$rouble s"ootng %atrces per syste% are proBded n secton 9.
2eference docu%ents l@e desgn sc"e%atcs are attac"ed n secton 10.
In the s3stem descri-tions some sim-lified sDetches ha+e 2een included as an aid to
EuicDl3 understand the main features of the o+erall s3stem. @o!e+er* it is to 2e
reali>ed that these sDetches are sim-lified and that for full understandin. of the
s3stem al!a3s reference shall 2e made to the latest as-2uilt P&IDFs.
1.1 Project Scope
$"e Pro)ect conssts of deBelop%ent of 1orood !lfelds5 located on D"arg Island n Isla%c
republc of Iran5 called t"e /e( Plant. $"e /e( Plant s on t"e (est sde of t"e Island and s
located at an appro<%ate eleBaton of && %eters fro% t"e %ean sea leBel.
$"e 1orood olfelds produces ol fro% a nu%ber of offs"ore and ons"ore (ells. $"e t(o
e<stng treat%ent facltes on t"e Island5 na%ely 1orood 1 and 1orood 2 proBde t"e
follo(ng t"ree treat%ent stepsF
LEud9gas separaton
!l de"ydraton =treat%ent for salt and 0'+>
!l stablsaton.
$"e pro)ect s e<ecuted t"roug"F
1rllng n7fll producton (ells5
I%ple%entng (ater and assocated gas n)ecton nto t"e feld5 and
Constructng addtonal ol treat%ent plant referred to as G1!2 #H.
$"e ne( facltes ncludeF
1. ,ea!ater Liftin.* 4reatment* and Injection
:. 6ommon Facilities and 7tilities. $"ese ncludeF
Gas s(eetenng and fuel gas dstrbuton5
6lectrcal po(er generaton5
Instru%ent ar5 ntrogen and ot"er utltes5
$ec"ncal buldngs.
3. Oil 4reatment
#. ;as treatment & Injection
(. Onshore Infield Pi-elines

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1.2 General Description of the Facility
1.:.1 Plant 6a-acities
Capactes of t"e /e( Plant (ll beF
In)ected (ater F 2,0 40+P1
In)ected gas F 1#0 44'CF1 I #* JC a%bent te%perature5 or
F 120 44'CF1 I 4& JC a%bent te%perature
1!2 # ol treat%ent F -05000 0!P1
Fuel Gas =HeaBy Case>F 40 44'CF1 =1esgn>
21.9, 44'CF1 =/or%al>5
2#.99 44'CF1 =4a<%u%>
6ffluent (ater dsc"argeF &4- %#9" =/or%al>5 -,4 %#9" =4a<%u%>
/oteF
' F 'tandard condtons at 1&JC and 1 at%.
4 F t"ousand
44 F %llon
CF1 F Cubc feet per day
0!P1 F 0arrels of ol per day
0+P1 F 0arrels of (ater per day
1.:.: Onshore Pi-elines
$"e deBelop%ent ncludes a total of 24 ons"ore (ells located n # clustersK na%ely5 /ort"7
+est5 /ort"76ast and 'out". $"ese (ells are of t"ree typesF
1# no. producton (ells
2 no. gas n)ecton (ells.
9 no. (ater n)ecton (ells5
$"e 1# ne( producton (ells (ll be routed to t"e ne( treat%ent faclty. $"ese are dBded
nto t"e # clusters5 as follo(sF
Cluster /o. of prod. (ells Lengt" of ppelne bet(een cluster and plant
/ort"east Cluster 4 &.& @%
/ort"(est Cluster 4 4.9 @%
'out" Cluster & 1.-& @%
$"e (ells n t"e ndBdual producton clusters are routed to et"er a 10H test "eader or an
1-H producton "eader. 6ac" cluster s proBded (t" dedcated test and producton "eaders
located n t"e /e( Plant. Producton control for eac" (ell s ac"eBed by a %anual c"o@e
BalBe proBded at t"e (ell"ead. $"e producton "eaders fro% eac" cluster are co%bned at
t"e producton %anfold n t"e /e( Plant and feed to t"e frst stage separator. '%larly5 t"e
test "eaders fro% eac" cluster co%bne at t"e test %anfold and enter t"e test separator.
$"e gas s n)ected to t(o gas n)ecton (ells n t"e 'out" Cluster Ba a 10H ppelne and t(o
-H flo( lnes. 8 20H gas lne fro% 1orood 2 faclty s also routed to t"e slug catc"er at t"e
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/e( Plant and supples gas for 1orood # to %a@e7up t"e gas n)ecton and startup
reEure%ents. 8 10H DH64C! gas ppelne s also routed to t"e treat%ent faclty and s
ter%nated at t"e /e( plant.
$"e (ater n)ecton %anfold s dstrbuted nto t(o "eaders routng to t"e nort" and sout" of
t"e Island. !ne 1-H "eader goes to /ort"76ast and /ort"7+est Clusters5 eac" Cluster
"aBng t"ree (ater n)ecton (ells. $"e "eader to t"e sout" of t"e Island s 1*H and s routed
to t"e 'out" Cluster (t" t"ree *H (ater n)ecton branc"es. 8 12H lne s furt"er tapped off
fro% t"e 1*H "eader and ta@es (ater for n)ecton to offs"ore platfor% G.
$"e follo(ng table llustrates t"e nu%ber of producton and n)ecton (ells for eac" ClusterF
Cluster /o. of
Producton
+ell
/o. of +ater
In)ecton +ell
/o. of Gas
In)ecton +ell
/o. of 'pare
'lots
/ort"76ast 4 # 0 2
/ort"7+est 4 # 0 #
'out" & # 2 2
$!$8L 1# 9 2 *
'ea(ater s delBered to t"e /e( Plant for t(o serBcesF
+ater n)ecton5 process coolng5 (as" (ater for crude desalters
Fre (ater.
'ea(ater for (ater n)ecton and processng unts s delBered to t"e /e( Plant fro% t"e sea
s"ore Ba t(o 1-H G2P lnes. $"e fre(ater s delBered t"roug" one 1*H G2P lne.
1.:.3 Oil 4reatment
!ne test separator s proBded for t"e faclty. Producton fro% any gBen (ell can be routed
to t"e $est 4anfold. Fro% t"e $est 4anfold5 producton s routed nto t"e $est 'eparator
=1'7#00>5 ("c" s desgned for t"ree7p"ase separaton. 8ssocated gas s flas"ed fro% t"e
crude ol and routed to t"e 4P %anfold.
Fro% t"e producton %anfold n t"e /e( Plant5 producton s routed to a sngle frst7stage
separator =1'7#01>. $"e 1st 'tage 'eparator (ll operate as a t"ree7p"ase separaton of
ol5 gas and (ater. Produced (ater separated n t"e 1st stage separator (ll be routed to
t"e +ater $reat%ent 'yste% for re%oBal of entraned ol.
$"e separated ol fro% t"e frst stage separator and test separator s co%bned and s routed
to LP separator Feed Pre7"eater =6C7#1#>. In t"s e<c"anger5 t"e nco%ng crude s "eated
by t"e "ot stabl;er botto% flud. $"e "eated crude s t"en routed to LP separator =1'7#02>.
$"e crude fro% LP separator s pu%ped to t"e 1esalter =1'7#20 890>. $(o stages of
desaltng are proBded. $"e nco%ng "ot feed s %<ed (t" recycle (ater fro% t"e second
stage. 4<ed flud s passed t"roug" a %<ng BalBe. 8fter t"e %<ng BalBe5 flud enters 1st
stage 1esalter. $"e ol and (ater s separated under a "g" electrcal potental dfference.
$"e separated (ater s routed to t"e (as" (ater pre"eater and t"en to t"e (ater treat%ent
secton. !l flo(s out fro% t"e top and s routed to t"e ne<t 1esalter.
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'eparated ol fro% t"e frst stage 1esalter s %<ed (t" pre"eated fres" (as" (ater and s
passed t"roug" a %<ng BalBe and t"en routed to t"e second stage 1esalter. 1ry ol
contanng L 0.2M by Bolu%e (ater fro% t"e 6lectrostatc 1e"ydrator5 s routed to t"e top of
t"e 'tabl;er Colu%n. ProBson s also aBalable for 1esalter operaton n bypass and
parallel %ode of operaton.
!l fro% desalter enters t"e top of t"e 'tabl;er Colu%n =C87#10>5 ("ere any Bapor
generated flas"es fro% t"e ol. Capor fro% t"e reboler passes up(ards t"roug" t"e colu%n5
contactng (t" descendng crude on t"e trays and strppng H2' and lg"t "ydrocarbons
fro% t"e crude. 'tabl;ed crude =L ,0pp% H2'> fro% t"e reboler drops nto t"e colu%n
botto%s secton fro% ("ere t s pu%ped out by t"e Crude ol transfer Pu%ps.
1.:.# ;as 4reatment and 6om-ression
Capor fro% t"e frst stage separator =1'7#01> and test separator =1'7#00> flo(s to t"e 4P
slug catc"er =1' #0&>. 4P gas fro% 1orood 2 plant s also connected to t"e slug catc"er.
Gas fro% t"e 4P %anfold feeds to a%ne unt =fuel gas> and 4P gas co%pressor =for gas
n)ecton>.
Co%pressed gas fro% t"e 4P Co%presson 'yste% =$(o stage centrfugal co%pressor> s
routed to t"e 4P boosted gas cooler. !utlet fro% t"s cooler enters 4P boosted gas
scrubber. $"e (et gas s t"en treated n a Gas 1e"ydraton 'yste% for t"e purpose of
re%oBng (ater fro% t"e gas. 4et"od of gas de"ydraton s by absorpton (t" lean $6G.
$"e syste% conssts of glycol contactor and rc" glycol regeneraton. 1e"ydrated gas =1e(
pont 0oC I 410 barg> fro% t"e syste% s routed to t"e HP Co%presson 'yste%. HP
co%presson syste% co%prses t(o7stage turbne drBen centrfugal co%pressor. 1sc"arge
fro% t"e second stage HP co%pressor s sent to t"e gas n)ecton (ells t"roug" t"e n)ecton
gas ppelne I 410 bara
1.:.( ,ea!ater 4reatment and Injection
'ea(ater s used for coolng purpose and n)ecton nto t"e (ater n)ecton (ells n t"e t"ree
/ort"76ast5 /ort"7+est and 'out" Clusters. +ater s transferred fro% t"e sea to an nta@e
staton basn close to t"e s"ore Ba t(o 42 nc" lnes. $"s basn s t"e sea(ater lft staton
and caters to sea(ater lftng pu%ps5 F+ )oc@ey pu%ps and F+ desel pu%ps. $"e lft
staton5 c"lornaton unt and poc@et flters are located close to t"e seas"ore at
appro<%ately #.& @% fro% t"e /e( Plant. $"e c"lornaton unt n)ects c"lorne n to t"e
sea(ater to suppress bologcal gro(t" n t"e lnes and do(nstrea% processng. 'ea(ater
s frst coarse fltered t"roug" poc@et flters to a t"res"old fltraton leBel of 100 %crons.
In t"e /e( Plant5 t"e sea(ater furt"er undergoes fne fltraton Ba pressure dual %eda
fltersK partcles up to 2 %crons are separated n t"ese flters. 4a)or porton of t"e fltered
sea(ater s drectly sent to a 1eaerator to re%oBe dssolBed o<ygen pror to t"e n)ecton to
t"e (ells. 2e%anng porton of t"e fltered (ater s sent to "eat e<c"angers as process
coolng (ater. 'ea(ater returns fro% t"e e<c"angers are also routed to t"e 1eaerator
colu%n. 1eaerated (ater fro% t"e botto% of t"e 1eaerator s fed to t"e %an (ater n)ecton
pu%ps usng sea(ater booster pu%ps.
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1.:.6 Produced =ater 4reatment
Produced (ater fro% t"e 1st and 2nd stage separators5 test separator5 1esalter and
stabl;er colu%n s routed to t"e degassng s@%%er dru% =1'7400>. 8 part of t"e H2' and
C!2 are separated n t"s dru% and t"e separated ol s re%oBed usng s@%%ng deBce.
LEud effluent fro% 1'7400 s sent to flotaton unt =1'7401>5 ("ere ol specfcaton n (ater
s ac"eBed. 2e%anng H2' n t"e (ater s re%oBed n t"e (ater flas" Bessel =1'7402>
("c" operates under Bacuu%. $"e collected crude fro% 1'7400 and 1'7401 s recycled
bac@ to t"e 1esalter pac@age for furt"er treat%ent.
1.:.8 Flarin. ,3stems
$"e /e( Plant "as t"ree flare stac@s on a co%%on derrc@ structureK Hg" Pressure =HP>5
Lo( pressure =LP> and 8cd flares.
$"e HP Flare syste% conssts of one #0H C' (ar% "eader5 one 1*H '' cold "eader5 one HP
Flare D! 1ru%5 t(o Bertcal pu%ps and t"e HP flare tp. $"e condensate fro% HP flare D!
1ru% s pu%ped to 2nd stage separator.
$"e LP Flare syste% conssts of a 20H C' "eader and one LP Flare D! 1ru%. $"e acd
flare syste% ncludes a 12H leadng to a 1*H '' "eader and a Bertcal acd Flare D! 1ru%.
$"e condensate fro% bot" LP and acd flare D! 1ru%s are routed to closed dran.
1.:.9 Fuel ;as ,3stem
Fuel gas for t"e /e( Plant consu%pton5 because of ts "g" H2' content5 s s(eetened
do(n to 200 pp%B n t"e 8%ne s(eetenng unt. $"e s(eetenng s done by contactng (t"
counter current flo( of lean a%ne n t"e a%ne contactor.
$"e s(eetened gas co%ng out fro% top of a%ne contactor s separated nto t(o strea%s.
!ne s t"e lo( pressure =LP> fuel gas gong to LP fuel gas consu%ersK .e.5 flare5 stea%
bolers5 glycol unts5 etc. $"e ot"er strea% s co%pressed n t"e fuel gas co%pressor and
sent to %edu% pressure =4P> fuel gas consu%ersK .e.5 co%pressors turbnes5 (ater
n)ecton pu%ps turbnes5 and turbo generators.
1.:.) Other 7tilities !ithin e! Plant
$"e follo(ng utltes are also generated at ste and aBalable n t"e /e( PlantF
Fres" +ater
0oler Feed (ater5
Lo( pressure stea%5
Po(er generaton5
/trogen5
Instru%ent ar5
1esel5 and
C"e%cal n)ecton syste%s
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Closed dran syste% receBes all process lEud9condensate drans. 8ll non process ols fro%
eEup%ent dran and floor (as"ng of pu%ps pedestals are routed to t"e open dran syste%.
8ll (ater strea%s fro% t"e plant are routed to t"e retenton pt and t"en nto retenton pool
("c" ult%ately flo(s to t"e sea. $"s ncludes treated oly (ater5 non7conta%nated coolng
and flter bac@(as" (ater5 oBerflo( fro% open dran syste%5 ran(ater fro% conta%nated
paBed areas5 etc.

1.:.1$ 5uildin.s
$"e faclty ncludes t"e follo(ng buldngs and all necessary roads5 fences5 etc.
!ffce buldng5
$ec"ncal bloc@ buldng consstng of control roo%5 nstru%ent tec"ncal roo%5
utltes roo%5 and laboratory5
6lectrcal substaton buldng5
+are"ouse and (or@s"op
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1.3 Basis of Design
1.3.1 Desi.n 5asis for Dorood 3
$"e desgn bass for 1orood # s gBen belo(F
1.3.1.1 Feed to New Plant
Co%poston F Producton fro% ne( clusters5 as per 'ecton 1.4.1
of t"s operatng %anual
1esgn G!2 F 1-&07#000 scft9bbl
Flo( 2ate F !l effluent N (ater to produce -05000 '0!P1
+ater Cut F 0 to #0M
+ater Flo( 2ateF #05000 0+P1 =4a<.>
+ater 'alt contentF 2efer to produced (ater c"aracterstcs ='ec. 1.4.4>
4a<. Gas Flo( 2ateF 240 44'CF1 =as total separated gas>
$urndo(n F #05000 0!P1
1esgn CapactyF 110M of flo( rates
1.3.1.2 Oil Prodct Specifications
Producton 2ateF -05000 0!P1 =at 'tandard condtons>
$rue Bapor pressureF L 14.& psa I &0J C
2ed Bapor pressure =2CP>F L -.& psa I 100J F
H2' contentF L ,0 pp% (t.
0'+F L 0.&M Bol.
'alt contentF L *0%g9l =or 20 ptb>
!l pressure at 0attery l%t * bar g %n5
1.3.: Flo! "ates
1.3.2.1 Oil Prodction
$"e desgn flo( rate fro% eac" cluster flo( rate s s"o(n belo(F
Cluster $otal !l N +ater
Flo( 2ate
=1>
5 0P1
+ater Cut Gas Flo( 2ate
=2>
5
44'CF1
/ort"76ast 405000 0 O #0M -0
/ort"7+est 405000 0 O #0M -0
'out" 405000 0 O #0M -0
/otesF
1> 1esgn producton flo( fro% eac" (ell s 125000 0P1 of !l N +ater
2> 1esgn assocated gas flo( fro% eac" (ell s #0 44'CF1
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1.3.2.2 Gas !njection
Gas n)ecton s for only t(o (ells n t"e 'out" Cluster. $"e desgn bass for Gas n)ecton
flo( and condtons are presented n t"e follo(ng tableF
/o%nal Gas In)ecton Flo( 2ate 120 44'CF1
1esgn Gas In)ecton Flo( 2ate 1#0 44'CF1 at #* JC e<ternal te%perature5 or
120 44'CF1 at 4& JC e<ternal te%perature
HP dsc"arge pressure 410 bar abs
+ater 1e( Pont n In)ecton Lnes 0 JC at 410 bar abs
2eEured Pressure at In)ecton +ell"ead 400 bar abs at all flo( rates up to t"e desgn flo(
rate
1esgn Gas In)ecton Flo( 2ate per
+ell
*& 44'CF1
$"e gas lne fro% 1orood 2 to t"e /e( Plant s desgned for a %a<%u% flo( of 200
44'CF1 and a pressure of 11 bar abs at t"e /e( Plant.
1.3.2.3 "ater !njection
Flo( CapactyF
$otal (ater n)ecton nor%al capacty of t"e faclty s 1-00 %#9"r. $"e desgn capacty s
19-0 %#9"rK .e.5 1005000 0+P1 =**0> %#9"r of (ater n)ected nto eac" of t"e #
clusters. $"e desgn (ater n)ecton nto eac" (ell s #05000 0+P1 =199 %#9"r>.
2eEured PualtyF
'ource F 'ea(ater
2esdual partcle F L 2 %% =$"e fne flters s"all re%oBe 9-M of all
partcles greater t"an 2 %crons>
!<ygen Content F L #0 ppb I #, JC
2eEuested PressureF
8t ons"ore n)ecton (ell"eadsF 2#& bar abs.
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1.# Flid $o%position
1.#.1 Production Fluid

$"e co%poston of producton flud for t"ree Gas to !l 2atos =G!2> n %ole percent dry
bass sF
Co%ponent G!2 Q 1-&0 G!2 Q 2400 G!2 Q #000
H
2
' 9.490 ,.*1& ,.,*
C!
2
&.4#& &.1,4 &.2,
C
1
4#.&11 &1.149 &#.*,
C
2
*.*01 -.*02 9.0#
C
#
#.**2 #.-* #.,*
C
4
0.,91 0.,2- 0.,1
nC
4
1.-90 2.014 1.9*
C
&
1.401 0.,,2 0.,0
nC
&
2.,,* 1.0&# 0.9*
nC
*
2.4&& 2.2&* 2.0&
nC
,
2.94# 2.4*, 2.14
nC
-
2.12& 1.,- 1.&&
nC
9
1.4-* 1.249 1.0-
nC
10
1.204 1.011 0.--
C/18 4.1*& 2.,#2 2.2#
C/1C -.1#1 &.&4,& 4.&#
C/12 0.,,2 1.,2*2 1.4&
/
2
1.1*# 0.2&&2 0.2,
Pseudo7co%ponents areF
Pseudo7Co%ponent 4+ 'tandard densty =g9c%#>
C/18 290.94 1.0##
C/1C 2*,.94 0.9&-
C/2 &&-.00 1.090
8Berage te%perature of t"e producton flud s ,0JC. 6st%ated range of flo(ng
te%perature at producton (ell"ead s *079&JC.
1.#.: Injection ;as
$"e co%poston of n)ecton gas5 for t(o lg"t and "eaBy cases at t"e co%pressor
dsc"arge5 n %ole M s s"o(n belo(F
Co%ponent Lg"t Case HeaBy Case
H
2
' *.&1 11.*0
C!
2
*.,4 ,.4,
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Co%ponent Lg"t Case HeaBy Case
C
1
,1.09 *2.,-
C
2
9.#* -.*2
C
#
#.** #.9#
C
4
0.&0 0.*4
nC
4
0.9& 1.##
C
&
0.#* 0.&-
nC
&
0.&* 0.94
nC
*
0.1, 0.29
nC
,
0.0, 0.09
nC
-
0.02 0.02
nC
9
0.0 0.0
nC
10
0.0 0.0
C/18 0.0 0.0
C/1C 0.0 0.0
C/12 0.0 0.0
/
2
0.0 1.,1
1.#.3 ,ea!ater
'ea(ater c"aracterstcs at t"e lft staton s e<pected to "aBe t"e follo(ng propertesF
Property .nt 'ea(ater
pH 77 -.2
$e%perature JC 20 O #&
1ensty @g9%# 10#0
Cscosty cP 1.0
!<ygen ppb 'aturated
ConductBty R%"os9c% I20JC *45000
$1' %g9l 405-40
$'' %g9l 2&
$otal Hardness %g9l as CaC!
#
,5*00
Ca
2N
%g9l as Ca -00
4g
2N
%g9l as 4g 15#*0
'!
4
27
%g9l as '!
4
25--0
'lca %g9l as '!
2
0.1&
/!
#
7
%g9l as /!
#
0.2&
Cl
7
%g9l as Cl 215910
HC!
#
7
%g9l as HC!
#
1,,
!rgancs =$!C> %g9l as C &.*
!l %g9l 1
/a
N
%g9l 12519&
D
N
%g9l 2#0
Fe
2N
%g9l 0.1
0a
2N
%g9l L 0.1
/aCl %g9l as /aCl #05990
'alnty g9l #*.1
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$"e n)ected (ater s e<pected to "aBe t"e sa%e c"aracterstcs as s"o(n aboBe e<cept for
suspended solds and dssolBed gases. 9-M of suspended partcles greater t"an 2 %crons
are re%oBed fro% t"e n)ecton sea(ater. !<ygen and carbon do<de content of t"e (ater
are reduced after "aBng passed t"roug" t"e 1eaerator. !<ygen content of n)ecton
sea(ater s #0 ppb or less.
1.#.# Produced =ater
Produced (ater Eualty used n t"e desgn s s"o(n belo(F
Property .nt Produced
+ater
pH 77 ,.0
ConductBty R%"os9c% I20JC 4,&5#20
$1' %g9l #005100
$'' %g9l 4#0
Ca
2N
%g9l as Ca 195000
4g
2N
%g9l as 4g #5240
'!
4
27
%g9l as '!
4
2-0
Hydrogen
'ulfde
%g9l as H
2
' *&.9
/H
4
N
%g9l as /H
4
L 0.02
'lca %g9l as '!
2
-0
Cl
7
%g9l as Cl 1*15-00
HC!
#
7
%g9l as HC!
#
#22
C!
2
%g9l as C!
2
2*.4
$!C %g9l as C 91
!l %g9l &.2
/a
N
%g9l ,-5100
D
N
%g9l #5#-0
Fe
2N
%g9l L 0.02
'r
2N
%g9l *20
/aCl %g9l as /aCl 19-5**0
'alnty g9l 2*,
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1.& Site and 'eteorological Data
$"e ste data pertan to t"e /e( Plant on D"arg Island.
1.(.1 Onshore Desi.n 6onditions
1.&.1.1 Baro%etric Pressre
0aro%etrc pressure F 1010 % bar
1.&.1.2 (le)ation
/e( plant locaton F around && %
1.&.1.3 *e%peratre
Hg"est %ont"ly aBerage N &JF F #* J C =9*.- J F>
Lo(est %ont"ly aBerage 710JF F 11 J C =&1.- J F>
4a<%u% 1esgn $e%perature F 4* J C
4n%u% 1esgn $e%perature F 11 J C
1.&.1.# +elati)e ,%idity
1esgn 2elatBe Hu%dty F -, M
1.&.1.& +ainfall intensity
1esgn 2anfall Intensty F 19*.& %%9day5 2#* %% 9year
1.&.1.- "ind
1esgn Belocty =for 'tructural 1esgn>F 1#0 @%9"
PreBalng drecton F /ort" +estO/ort"
1.(.: Offshore Desi.n 6onditions
1.&.2.1 Seawater Properties
2efer to 'ecton 1.4.# of t"s operatng %anual.
1.&.2.2 +ainfall
Hg"est 8nnual F #&-.1 %%9year
8Berage 8nnual F 2#*.0 %%9year
4a<%u% 1aly F 19*.& %%9year
4a<%u% 4ont"ly F #2-.1 %%9%ont"
1.&.2.3 .ir *e%peratre
4a<%u% 'urface $e%perature F -0JC =n drect sunlg"t>
4a<%u% 8%bent F 4*JC
4n%u% 8%bent F 0JC
4ean 8%bent F 24JC
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1.&.2.# +elati)e ,%idity
4a<%u% F -,M
1.&.2.& Baro%etric Pressre
!ffs"ore 4n%u% F 991 %bar
!ffs"ore 4a<%u% F 102- %bar
1.(.3 6limatic 6ondition
8r $e%perature Puarter of t"e ?ear =Gregoran>
Frst 'econd $"rd Fourt"
8Berage 4a<%u% #*.1 JC
8Berage 4n%u% 10.&JC
4a<%u% 2ecorded 4*JC
4n%u% 2ecorded 0JC
2elatBe Hu%dty Puarter of t"e ?ear =Gregoran>
4n%u% *& M
4a<%u% 100 M

2anfal Puarter of t"e ?ear =Gregoran>
4a<%u% 1aly 19*.&
%%9day
+nd Puarter of t"e ?ear =Gregoran>
PreBalng +nd
1rectonF /+7/
1esgn Celocty &&.9 @%9"

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: P"O6E,, DE,6"IP4IO OF OIL P"O6E,,I;
,<,4E/,
2.1 O)er)iew
C"apter 2 proBdes t"e reader (t" a descrpton of all facltes aBalable for ol treat%ent to
allo( a clear understandng of t"e operatons. 8 sc"e%atc dagra% s"o(ng t"e oBerall
treat%ent process s gBen n fgure 2.1.1 at t"e end of t"s secton.
2.2 Oil Prodcer "ellheads and Prodction 'anifolds
2efer PF1 I2 40 111 :00 88100 888 0240 '"eet 1
2efer P3I1 I2 40 111 :00 88100 888 1,10 '"eet 1 of #.
I2 40 111 80* 88100 888 1,11 '"eet 1929# of #
I2 40 011 002 88#00 888 1940 '"eet 192 of 2
:.:.1 Introduction on Oil Production
Crude ol fro% t"e ol reserBors flo(s out t"roug" t"e (ell"eads under t"e pressure of t"e
reserBor. !l produced fro% %any reserBors contans produced (ater =For%aton (ater>
and gas. $"e content of gas s nor%ally e<pressed by a factor called as Gas to !l 2ato =or
Gas to lEud rato5 G!29 GL2>. $"e (ater content of ol s e<pressed as (ater cut
percentage =Col. M> of t"e total fluds.
$"e ol co%poston5 Bscosty and specfc graBty =Bscosty and specfc graBty depends on
t"e co%poston of crude> of crude produced fro% ol feld Bares fro% reserBor to reserBor.
Generally t s %ore dffcult to separate (ater fro% crude (t" "g" specfc graBty and
Bscosty.
4he .as associated !ith the crude consists of mainl3 methane* ethane* -ro-ane and
2utane and non-h3drocar2on .ases such as nitro.en* car2on dioGide and -ossi2l3
h3dro.en.
8l%ost all of t"e salt present n t"e crude s contaned n t"e for%aton (ater. $"e produced
(ater n crude s present n t(o for% na%ely free (ater and e%ulsfed (ater. Free (ater s
easly separated n t"e t"ree p"ase separators and n t"e storage tan@ (t"n reasonable
settlng t%e.
$"e co%poston and flo( condton of crude produced fro% t"e (ells s tested perodcally5
by connectng t"e (ells to t"e test separator.
Generally t"e (ater content of t"e crude produced fro% a reserBor ncreases (t" t%e and
to(ards t"e end of t"e lfe of a reserBor t"e (ater content s %a<%u%.
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:.:.: =ellheads
2.2.2.1 "ellhead description
8s part of 1!2 # pro)ect5 1# ne( producton (ells (ll be routed to t"e ne( treat%ent
facltes. $"ese are dBded nto # clusters5 ("c" areF
/ort"east Cluster F 4 (ells
/ort"(est Cluster F 4 (ells
'out" Cluster F & (ells
6ac" (ell s eEupped (t"F
7 Hydraulcally operated do(n "ole safety BalBe ='urface controlled 'ub7surface
'afety BalBe5 'C''C>
7 Hydraulcally operated %aster BalBe ='urface 'afety BalBe5 ''C>
7 4anually operated 4aster BalBe
7 4anually operated (ng BalBe
7 4anually operated (re lne BalBe ='+80 C8LC6>
7 4anually operated C"o@e BalBe.
7 +ell"ead pressure gauge located upstrea% of t"e (ng BalBe
$"e 'C''C and t"e ''C are "ydraulcally actuated and controlled by t"e (ell"ead control
panel and t"ey are nor%ally et"er fully closed or fully opened.
$"e opt%u% poston of t"e %anual c"o@e BalBe (ll be deter%ned durng t"e (ell tests
follo(ng t"e start up. $"ereafter5 t"e c"o@e openng s"all only be c"anged after consultaton
of producton engneerng and geoscences depart%ents.
2.2.2.2 "ellhead $ontrol Panels
2efer to Cendor =Petro Controls> P3I1F I240 1 #04, :00 88000 88D 0010
6ac" +HCP s po(ered by %otor drBen N "and pu%p5 proBdes fal7safe close actuaton of
t"e ''C 3 'C''C5 co%bned (t" (ell s"utdo(n n case fre or "g" 9 lo( flo( lne pressure
and re%ote 6'1. $"e safety cabnet s co%posed of t"e follo(ng te%sF
Ite%s co%%on to t"e ''C and 'C''C crcutsF
7 Flud reserBor (t" ol ndcator
7 6lectrc pu%p (t" standby "and pu%p to generate 2007barg "ydraulc pressure.
8 safety relef BalBe set at #14 barg s proBded on t"e pu%p dsc"arge.
!n t"e control crcutF
7 8 safety relef BalBe set at *.0 barg nstalled on t"e control crcut
7 8 "ydraulc accu%ulator (t" a capacty of 0.& lter pre7c"arged at #.& barg.
!n t"e ''C "ydraulc crcut =HP>F
7 8 "ydraulc accu%ulator (t" a capacty of #2 lter pre7c"arged at 1#& barg5
nstalled on t"e "ydraulc "eader.
7 8 pressure regulator set at &.& barg to energ;e t"e control crcut
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!n t"e 'C''C "ydraulc crcut =CHP>F
7 8n ntensfer to step up t"e pressure fro% 200 barg to #00 barg
7 'afety relef BalBe set at 490 barg
7 8 "ydraulc accu%ulator (t" a capacty of 2.& lters pre7c"arged at 220 barg5
nstalled on "ydraulc "eader.
7 8n ad)ustable t%e delay crcut for seEuental operaton of t"e 'C''C.
:.:.3 ;atherin. ,3stem
2.2.3.1 Description
$"e producton fro% t"e (ell"ead clusters (ll be routed to t"e 1orood7# faclty as per t"e
table belo(F
Production B,our EffluentC
Fro% /ort"east /ort"(est 'out"
$o /e( Plant /e( Plant /e( Plant
/u%ber of Producton (ells 4 4 &
Flo( rate producton lne 40000 bpd 40000 bpd 40000 bpd
Flo( rate test lne 12000 bpd 12000 bpd 12000 bpd
$"e /e( Plant s s;ed for -0000 bopd and #05000 b(pd. 'o all t"e 1# producton (ells
need not produce at t"e sa%e t%e.
8 sc"e%atc of t"e gat"erng syste% s s"o(n n fgure 2.2.1 at t"e end of t"s secton. $"e
(ells n t"e ndBdual clusters are routed to et"er a 10H test "eader or an 1-H producton
"eader. 6ac" cluster s proBded (t" dedcated test and producton "eaders. $"e producton
control for eac" (ell s ac"eBed by a %anual c"o@e BalBe proBded at t"e (ell "ead. $"e
producton "eaders fro% eac" cluster are co%bned at t"e producton %anfold n t"e ne(
plant and feed to t"e frst stage separator. '%larly5 t"e test "eaders fro% eac" cluster are
co%bned at t"e test %anfold and feeds to t"e test separator. 2outng of t"e (ells to a
producton "eader or to a test "eader s ac"eBed by operatng t"e %anual solaton BalBes
proBded.
Corroson n"btor n)ecton proBson s aBalable at clusters. 2efer secton 2.9 for detals on
t"e c"e%cal n)ecton.
2.2.3.2 Pressre Protection
Fgure 2.2.2 at t"e end of t"s secton s"o(s a s%plfed s@etc" of t"e pressure protecton
syste% proBded for t"e gat"erng syste%. 8ll flo(lnes and cluster %anfolds are desgned
for t"e (ell"ead s"ut7n pressure. $"e ppelnes fro% t"e Clusters to t"e /e( Plant and t"e
nlet %anfolds at t"e /e( Plant "aBe a 900S ratng. Protecton of t"e 900S syste% for
oBerpressure s as follo(sF 6ac" flo(lne s proBded (t" a P'HH set at #- barg. +"en t"s
one s actBated t (ll ntate closure of t"e %aster BalBe of t"e concerned (ell"ead Ba t"e
+HCP. 6ac" (ell"ead lnes connectng to t"e cluster %anfold "as an 6'1C. $"ere s
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anot"er 6'1C on t"e co%%on test and producton "eaders orgnatng fro% eac" cluster.
$"ese 6'1Cs are operated on t"e 2 out of # Botng "g" pressure s(tc"es on t"e
producton and test %anfolds =set at ,0 barg>. 2efer secton 4.* for t"e tag nu%bers for t"e
ndBdual (ell "ead 9 flo( lnes.
6'1Cs are nstalled also on t"e test9producton lnes at t"e nlet to t"e ne( plant. 8part fro%
plant 6'1 eBents5 t"ese (ll be actBated by P'HHs on t"e nco%ng pplnes5 set at #-
barg. In order to protect t"e ppelne fro% (ell "ead s"ut n pressure5 safety BalBes are
nstalled on t"e producton and test lnes co%ng fro% clusters =set at 12, barg>. 2efer
secton 4.& for t"e tag nu%bers for t"e P'Cs nstalled on ndBdual cluster test9producton
"eaders co%ng to t"e plant. $"ese P'Cs can relef t"e full cluster producton.
$"e Producton and $est 'eparators "aBe a desgn pressure of 2, barg and are protected
by nlet '1Cs actBated by P'HHs =set at 24 barg> and P'Cs =set at 2, barg>.
In case of a Plant 6'15 t"e 6'1Cs at t"e plant nlet (ll be closed. $"s (ll result n a
pressure rse at t"e (ell"eads5 suc" t"at t"e flo(lne P'HHs (ll close t"e (ell"eads %aster
BalBes. In case of falure to close of one or %ore of t"e (ell"eads5 t"e P'HHs on t"e
Cluster %anfolds (ll close t"e 6'1Cs at nlet and outlet of t"e cluster %anfolds. !nly n
case of t"e co%bned falure to close of t"e 6'1C n t"e sa%e flo(lne as ("ere t"e (ell
faled to close and t"e %anfold outlet 6'1C of t"e %anfold to ("c" t"at flo(lne (as
connected5 t"e P'C at t"e plant nlet (ll be actBated.
2.2.3.3 $lster (SD/ panels
2efer to Cendor =Petro Controls> P3I1sF
'out" Cluster F I240 1 #04, :00 88000 88D 001#
I240 1 #04, :00 88000 88D 0014
I240 1 #04, :00 88000 88D 001&
I240 1 #04, :00 88000 88D 001*
/ort" 6ast ClusterF I240 1 #04, :00 88000 88D 001,
I240 1 #04, :00 88000 88D 001-
I240 1 #04, :00 88000 88D 0019
/ort" +est ClusterF I240 1 #04, :00 88000 88D 0020
I240 1 #04, :00 88000 88D 0021
I240 1 #04, :00 88000 88D 0022
$"e 6'1C panel s po(ered by 2 %otor drBen and one "and pu%p5 proBdes fal safe close
actuaton of t"e 6'1 BalBes5 co%bned (t" (ell s"utdo(n control n case of fre or "g"
ppelne pressure and re%ote 6'1. $"e 6'1C panel s co%posed of t"e follo(ng te%sF
7 $(o %otor drBen N one "and pu%p (t" safety relef BalBes set at #14 barg to
generate 200 barg of "ydraulc pressure to 6'1 BalBes at t"e cluster %anfolds.
7 $(o pressure regulators set at &.& barg to energ;e t"e plot crcut and 6'1
control crcut
7 8 safety relef BalBe set at , barg nstalled on t"e plot crcut and 6'1 control
crcut
7 $(o "ydraulc accu%ulators pre7c"arged at 140 barg5 nstalled on t"e "ydraulc HP
supply "eader.
7 !ne "ydraulc accu%ulator pre7c"arged at # barg5 nstalled on t"e "ydraulc control
"eader.
7 Flud reserBor
7 !l ndcator
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7 Hydraulc control logc for perfor%ng t"e reEured 6'1 actons
2.2.3.# $lster Drainage
2efer P3I1F I24071117:0078810078887&0-#
8 dranage syste% s proBded at eac" cluster for depressur;aton9 dranage of (ell"ead
annulus5 flo(lnes and %anfolds. 8t eac" cluster s nstalled one %ult7purpose dran "eader.
Ca a nu%ber of portable spools t"e Barous Bent and dran ponts on t"e faclty can be
connected to t"s dran "eader. !ne %oble burner unt s proBded t"at can be connected to
t"e dran "eader at any of t"e clusters to allo( for safely dsposal of t"e fluds.
1etaled operatng procedures for t"s syste% are proBded nF !IL9!P90*5 G+ell 8nnulus
0leed ProcedureH and !IL9'190*5 GCluster Isolaton5 1ranage and +ater Flus"ngH.
:.:.# 6ontrol & /onitorin.
2.2.#.1
2.2.#.2
Control and %ontorng sc"edule for t"s secton s as belo(
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4a. o. 43-e Function?Location
PG 1T
0P:::
Pressure Gauge !l Producer +ell C"rst%as tree
PG 1T
1P:::
Pressure Gauge !l Producer +ell lne to cluster
PG 1T
2P:::
Pressure Gauge !l Producer +ell lne depressur;aton connecton
PG 1T
#P:::
Pressure Gauge !l Producer +ell 8nnulus bleed
PG 1T
4P:::
PG 1T
&P:::
P'HH O
1::2P
Pressure '(tc" !l Producer +ell lne to cluster
P'LL O
1::#P
Pressure '(tc" !l Producer +ell lne to cluster
''C 1::1P 4aster CalBe !l Producer +ell
'C''C
1::0P
'ub7 'urface 'afety CalBe !l Producer +ell
$G 17
0::!P
$e%perature Gauge !l Producer +ell lne to cluster
6'1C 10-17
10-*
6%ergency '"utdo(n
BalBes
/ort" east cluster e%ergency s"utdo(n BalBes
6'1C 10917
109*
6%ergency '"utdo(n
BalBes
/ort" (est cluster e%ergency s"utdo(n BalBes
6'1C 11017
110,
6%ergency '"utdo(n
BalBes
'out" cluster e%ergency s"utdo(n BalBes
FG -#,05
-#-05 -#90
Flo( Gauge /65/+ 3 'out" cluster C"e%cal In). Pu%ps
1sc"arge
LG -#,05
-#-05 -#90
LeBel Gauge /65/+ 3 'out" cluster C"e%cal In)ecton $an@
LeBel
L'LL -#,05
-#-05 -#90
LeBel '(tc" /65/+ 3 'out" cluster C"e%cal In)ecton $an@
LeBel s(tc"
PG -#,15
-#-15 -#91
Pressure Gauge /65/+ 3 'out" cluster C"e%cal In). Pu%ps Inlet
Pr.
PG98 -#,05
-#-05 -#90
Pressure Gauge /65/+ 3 'out" cluster C"e%cal In). Pu%ps
1sc"arge Pr.
PG90 -#,05
-#-05 -#90
Pressure Gauge /65/+ 3 'out" cluster C"e%cal In). Pu%ps
1sc"arge Pr.
P'HH
10-&8505C
Pressure Plots HH pressure s(tc" /6 cluster test "eader
P'HH 109&
8505C
Pressure Plots HH pressure s(tc" /+ cluster test "eader
P'HH 110&
8505C
Pressure Plots HH pressure s(tc" sout" cluster test "eader
P'HH
10-*8505C
Pressure Plots HH pressure s(tc" /6 cluster producton "eader
P'HH 109*
8505C
Pressure Plots HH pressure s(tc" /+ cluster producton "eader
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P'HH 110*
8505C
Pressure Plots Fro% !l +ell to Producton Header
P'C -#,05
-#-05 -#90
Pressure 'afety CalBe /65/+ 3 'out" cluster C"e%cal In). Pu%ps
dsc"arge
PG 10#0 Pressure Gauge /ort" 6ast Cluster $est nlet 4anfold
PG 10#2 Pressure Gauge /ort" 6ast Cluster nlet 4anfold
PG 10#* Pressure Gauge /ort" (est Cluster $est nlet 4anfold
PG 10#, Pressure Gauge /ort" +est Cluster nlet 4anfold
PG 10#- Pressure Gauge 'out" Cluster $est nlet 4anfold
PG 10#9 Pressure Gauge 'out" Cluster nlet 4anfold
PG 1000 Pressure Gauge /ort" 6ast Cluster $est Inlet 4anfold
PG 1002 Pressure Gauge /ort" 6ast Cluster Inlet 4anfold
PG 100* Pressure Gauge /ort" +est Cluster $est Inlet 4anfold
PG 100, Pressure Gauge /ort" +est Cluster Inlet 4anfold
PG 100- Pressure Gauge 'out" Cluster $est Inlet 4anfold
PG 1009 Pressure Gauge 'out" Cluster $est Inlet 4anfold
PI 1020 Pressure Indcator /ort" 6ast Cluster $est Inlet 4anfold
PI 102# Pressure Indcator /ort" 6ast Cluster Inlet 4anfold
PI 102* Pressure Indcator /ort" +est Cluster $est Inlet 4anfold
PI 102, Pressure Indcator /ort" +est Cluster Inlet 4anfold
PI 102- Pressure Indcator 'out" Cluster $est Inlet 4anfold
PI 1029 Pressure Indcator 'out" Cluster Inlet 4anfold
P'HH 1010 Cery Hg" Pressure '(tc" /ort" 6ast Cluster $est Inlet 4anfold
P'HH 1012 Cery Hg" Pressure '(tc" /ort" 6ast Cluster Inlet 4anfold
P'HH 101* Cery Hg" Pressure '(tc" /ort" +est Cluster $est Inlet 4anfold
P'HH 101, Cery Hg" Pressure '(tc" /ort" +est Cluster Inlet 4anfold
P'HH 101- Cery Hg" Pressure '(tc" 'out" Cluster $est Inlet 4anfold
P'HH 1019 Cery Hg" Pressure '(tc" 'out" Cluster Inlet 4anfold
P'LL 1010 Cery Lo( Pressure '(tc" /ort" 6ast Cluster $est Inlet 4anfold
P'LL 1012 Cery Lo( Pressure '(tc" /ort" 6ast Cluster Inlet 4anfold
P'LL 101* Cery Lo( Pressure '(tc" /ort" +est Cluster $est Inlet 4anfold
P'LL 101, Cery Lo( Pressure '(tc" /ort" +est Cluster Inlet 4anfold
P'LL 101- Cery Lo( Pressure '(tc" 'out" Cluster $est Inlet 4anfold
P'LL 1019 Cery Lo( Pressure '(tc" 'out" Cluster Inlet 4anfold
P$ 1020 Pressure $rans%tter /ort" 6ast Cluster $est Inlet 4anfold
P$ 102# Pressure $rans%tter /ort" 6ast Cluster Inlet 4anfold
P$ 102* Pressure $rans%tter /ort" +est Cluster $est Inlet 4anfold
P$ 102, Pressure $rans%tter /ort" +est Cluster Inlet 4anfold
P$ 102- Pressure $rans%tter 'out" Cluster $est Inlet 4anfold
P$ 1029 Pressure $rans%tter 'out" Cluster Inlet 4anfold
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2.3 Separator section
2efer PF1F I2 40 011 002 88#00 0240 '"t 001
$"s syste% s desgned to process producton flud fro% ol (ells to produce -05000 bopd of
ol and assocated gas and (ater. $"e secton conssts of t"e follo(ng eEup%ent.
1
st
stage separator =1' #01>
$est 'eparator =1' #00>
LP separator feed pre"eater =6C #1#>
2
nd
stage separator =1' #02>
!l booster pu%ps =G: #10 890>
:.3.1 Princi-le of ,e-aration of =ater from Oil in ,e-arators
$"e functon of a separator s to proBde re%oBal of free gas fro% ol and 9 or (ater at a
specfc pressure and te%perature. 8ll t"e separators n t"e /e( plant are desgned to %eet
t"e follo(ng reEure%entsF
7 LEud %ust be separated fro% gas n a pr%ary separatng secton
7 Gas Belocty %ust be lo(ered to allo( lEuds to drop out
7 Gas %ust be scrubbed t"roug" an effcent de%ster
7 +ater and ol %ust be dBerted to a turbulence7free secton of t"e Bessel
7 LEuds %ust be retaned n t"e Bessel long enoug" to allo( separaton
7 $"e (ater O ol nterface %ust be %antaned
7 +ater and ol %ust be re%oBed fro% t"e Bessel at t"er respectBe outlets
$"e basc prncple of separaton of (ater fro% crude ol n t"e separators s by settlng of t"e
"eaBer p"ase =(ater> under graBtatonal force. In a %<ture of %%scble lEuds t"e "eaBer
p"ase traBels do(n(ards and t"e lg"ter p"ase traBels up(ards.
1ensty of (ater droplets s "g"er t"an t"e densty of ol =contnuous p"ase>. 1ue to t"s
dfference n denstes5 (ater droplets (ll traBel do(n(ards under graBtatonal forces. $"e
"g"er t"e s;e of a (ater droplets5 t"e faster (ll be t"e speed of do(n(ard %oBe%ent.
'%larly ol droplets n (ater p"ase (ll traBel up(ards due to buoyancy forces. $"s
separaton of ol and (ater =free (ater> p"ases by graBtatonal forces due to densty
dfference s called as GraBty settlng.
0ul@ of t"e (ater n t"e ol s easly separated as t enters nto t"e separators. For relatBely
large s;e droplets =aboBe 1000 %crons>5 /e(tons La( gBen belo( goBerns t"e separaton
of (aterK
C
t
Q 1.,4

+"ereF
Ct Q $er%nal Belocty of (ater drop ft9sec
g Q 8cceleraton due to graBty #2.2 ft9sec2
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1P Q 1a%eter of (ater droplet5 ft
(
Q LEud densty lb9ft#
l
Q !l densty lb9ft#
$"e Belocty of s%all (ater droplets =free coalesced (ater> n !l p"ase s goBerned by t"e
follo(ng 'to@es La(.
C
t
Q 14-- < g < 1
p
2

< =
(
V 7
l
U >
+"ereF
Ct K $er%nal Belocty ft9sec
g K 8cceleraton due to graBty #2.2 ft9sec2
1p K 1a%eter of lEud partcle ft
( K LEud densty lb9ft#
l K !l densty lb9ft#
$"e aboBe eEuaton s not applcable to Bery s%all lEud droplet s;es. Cery s%all (ater
droplets =stable e%ulson> n ol e%ulson (ll %oBe (t" e<tre%ely lo( Belocty and t"ey can
not be separated =n reasonable t%e> n nor%al separators.

'eparaton of LEud n Gas
$"e Bertcally do(n(ard Belocty of a lEud partcle n t"e gas p"ase s goBerned by t"e
follo(ng eEuaton.
C
t
Q D
+"ereF
C
t
Q $er%nal Belocty of (ater drop ft9sec
D Q Factor dependng on t"e geo%etry of separator
(
Q LEud densty lb9ft#
l
Q !l densty lb9ft#
$"e aboBe eEuaton s generally used for s;ng t"e Bessel da%eters. For furt"er nfor%aton
refer to 8PI 12 A.
,e-arator ,ections
$"e purpose of a separator s re%oBal of free gas and (ater =t"ree7p"ase separator> fro%
t"e ol. For effcent operaton of t"e gas lEud separators5 t"e follo(ng features are adopted
for t"e desgn of separators.
2efer to t"e attac"ed fgure for t"e detals of t"e separator.
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Inlet de+ice 0Pri%ary separation section1
$"e nlet strea% co%es upon t"e nlet deflector5 ("c" acts as a %o%entu% brea@er =Ite%1>.
Collson of %<ed flo( (t" t"s deflector causes a pr%ary separaton of gas and lEuds.
$"s deBce s consttuted of 2 ro(s of "or;ontal angle bars rectangular to t"e drecton of
t"e flo(. It s fr%ly f<ed to t"e Bessel s"ell n order to support t"e %portant loads and
stresses nduced by t"e %pnge%ent.
,trai.htenin. section 0Secondary separation section1
8fter t"e pr%ary separaton gas flo(s t"roug" t"e coalescng secton consstng of
structured pac@ng =Ite%2>.
$"e purpose of t"s syste% s to cal% and strag"ten t"e gas p"ase furt"er t"e nlet deBce.
4a)or part of lEud droplets contaned n t"e gas flo( s re%oBed by coalescng on t"s
secton.
Purpose of t"s eEup%ent s to brea@ foa%5 as gas s foa%y.
Final .as clean-u- section
8fter t"ese t(o stages of gas7lEud separaton5 t"e gas enters nto t"e fnal gas clean up
secton =Ite% #> n ("c" t"e re%anng lEud droplets are re%oBed by coalescng effect.
8 sngle entry type gas bo<5 ftted (t" one (re %es" de%ster pad consttutes t"s secton.
8 dran tube s located do(nstrea% of t"e de%ster to proBde dranng of t"e coalesced
lEud and s sealed by t"e separator lEud leBel.
$"s secton toget"er (t" t"e Bapour dsengagng space aboBe "g" ol leBel proBdes t"e
lEud carryoBer perfor%ance of t"e separator. LEud carry oBer fro% separators s nor%ally
less t"an 0.1 gallons per 44'CF.
LiEuid accumulator section
$"e lEuds are collected n t"s secton ("ere ol and (ater separaton s obtaned by graBty
settlng.
$o aBod dsturbance n lEud p"ases5 and t"en for effcent separaton5 Bertcal lEud
stablsers =perforated baffles> "aBe been nstalled =Ite% &>.
$"e lEud secton s dBded n t(o co%part%ents by a Bertcal (er =Ite%4>.
In frst co%part%ent ol and (ater are separated by graBty settlng and (ater s re%oBed n
a su%p. $"e second co%part%ent collects t"e ol.
Oil-!ater se-aration com-artment
GraBty separaton s ac"eBed. Free (ater s re%oBed ol and (ater s"all not for% a stable
e%ulson. $"e desgn of t"s co%part%ent s based on 'to@es la( and retenton t%es. For a
gBen retenton t%e5 t"e Bertcal traBel of (ater or ol droplets "aBe to be greater t"an t"e
"eg"t of contnuous p"ase =ol or (ater> to ac"eBe a gBen perfor%ance or separaton
effcency.
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+8$62 !l P"ase
Partcles
!IL
Partcles +ater p"ase !l p"ase

Oil com-artment
$"e second co%part%ent s ol7collectng co%part%ent. !l oBerflo(s t"e Bertcal (er
("ose "eg"t s c"osen5 to aBod any (ater carry oBer n co%part%ent for all t"e specfed
flo( rates. =$"s (er s ad)ustable to co%ply (t" all operatng cases>.
8 Borte< brea@er s located oBer t"e ol and (ater outlet no;;les to preBent gas entran%ent.
Formation of Emulsions
'eparaton of e%ulsfed (ater ta@es a Bery long t%e for settlng and t s not possble to
separate e%ulsfed (ater =stable e%ulsons> n separators. $"e e%ulsfed produced (ater f
not separated at t"e treat%ent plant5 (ll be carred nto t"e e<port lnes and to t"e end
users. 1e%ulsfer c"e%cals are n)ected at t"e upstrea% of t"e separators to (ea@en or
re%oBe t"e effect of e%ulsfyng co%ponents n ol5 so t"at t"e (ater droplets can coalesce
nto larger droplets for separaton n t"e separators.
6%ulson s a stable %<ture =.e.5 s%all (ater droplets do not %oBe do(n (ards under
graBtatonal forces> of t(o %%scble lEuds5 t"e nner p"ase =dspersed> beng dstrbuted
as droplets n t"e contnuos =bul@ part> p"ase. $"e for%aton of stable e%ulson reEures t(o
%%scble lEuds5 agtaton and presence of co%pounds5 ("c" stabl;e t"e e%ulson.
$"e follo(ng are t"e t(o types of e%ulsons t"at can occur n ol (ater separatonK
a> +ater n !l typeK (ater p"ase dspersed as s%all droplets n t"e contnuous !l p"ase.
$"s poses proble%s n t"e separaton of (ater n t"e 'eparators and 'torage $an@s.
b> !l n +ater typeK !l p"ase dspersed as s%all droplets n t"e contnuous (ater p"ase.
$"s poses proble%s n reducng t"e ol concentraton n t"e effluent (ater.
1e%ulsfyng c"e%cals are added for brea@ng t"e stable e%ulsons and coalescng t"e
s%all droplets nto bgger droplets.
1e%ulsfyng c"e%cals "aBe t"e follo(ng c"aracterstcsK
It "as preference to get adsorbed at t"e nterface of t"e (ater droplets.
It can effectBely dsplace t"e co%pounds t"at stabl;e t"e ol (ater nterface.
It can %a@e t"e droplets prone to coalesce =loosen t"e t"c@ nterface fl%>.
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$o dsperse t"e de%ulsfer t"oroug"ly (t" t"e crude t"e de%ulsfer s"all be at any pont
("ere suffcent turbulent condtons e<st n t"e crude flo( to "aBe good %<ng.
8fter re%oBal of t"e e%ulsfyng agent by t"e de%ulsfer c"e%cal5 coalescng of t"e (ater
drops can ta@e place5 or t"e droplets can co%e closer (t" only a t"n5 (ea@ fl%
surroundng eac" drop.
$"e %olecular attracton bet(een drops beco%es stronger t"an before snce less dstance
separates t"e drops. +"en t(o (ater drops co%e nto contact and t"e attracton bet(een
t"e tny (ater drops n e%ulson s strong enoug" to brea@ t"e surroundng fl%5 t"e droplets
coalesce nto larger drops. $"e larger drops of (ater drop do(n by graBty nto t"e (ater
layer and get separated fro% t"e ol. $"s process s @no(n as C"e%cal Coalescng.
6onser+ation of Oil
$"e content of ol t"at can be produced fro% t"e +ell flud s referred as 'toc@ $an@ !l.
'toc@ $an@ !l s n eEulbru% (t" t"e Bapor at at%osp"erc pressure of 1.0# 0ara and at
a%bent te%perature. 8ll of t"e (ater fro% t"e (ell flud s e<cluded n t"e ,tocD 4anD.
If t"e (ell flud contans large a%ount of gaseous co%ponents5 t"e content of stoc@ $an@ ol
(ll be less. 8ll of t"e gas s separated n t"e separators and any re%anng dssolBed gas s
separated n t"e storage $an@s. Ideal separaton of gas fro% crude ol reEures t"at all C&N
co%ponents s"all be retaned n t"e crude. Ho(eBer n t"e nor%al separaton process
consderable a%ount of C& s also lost along (t" t"e Bapor.
/ulti ,ta.e ,e-aration
'ngle stage flas"ng of (ell flud fro% (ell"ead pressure to at%osp"erc pressure (ll result
n e<cess loss of Baluable "ydrocarbon co%ponents fro% t"e crude. 'eparatng =Flas"ng>
t"e (ell fluds n %ult stage separaton (ll %n%;e t"e loss of C& N co%ponents fro% t"e
crude. 4ult stage separaton of crude also supples substantal a%ount of gas at "g"
pressures sutable for do(nstrea% processng.
:.3.: 1
st
,ta.e ,e-arator
2efer to P3I1 I2 40 011 002 1' #01 888 19&1.
Fro% t"e producton %anfold n t"e ne( plant5 producton s routed to a sngle frst stage
separator =1' #01>. $"e 1
st
'tage 'eparator (ll operate as a t"ree7p"ase separator of ol5
gas and (ater. Produced (ater separated n t"e 1
st
stage Inlet 'eparators (ll be routed to
t"e !ly +ater $reat%ent 'yste% for re%oBal of entraned ol.
$"e separated ol fro% t"e frst stage separator and test separator s co%bned and s routed
to LP separator Feed Pre7"eater =6C #1#>. $"e nlet separator5 1' #015 s a t"ree7p"ase
separator5 desgned to process -05000 bpd of ol and #05000 bpd of (ater. It s a "or;ontal
pressure Bessel5 4*00 %% I1 and 1#,00 %% $9$ lengt"5 desgned for 2, barg and 110
o
C.
$"e specfcatons of t"e separator are %entoned n t"e table belo(.
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$"e separator s
desgned to
operate n t(o
dfferent pressure
leBels5 referred to
as HP and LP %odes
of operaton. $"e
operatng
pressure of t"e
separator s 20.,7
barg n HP %ode and
12.4 barg n LP %ode.
$"e Bessel s
nsulated. $"e
Bessel s ftted
(t" leBel
%easure%ents on
et"er sde of t"e
(er5 to proBde
nterface and ol
leBel
%easure%ent
besdes adeEuate
connectons for
pressure
%easure%ent.
In case of Bery lo(
(ater cut5 t %ay
be %possble to
establs" an ol7
(ater nterface
leBel n t"e secton up strea% t"e (er. In t"at case 5 t"e lne to t"e oly (ater lne s"all be
@ept close and t"e *H by7pass lne *H7GH7#0070#97C&2#8 s"all be opened5 suc" t"at t"e
separator effectBely operates as 27p"ase separator only.
Pressure n t"e Bessel s %antaned by controllng t"e Bapor outlet flo( et"er to 'lug
Catc"er =1' #0&> or to HP flare. Flo( %easure%ent s proBded on t"e (ater9Bapor outlet
fro% separator.
$"e separator s eEupped (t" 4H dran connectons on et"er sde of t"e (er and a utlty
connecton to facltate Bessel dranng9purgng. PostBe solaton of t"e separator s
ac"eBed by t"e spectacle blnds9spacers nstalled at Bessel no;;le flanges pror to
%antenance 9 nspecton.
2efer to secton 2.9 for detals on c"e%cal n)ecton to t"e 1
st
stage separator.
'eparator s protected aganst oBerpressure by Pressure safety BalBes =P'C #011 890C1 O
# +or@ng N 1 'tandby>. 1urng e%ergency5 t"e separator can be depressur;ed t"roug"
01C #01*.
Page #9 of 149
6@%"%64E"I,4I6, 7I4 '%L7E
1
st
,4%;E ,EP%"%4O"
G8' 1esgn flo( rate F @g9" 49-9*
!IL 8ctual desgn flo( rate F @g9" -22*9
+8$62 8ctual desgn flo( rate F @g9"
0 O 2,., M
+C
!peratng pressure F HP 4ode barg 20.,
!peratng pressure F LP 4ode barg 12.41
4a<%u% operatng te%perature F JC ,0
4n%u% operatng te%perature F JC 2&
4a<%u% carryoBer of ol n (ater PP4 L 1000
4a<%u% (ater carryoBer n ol M 10.0
4a<%u% slug capacty5 =reEured
bet(een HLL and HHLL>
%# 24
+ater retenton t%e /IL to bot5 %n &
HC retenton t%e /!L to /IL5 %n 10.0
1esgn Pressure5 barg 2,
1esgn $e%perature5
o
C
o
C 110 9 =7> 1&
4ateral of constructon C' =/8C6>
Insulaton
Personnel
Protecton
Internals
Doc. o. I"#$-%11-&$$-%%%$$$-P"'-($1)*
"e+ $1
2efer secton 2.#.1 of t"s %anual for t"e detals of nternals n t"e separator.

01C #01* !n9!ff CalBe =0all $ype> 1' #01 1st 'tage 'eparator 0lo(do(n
06C #01* 'olenod CalBe 1' #01 1st 'tage 'eparator 0lo(do(n
0WH #01* !pen L%t s(tc" 1' #01 1st 'tage 'eparator 0lo(do(n
0WIH #01* Indcator 1' #01 1st 'tage 'eparator 0lo(do(n
0WIL #01* Indcator 1' #01 1st 'tage 'eparator 0lo(do(n
0WL #01* Close L%t '(tc" 1' #01 1st 'tage 'eparator 0lo(do(n
F6 #010 'enor !rfce plate 1' #00 1st 'tage 'eparator Gas !utlet
F6 #011 'enor !rfce plate 1' #00 1st 'tage 'eparator +ater !utlet
FI #011 1P9Cell $rans%tter 1' #00 1st 'tage 'eparator +ater !utlet
FI2 #010 2ecorder 1' #00 1st 'tage 'eparator Gas !utlet
FPI #010 $otal;er 1' #00 1st 'tage 'eparator Gas !utlet
FPI #011 $otal;er 1' #00 1st 'tage 'eparator +ater !utlet
F$ #010 1P9Cell $rans%tter 1' #00 1st 'tage 'eparator Gas !utlet
F$ #011 1P9Cell $rans%tter 1' #00 1st 'tage 'eparator +ater !utlet
H' #012 'elector '(tc" 1uty9'tandby
L8H #01& Hg" 8lar% 1' #01 1st 'tage 'eparator LeBel
L8L #01& Lo( alar% 1' #01 1st 'tage 'eparator LeBel
L18H #012 Hg" 8lar% 1' #01 1st 'tage 'eparator 7 Interface LeBel
L18L #012 Lo( alar% 1' #01 1st 'tage 'eparator 7 Interface LeBel
L1G #010 LeBel Gauge =$ransparent> 1' #01 1st 'tage 'eparator 7 Interface LeBel
L1IC #012 Controller 1' #01 1st 'tage 'eparator 7 Interface LeBel
L1$ #011 1splacer $rans%tter 1' #01 1st 'tage 'eparator 7 Interface LeBel
L1$ #012 1splacer $rans%tter 1' #01 1st 'tage 'eparator 7 Interface LeBel
L1C #012 Control BalBe =Globe $ype> 1' #00 1st 'tage 'eparator +ater !utlet
LG91 #01# LeBel Gauge =$ransparent> 1' #01 1st 'tage 'eparator leBel
LG92 #01# LeBel Gauge =$ransparent> 1' #01 1st 'tage 'eparator leBel
LIC #01& Controller 1' #01 1st 'tage 'eparator LeBel
L$ #014 1ap"rag% 'eal LeBel
$rans%tter =1P>
1' #01 1st 'tage 'eparator leBel
L$ #01& 1ap"rag% 'eal LeBel
$rans%tter =1P>
1' #01 1st 'tage 'eparator LeBel
LC #01& Control BalBe =Globe $ype> 1' #00 1st 'tage 'eparator !ly 6ffluent !utlet
P8H91 #012 Hg" 8lar% 1' #01 1st 'tage 'eparator pressure
P8H92 #012 Hg" 8lar% 1' #01 1st 'tage 'eparator pressure
P8L91 #012 Lo( alar% 1' #01 1st 'tage 'eparator pressure
PG #010 Pressure Gauge 1' #00 1st 'tage 'eparator !ly 6ffluent !utlet
PIC91 #012 Controller 1' #01 1st 'tage 'eparator pressure
PIC92 #012 Controller 1' #01 1st 'tage 'eparator pressure
P'HH #011 Cery Hg" 'afety 1' #01 1st 'tage 'eparator pressure
P'LL #011 Cery Lo( 'afety 1' #01 1st 'tage 'eparator pressure
Page 40 of 149
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P'C98 #011 Pressure 'afety BalBe 1' #01 1st 'tage 'eparator blo(do(n
P'C90 #011 Pressure 'afety BalBe 1' #01 1st 'tage 'eparator 0lo(do(n
P'C9C #011 Pressure 'afety BalBe 1' #01 1st 'tage 'eparator 0lo(do(n
P'C9F #011 Pressure 'afety BalBe 1' #01 1st 'tage 'eparator 0lo(do(n
P$ #011 Pressure $rans%tter 1' #01 1st 'tage 'eparator pressure
P$ #012 Pressure $rans%tter 1' #01 1st 'tage 'eparator pressure
PC91 #012 Control BalBe =Globe $ype> 1' #00 1st 'tage 'eparator $o +ar% HP Flare
PC928 #012 Control BalBe =Globe $ype> 1' #00 1st 'tage 'eparator Gas !utlet $o 1' #0&
PC920 #012 Control BalBe 1' #00 1st 'tage 'eparator Gas !utlet $o 1' #0&
2! #011 2estrcton orfce 1' #01 1st 'tage 'eparator 0lo(do(n
2! #01- 2estrcton orfce 1' #01 1st 'tage 'eparator 0lo(do(n
'1C #010 !n9!ff CalBe =0all $ype> 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'1C #011 !n9!ff CalBe =0all $ype> 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'1C #012 !n9!ff CalBe =0all $ype> 1' #01 1st 'tage 'eparator +ater !utlet
'1C #01# !n9!ff CalBe =0all $ype> 1' #01 1st 'tage 'eparator !ly 6ffluent !utlet
'1C #014 !n9!ff CalBe =0all $ype> 1' #01 1st 'tage 'eparator Gas !utlet = $o 1' #0&>
'1C #01& !n9!ff CalBe =0all $ype> 1' #01 1st 'tage 'eparator !ff 'pec !l I9L
'WH #010 !pen l%t s(tc" 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'WH #011 !pen l%t s(tc" 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'WH #012 !pen l%t s(tc" 1' #01 1st 'tage 'eparator +ater !utlet
'WH #01# !pen l%t s(tc" 1' #01 1st 'tage 'eparator !ly 6ffluent !utlet
'WH #014 !pen l%t s(tc" 1' #01 1st 'tage 'eparator Gas !utlet = $o 1' #0&>
'WH #01& !pen l%t s(tc" 1' #01 1st 'tage 'eparator !ff 'pec !l I9L
'WIH #010 Indcator 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'WIH #011 Indcator 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'WIH #012 Indcator 1' #01 1st 'tage 'eparator +ater !utlet
'WIH #01# Indcator 1' #01 1st 'tage 'eparator !ly 6ffluent !utlet
'WIH #014 Indcator 1' #01 1st 'tage 'eparator Gas !utlet = $o 1' #0&>
'WIH #01& Indcator 1' #01 1st 'tage 'eparator !ff 'pec !l I9L
'WIL #010 Indcator 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'WIL #011 Indcator 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'WIL #012 Indcator 1' #01 1st 'tage 'eparator +ater !utlet
'WIL #01# Indcator 1' #01 1st 'tage 'eparator !ly 6ffluent !utlet
'WIL #014 Indcator 1' #01 1st 'tage 'eparator Gas !utlet = $o 1' #0&>
'WIL #01& Indcator 1' #01 1st 'tage 'eparator !ff 'pec !l I9L
'WL #010 Close L%t '(tc" 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'WL #011 Close L%t '(tc" 1' #01 1st 'tage 'eparator !ly 6ffluent Inlet
'WL #012 Close L%t '(tc" 1' #01 1st 'tage 'eparator +ater !utlet
'WL #01# Close L%t '(tc" 1' #01 1st 'tage 'eparator !ly 6ffluent !utlet
'WL #014 Close L%t '(tc" 1' #01 1st 'tage 'eparator Gas !utlet = $o 1' #0&>
'WL #01& Close L%t '(tc" 1' #01 1st 'tage 'eparator !ff 'pec !l I9L
Page 41 of 149
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"e+ $1
$8L #011 Lo( alar% 1' #00 1st 'tage 'eparator Gas !utlet $e%p
$G #010 $e%perature Gauge 1' #01 1st 'tage 'eparator Gas !utlet
$I #011 Indcator 1' #00 1st 'tage 'eparator Gas !utlet $e%p
$$ #011 $e%perature $rans%tter 1' #00 1st 'tage 'eparator Gas !utlet $e%p
:.3.3 4est ,e-arator
2efer to P3I1 I2 40 011 002 1' #00 888 19&0
!ne test separator s proBded for t"e faclty. In t"e test separator5 t"e producton fro% one
(ell s %etered. Flo( %eters are proBded on ol5 (ater and gas. Producton fro% any gBen
(ell can be routed to t"e $est 4anfold. Fro% t"e $est 4anfold5 producton s routed nto t"e
$est 'eparator =1' #00>5 ("c" s desgned for t"ree7p"ase separaton. 8ssocated gas s
flas"ed fro% t"e ol and routed to t"e 4P %anfold =1' #0&>.
$"e test separator s desgned to "andle 125000 bopd of ol (t" 0 O &0 M (ater cut and #0
44'CF1 of assocated gas. $"e constructon and operaton of t"e Bessel s s%lar to t"e
frst stage separator.
$"e specfcaton of t"e separator s %entoned n t"e table belo(.
6@%"%64E"I,4I6, 7I4 '%L7E
G8'
1esgn flo( rate F @g9" ##2*40
4olecular (eg"t F 2&.01
Gas densty F @g 9 %X 12.2&
Co%presson factor F 0.9*02
Cscosty F cP 0.01#
!IL 8ctual desgn flo( rate F @g9" &4-4*0
+8$62 8ctual desgn flo( rate F @g9" 21*1,2
!peratng pressure F HP 4ode barg 20
!peratng pressure F LP 4ode barg 12.41
4a<%u% operatng te%perature F JC ,0
4n%u% operatng te%perature F JC 2&
4a<%u% (ater carryoBer n ol M 10.0
%# #.&
Page 42 of 149
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6@%"%64E"I,4I6, 7I4 '%L7E
HC retenton t%e /!L to /IL5 %n &
1esgn Pressure5 barg 2,
1esgn $e%perature5
o
C
o
C 110 9 =7> 1&
Insulaton
Personnel
Protecton
Internals 0y Bendor
2efer to secton 2.9 for detals on c"e%cal n)ecton to t"e $est separator.
'eparator s protected aganst oBerpressure by Pressure safety BalBes =P'C #000 890 O 1
+or@ng N 1 'tandby>. 1urng e%ergency5 t"e separator can be depressur;ed t"roug" 01C
#00#.
01C #00# !n9!ff CalBe =0all $ype> 1' #00 $est 'eparator 0lo(do(n
0WH #00# !pen L%t s(tc" 1' #00 $est 'eparator 0lo(do(n
0WIH #00# Indcator 1' #00 $est 'eparator 0lo(do(n
0WIL #00# Indcator 1' #00 $est 'eparator 0lo(do(n
0WL #00# Close L%t '(tc" 1' #00 $est 'eparator 0lo(do(n
F8L #001 Lo( alar% 1' #00 $est 'eparator +ater !utlet
FI2 #002 2ecorder 1' #00 $est 'eparator Gas !utlet
FPI #000 $otal;er 1' #00 $est 'eparator !ly 6ffluent !utlet
FPI #001 $otal;er 1' #00 $est 'eparator +ater !utlet
FPI #002 $otal;er 1' #00 $est 'eparator Gas !utlet
F$ #000 4ass Flo( 4eter =Corols
$ype>
1' #00 $est 'eparator !ly 6ffluent !utlet
F$ #001 1P9Cell $rans%tter 1' #00 $est 'eparator +ater !utlet
F$ #002 1P9Cell $rans%tter 1' #00 $est 'eparator Gas !utlet
H' #00# 'elector '(tc" 1uty9'tandby
L8H #00& Hg" 8lar% 1' #00 $est 'eparator leBel
L8L #00& Lo( alar% 1' #00 $est 'eparator leBel
L18H #002 Hg" 8lar% 1' #00 $est 'eparator7 Interface LeBel
L18L #002 Lo( alar% 1' #00 $est 'eparator7 Interface LeBel
L1G #000 LeBel Gauge =$ransparent> 1' #00 $est 'eparator7 Interface LeBel
L1IC #002 Controller 1' #00 $est 'eparator7 Interface LeBel
L1'LL #001 Cery Lo( 'afety 1' #00 $est 'eparator7 Interface LeBel
L1$ #001 1splacer $rans%tter 1' #00 $est 'eparator7 Interface LeBel
L1$ #002 1splacer $rans%tter 1' #00 $est 'eparator7 Interface LeBel
LG #00# LeBel Gauge =$ransparent> 1' #00 $est 'eparator LeBel
LIC #00& Controller 1' #00 $est 'eparator leBel
L'HH #004 Cery Hg" 'afety 1' #00 $est 'eparator LeBel
L'LL #004 Cery Lo( 'afety 1' #00 $est 'eparator LeBel
Page 4# of 149
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$rans%tter =1P>
1' #00 $est 'eparator LeBel
$rans%tter =1P>
1' #00 $est 'eparator leBel
LC #002 Control BalBe =Globe $ype> 1' #00 $est 'eparator +ater !utlet
LC #00& Control BalBe =Globe $ype> 1' #00 !ly 6ffluent !utlet $o 1' #02
P8H91 #00# Hg" 8lar% 1' #00 $est 'eparator Pressure
P8H92 #00# Hg" 8lar% 1' #00 $est 'eparator !utlet $o +ar% HP Flare
P8L91 #00# Lo( alar% 1' #00 $est 'eparator Pressure
P8L92 #00# Lo( alar% 1' #00 $est 'eparator !utlet $o +ar% HP Flare
PG #000 Pressure Gauge 1' #00 !ly 6ffluent Inlet
PG #001 Pressure Gauge 1' #00 $est 'eparator 0lo(do(n
PIC91 #00# Controller 1' #00 $est 'eparator Pressure
PIC92 #00# Controller 1' #00 $est 'eparator !utlet $o +ar% HP Flare
P$ #002 Pressure $rans%tter 1' #00 $est 'eparator Pressure
P$ #00# Pressure $rans%tter 1' #00 $est 'eparator Pressure
PC91 #00# Control BalBe =Globe $ype> 1' #00 $est 'eparator !utlet $o +ar% HP Flare
PC298 #00# Control BalBe =Globe $ype> 1' #00 $est 'eparator !ly 6ffluent !9L
PC290 #00# Control BalBe =Globe $ype> 1' #00 $est 'eparator !ly 6ffluent !9L
2! #002 2estrcton orfce 1' #00 $est 'eparator !ly 6ffluent Inlet
2! #00* 2estrcton orfce 1' #00 $est 'eparator !ly 6ffluent 0lo(do(n
'1C #000 !n9!ff CalBe =0all $ype> 1' #00 !ly 6ffluent Inlet
'1C #001 !n9!ff CalBe =0all $ype> 1' #00 $est 'eparator !ly 6ffluent Inlet
'1C #004 !n9!ff CalBe =0all $ype> 1' #00 $est 'eparator +ater !utlet
'1C #00& !n9!ff CalBe =0all $ype> 1' #00 $est 'eparator !ly 6ffluent !utlet
'1C #00, !n9!ff CalBe =0all $ype> 1' #00 $est 'eparator Gas !utlet
'WH #000 !pen l%t s(tc" 1' #00 $est 'eparator !ly 6ffluent Inlet
'WH #001 !pen l%t s(tc" 1' #00 $est 'eparator !ly 6ffluent Inlet
'WH #004 !pen l%t s(tc" 1' #00 $est 'eparator +ater !utlet
'WH #00& !pen l%t s(tc" 1' #00 $est 'eparator !ly 6ffluent !utlet
'WH #00, !pen l%t s(tc" 1' #00 $est 'eparator Gas !utlet
'WIH #000 Indcator 1' #00 $est 'eparator !ly 6ffluent Inlet
'WIH #001 Indcator 1' #00 $est 'eparator !ly 6ffluent Inlet
'WIH #004 Indcator 1' #00 $est 'eparator +ater !utlet
'WIH #00& Indcator 1' #00 $est 'eparator !ly 6ffluent !utlet
'WIH #00, Indcator 1' #00 $est 'eparator Gas !utlet
'WIL #000 Indcator 1' #00 $est 'eparator !ly 6ffluent Inlet
'WIL #001 Indcator 1' #00 $est 'eparator !ly 6ffluent Inlet
'WIL #004 Indcator 1' #00 $est 'eparator +ater !utlet
'WIL #00& Indcator 1' #00 $est 'eparator !ly 6ffluent !utlet
'WIL #00, Indcator 1' #00 $est 'eparator Gas !utlet
'WL #000 Close L%t '(tc" 1' #00 $est 'eparator !ly 6ffluent Inlet
'WL #001 Close L%t '(tc" 1' #00 $est 'eparator !ly 6ffluent Inlet
'WL #004 Close L%t '(tc" 1' #00 $est 'eparator +ater !utlet
'WL #00& Close L%t '(tc" 1' #00 $est 'eparator !ly 6ffluent !utlet
'WL #00, Close L%t '(tc" 1' #00 $est 'eparator Gas !utlet
$G #000 $e%perature Gauge 1' #00 $est 'eparator Gas !utlet
Page 44 of 149
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"e+ $1
$I #001 Indcator 1' #00 $est 'eparator Gas !utlet
$$ #001 $e%perature $rans%tter 1' #00 $est 'eparator Gas !utlet
01C #01* !n9!ff CalBe =0all $ype> 1' #01 1st 'tage 'eparator 0lo(do(n
:.3.# LP ,e-arator Feed Preheater* E6-313 %?5?6?D
2efer to P3I1 I2 40 011 002 6C #1# 888 19&# '"eet 1 of 2
LP 'eparator Feed Pre"eater s proBded for "eatng t"e co%bned separated ol fro% Frst
stage and t"e $est 'eparators before sendng to second stage separator. $"e pre"eatng
"as t"e follo(ng adBantages.
7 6n"ances t"e 1egassng n 'econd stage separator
7 Hg" te%perature (ll ncrease t"e actBty of de%ulsfyng agents
7 $"e Bscosty of t"e ol (ll be reduced ("c" reduces t"e drag forces and allo(s
faster settlng Belocty of (ater drops.
7 8 "g"er te%perature (ll (ea@en or rupture t"e fl% bet(een t"e ol 3 (ater drops.
7 Hg"er te%perature ncreases t"e dfference n graBty =or (eg"t> bet(een (ater and
ol so t"at (ater droplets fall faster O t"us decrease t"e settlng t%e.
7 1esalter effcency s %proBed at eleBated te%peratures.
7 Lo(er operatng9desgn pressure of t"e 1esalter.
7 2educng t"e (a<ng tendency of t"e crude at lo( a%bent condtons.
7 Heat conserBaton by reducng t"e "eat load n 'tabl;er reboler.
LP 'eparator Feed Pre7"eater specfcatons are as gBen belo(.
Page 4& of 149
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6@%"%64E"I,4I6, 7I4 '%L7E
LP ,e-arator Feed Preheater* E6-313
Puantty 4 unts n parallel
6<c"anger $ype Plate and Fra%e
'erBce !l 'tabl;ed ol
+or@ng Pressure barg ,.& 1,
1esgn Pressure barg 20 20
!peratng $e%perature
o
C 2# to -1.& 12,.4 to #,.#
1esgn $e%perature
o
C 1*& 1*&
Flo( rate @g9"r &92000 4,4000
1esgn Heat Flo(5 total @cal9" 19.2 < 10
*
4ateral of constructon $tanu%
Insulaton ?es ="eat conserBaton>
In t"s e<c"anger5 t"e "ot stabl;er botto%s outlet co%ng fro% 'tabl;ed ol pu%p G: #11
"eats t"e co%bned ol fro% 1st stage and test separators. $"e "eated ol s t"en routed to
2
nd
stage separator =1' #02>. $"e e<c"anger s proBded (t" dran connectons =to closed
dran> and nlet straners. 1fferental pressure gauges are proBded to %easure YP across
t"e straner5 ("c" n turn (ll ndcate t"e e<tent of sold buld up and reEure%ent of straner
cleanng. 8 bypass lne (t" a control BalBe s proBded for t"e e<c"anger5 ("c" (ll bypass
reEured a%ount of ol to control t"e outlet te%perature of ol gong to t"e second stage
separator.
6C #1# e<c"anger s protected aganst oBerpressur;aton resultng fro% e<c"anger nternal
bloc@age by P'C #1#0 890 nstalled upstrea% of t"e e<c"anger.
$$ #1#4 $e%perature $rans%tter 6C #1# LP separator feed pre"eater !l !utlet
$C #1#4 Control BalBe =0all $ype> 6C #1# LP separator feed pre"eater 0ypass
$IC #1#4 Controller 6C #1# LP separator feed pre"eater !l !utlet
PG #1#2 Pressure Gauge 6C #1#8909C91 LP 'eparator Feed Pre"eater !IL I9L
PG #1## Pressure Gauge 6C #1#8909C91 LP 'eparator Feed Pre"eater !IL !9L
PG #1#1 Pressure Gauge 6C #1#8909C91 LP 'eparator Feed Pre"eater !IL !9L
P1G #1#4871 1fferental Pressure Gauge 6C #1#871 LP 'eparator Feed Pre"eater 1P
P1G #1#& 871 1fferental Pressure Gauge 6C #1# 871 LP 'eparator Feed Pre"eater 1P
:.3.( ,econd ,ta.e ,e-arator* D,-3$:
2efer to P3I1 I2 40 011 002 1' #02 888 19&# '"eet 2 of 2
$"e second stage separator5 1' #025 s a t"ree7p"ase separator5 desgned to process
-05000 bpd of ol and 105000 bpd of (ater to attanng a %a<%u% (ater carryoBer n ol of
Page 4* of 149
Doc. o. I"#$-%11-&$$-%%%$$$-P"'-($1)*
"e+ $1
about #M. It s a "or;ontal pressure Bessel5 #900 %% I1 and 1,200 %% $9$ lengt"5
desgned for 10 barg 110
o
C.
$"e separator operates at &.47barg =LP %ode> and *.4 barg =HP %ode> pressure and -0
o
C
te%perature. $"e Bessel s nsulated. $"e Bessel s ftted (t" leBel brdles on et"er sde of
t"e (er5 to proBde nterface and ol leBel %easure%ent besdes adeEuate connectons for
pressure %easure%ent.
6@%"%64E"I,4I6, 7I4 '%L7E
G8' 1esgn flo( rate F @g9" ##-&-
!IL 8ctual desgn flo( rate F @g9" &442-0
+8$62 8ctual desgn flo( rate F @g9" ,4#1*
!peratng pressure F HP 4ode barg *.41
!peratng pressure F LP 4ode barg &.41
4a<%u% operatng te%perature F JC -2
4n%u% operatng te%perature F JC ,&
4a<%u% (ater carryoBer n ol M #.0
%#
/ot
reEured
HC retenton t%e /!L to /IL5 %n 1&
1esgn Pressure5 barg 10
1esgn $e%perature5
o
C
o
C 110 9 =7> 1&
Insulaton Hot
Internals 0y Bendor
In case of Bery lo( (ater cut5 t %ay be %possble to establs" an ol7(ater nterface leBel n
t"e secton up strea% t"e (er. In t"at case 5 t"e lne to t"e oly (ater lne s"all be @ept close
and t"e #H by7pass lne #H7GH7#0070,170&2#7P s"all be opened5 suc" t"at t"e separator
effectBely operates as 27p"ase separator only.
$"e separator s eEupped (t" dran connectons on et"er sde of t"e (er and a utlty
connecton proBson to facltate Bessel dranng. PostBe solaton of t"e separator s
ac"eBed by t"e spectacle blnds9spacers nstalled at Bessel no;;le flanges pror to
%antenance 9 nspecton. 2efer secton 2.#.1 of t"s %anual for t"e detals of nternals n t"e
separator.
2efer to secton 2.9 for detals on c"e%cal n)ecton to t"e 2
nd
stage separator.
Page 4, of 149
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'eparator s protected aganst oBerpressure by Pressure safety BalBes =P'C #020 890C O 2
+or@ng N 1 'tandby>. 1urng e%ergency5 t"e separator can be depressur;ed t"roug" 01C
#02#.
FI #021 Indcator 1' #02 2nd 'tage 'eparator Gas !utlet
FI2 #020 2ecorder 1' #02 2nd 'tage 'eparator Gas !utlet
FPI #021 $otal;er 1' #02 2nd 'tage 'eparator Gas !utlet
F$ #020 1P9Cell $rans%tter 1' #02 2nd 'tage 'eparator Gas !utlet
F$ #021 1P9Cell $rans%tter 1' #02 2nd 'tage 'eparator Gas !utlet
L8H #02& Hg" 8lar% 1' #02 2nd 'tage 'eparator LeBel
L8L #02& Lo( alar% 1' #02 2nd 'tage 'eparator LeBel
L18H #022 Hg" 8lar% 1' #02 2nd 'tage 'eparator7 Interface LeBel
L18L #022 Lo( alar% 1' #02 2nd 'tage 'eparator7 Interface LeBel
L1G92 #020 LeBel Gauge =$ransparent> 1' #02 2nd 'tage 'eparator7 Interface LeBel
L1IC #022 Controller 1' #02 2nd 'tage 'eparator7 Interface LeBel
L1$ #021 1splacer $rans%tter 1' #02 2nd 'tage 'eparator7 Interface LeBel
L1$ #022 1splacer $rans%tter 1' #02 2nd 'tage 'eparator7 Interface LeBel
L1C #022 Control BalBe =Globe $ype> 1' #02 2nd 'tage 'eparator +ater !utlet
LG91 #02# LeBel Gauge =$ransparent> 1' #02 2nd 'tage 'eparator LeBel
LG92 #02# LeBel Gauge =$ransparent> 1' #02 2nd 'tage 'eparator LeBel
LG9# #02# LeBel Gauge =$ransparent> 1' #02 2nd 'tage 'eparator LeBel
LIC #02& Controller 1' #02 2nd 'tage 'eparator LeBel
$rans%tter =1P>
1' #02 2nd 'tage 'eparator LeBel
$rans%tter =1P>
1' #02 2nd 'tage 'eparator LeBel
P8H #022 Hg" 8lar% 1' #02 2nd 'tage 'eparator Pressure
P8L #022 Lo( alar% 1' #02 2nd 'tage 'eparator Pressure
PG #020 Pressure Gauge 1' #02 2nd 'tage 'eparator
PG #1#1 Pressure Gauge 6C #1#8909C91 LP 'eparator Feed Pre"eater !IL !9L
PG #1## Pressure Gauge 6C #1#8909C91 LP 'eparator Feed Pre"eater !IL !9L
PIC #022 Controller 1' #02 2nd 'tage 'eparator Pressure
P$ #021 Pressure $rans%tter 1' #02 2nd 'tage 'eparator Pressure
P$ #022 Pressure $rans%tter 1' #02 2nd 'tage 'eparator Pressure
PC #022 Control BalBe =Globe $ype> 1' #02 2nd 'tage 'eparator !utlet $o +ar% HP Flare
2! #024 2estrcton orfce 1' #02 2nd 'tage 'eparator 0lo(do(n
'1C #020 !n9!ff CalBe =0all $ype> 1' #02 2nd 'tage 'eparator +ater !utlet
'1C #021 !n9!ff CalBe =0all $ype> 1' #02 2nd 'tage 'eparator !ly 6ffluent !utlet
'WH #020 !pen l%t s(tc" 1' #02 2nd 'tage 'eparator +ater !utlet
'WH #021 !pen l%t s(tc" 1' #02 2nd 'tage 'eparator !ly 6ffluent !utlet
'WIH #020 Indcator 1' #02 2nd 'tage 'eparator +ater !utlet
'WIH #021 Indcator 1' #02 2nd 'tage 'eparator !ly 6ffluent !utlet
'WIL #020 Indcator 1' #02 2nd 'tage 'eparator +ater !utlet
'WIL #021 Indcator 1' #02 2nd 'tage 'eparator !ly 6ffluent !utlet
Page 4- of 149
Doc. o. I"#$-%11-&$$-%%%$$$-P"'-($1)*
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'WL #020 Close L%t '(tc" 1' #02 2nd 'tage 'eparator +ater !utlet
'WL #021 Close L%t '(tc" 1' #02 2nd 'tage 'eparator !ly 6ffluent !utlet
$8H #1#4 Hg" 8lar% 6C #1# LP separator feed pre"eater !l !utlet
$8L #1#4 Lo( alar% 6C #1# LP separator feed pre"eater !l !utlet
$G #020 $e%perature Gauge 1' #02 2nd 'tage 'eparator Gas !utlet
$I #021 Indcator 1' #02 2nd 'tage 'eparator Gas !utlet
$IC #1#4 Controller 6C #1# LP separator feed pre"eater !l !utlet
$$ #021 $e%perature $rans%tter 1' #02 2nd 'tage 'eparator Gas !utlet
$$ #1#4 $e%perature $rans%tter 6C #1# LP separator feed pre"eater !l !utlet
$C #1#4 Control BalBe =0all $ype> 6C #1# LP separator feed pre"eater 0ypass
:.3.6 Oil 5ooster Pum-s* ;& 31$ %?5
2efer to P3I1 I2 40 011 004 G: #10 888 19&4
!l 0ooster Pu%ps5 G: #10 8905 are used to pu%p ol fro% second stage separator to a
pressure reEured for t"e 1esalter. !peraton pressure n t"e 1esalter s"all be at least 1 bar
aboBe t"e second stage separator pressure to aBod any gas release fro% t"e crude.
1fferental pressure generated by t"e pu%p also ncludes t"e pressure drops n %<ng
BalBes and t"e frst stage 1esalter.
!l booster pu%p s a "or;ontal5 sngle stage5 centrfugal process pu%ps (t" a<al splt5
near centerlne %ounted5 bet(een bearng casng (t" closed %peller. 'pecfcaton of t"e
ol booster pu%ps s gBen n t"e table belo(.
6@%"%64E"I,4I6 7I4 '%L7E
Oil 5ooster Pum-s B;& 31$ %?5C
Puantty 2 =1 N 1>
$ype
Hor;ontal5
centrfugal
/u%ber of 'tages 1
'ucton $e%perature
o
C -0
2ated 'ucton Pressure barg &.-7*.-
1sc"arge +or@ng Pressure barg 12.,71#.,
1esgn Flo( 2ate %
#
9"r *-2
+or@ng Flo( 2ate %
#
9"r *20
4n%u% Flo( 2ate %
#
9"r 242
1fferental Head % -#.#
/P'H 2eEured % #.0
/P'H 8Balable % 4.&
4otor 'peed rp% 14*0
4ateral C' =/8C6>
2ated Po(er @+ 22&
4ec"ancal 'eal Flus"ng Plan 8PI 115 *15 &#4
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$"e pu%ps are desgned for contnuous operaton. /or%ally one pu%p s n operaton and
t"e ot"er s a stand by.
$"e pu%ps are ftted (t" double %ec"ancal seals5 ("c" use an e<ternal barrer flud =I'!
CG Gr 1&> suppled fro% an accu%ulator t"at s on contnuous re7crculaton durng t"e
operaton of t"e pu%ps. 0arrer flud pressure s %antaned at least 2 bar aboBe t"e stuffng
bo< pressure.
6ontrol and monitorin. schedule for this section is as 2elo!
F8H #110 Hg" 8lar% G: #10890 !l 0ooster Pu%p Z890Z !utlet Flo(
F8H #21& Hg" 8lar% 1' #20 890 1esalter Inlet Flo(
F8L #110 Lo( alar% G: #10890 !l 0ooster Pu%p Z890Z !utlet Flo(
FIC #110 Controller G: #10890 !l 0ooster Pu%p Z890Z !utlet Flo(
FIC #21& Controller 1' #20 890 1esalter Inlet Flo(
F$ #110 1P9Cell $rans%tter G: #10890 !l 0ooster Pu%p Z890Z !utlet Flo(
F$ #21& 1P9Cell $rans%tter 1' #20 890 1esalter Inlet Flo(
FC #110 Control BalBe =Globe $ype> G: #10890 !l 0ooster Pu%p Z890Z !utlet Flo(
PG #1108 Pressure Gauge G: #108 1sc"arge
PG #1100 Pressure Gauge G: #100 1sc"arge
PG #11#8 Pressure Gauge G: #108 Inlet
PG #11#0 Pressure Gauge G: #100 Inlet
P'HH #1118 Cery Hg" 'afety G: #108 !l 0ooster Pu%p !utlet
P'HH #1110 Cery Lo( 'afety G: #100 !l 0ooster Pu%p !utlet
P'LL #1118 Cery Lo( 'afety G: #108 !l 0ooster Pu%p !utlet
P'LL #1110 Cery Lo( 'afety G: #100 !l 0ooster Pu%p !utlet
P'LL #11#8 Cery Lo( 'afety G: #108 !l 0ooster Pu%p Inlet Pressure
P'LL #11#0 Cery Lo( 'afety G: #100 !l 0ooster Pu%p Inlet Pressure
P$ #1118 Pressure $rans%tter G: #108 !l 0ooster Pu%p !utlet
P$ #1110 Pressure $rans%tter G: #100 !l 0ooster Pu%p !utlet
P$ #11#8 Pressure $rans%tter G: #108 !l 0ooster Pu%p Inlet Pressure
P$ #11#0 Pressure $rans%tter G: #100 !l 0ooster Pu%p Inlet Pressure
Page &0 of 149
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2.# Desalter Section
2efer PF1F I2 40 011 004 88#40 888 0241
:.#.1 Princi-le of o-eration
For effectBe de"ydraton5 t"e follo(ng basc steps are to be follo(edK
7 0rea@ng =destabl;aton> of t"e e%ulson.
7 Coalescence of t"e destabl;ed (ater droplets
7 'eparaton of t"e (ater fro% t"e ol p"ase
In t"e 1esalter follo(ng steps are used for brea@ng t"e stable e%ulsons and coalescng
t"e s%all droplets nto bgger droplets.
7 8ddton of de%ulsfer
7 6lectrostatc coalescng
7 4<ng (t" dluton (ater
8ddton of de%ulsferF
For detaled dscussons on t"e de%ulsfyng c"e%cal acton refer to secton 2.#.
6lectrostatc CoalescngF
+"en an e%ulson of (ater7n7ol passes t"roug" an electrcal feld5 t"e (ater droplets are
polar;ed ("ere as t"e ol p"ase s not affected by t"e electrc feld. 1ue to t"e alternatng
nature of t"e Boltage at Bery "g" freEuency5 t"e (ater droplets are sub)ected to Bery rapd
%oton5 ("c" %a@es t"e droplets to collde (t" eac" ot"er. $"ese collsons of t"e (ater
droplets (ll cause coalescence of t"e tny droplets nto larger (ater droplets. $"e electrc
feld causes destabl;aton of t"e e%ulson.
$"e Boltage dfference across t"e 6lectrodes n t"e 1esalters s of t"e order of 1& to #0 @C.
$"e feld strengt" bet(een t"e electrodes s usually n t"e range of 1 to 2 @C9c%. 1ue to t"e
"g" delectrc strengt" of t"e ol p"ase5 t"e strengt" of current bet(een t"e electrodes s
Bery lo(. $"e feld strengt" =Coltage across t"e electrodes> depends on t"e nature of t"e
e%ulson5 operatng te%perature of t"e 1esalters and t"e nature and Euantty of t"e
de%ulsfyng c"e%cals added.
$"s process of forcng (ater drops to get toget"er under 6lectrc feld s @no(n as
G6lectrostatc CoalescngH. Its acton s s"o(n n t"e s@etc" s"o(n at Fg 2 Page 2&.
7G8H F '"o(s a suspended and unc"arged (ater droplet O ("ere no "g" Boltage electrc
feld s beng appled. $"e s"ape of t"e drop s sp"ercal =round>.
7G0H F '"o(s t"e sa%e drop n an energ;ed electrc feld (t" t"e c"arges beng attracted
to t"e opposte electrode. $"s drop s pulled and elongated by t"e attracton of t"e c"arges
to t"e opposte electrode. Ho(eBer5 t"e drop7center tself does not %oBe as t"e forces are
alternatng Eute rapdly =8C current>
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7GCH F '"o(s t(o drops near one anot"er5 and "aBe an electrcal attracton to eac" ot"er.
$"e negatBe end of t"e droplet s nearest to t"e postBe end of t"e ot"er droplet. 'o t"ere s
an attracton force bet(een t"e t(o droplets5 t"at tends to dra( t"e% toget"er5 t"e "g"
Boltage feld forces t"e t(o droplets to collde. $"en5 t"e outer fl%s =s@n> rupture5 allo(ng
t"e droplets to coalesce =co%bne> nto one larger droplet and falls to t"e botto% because t
s "eaBer t"an ol.
$"e 'peed of Coalescng n 6lectrc 1esalters.
$"e collson and coalescng of (ater droplets bet(een t"e electrcal grds s Bery
rapd due to "g" freEuency =&0 H;> of t"e 8lternatng Current =electrc feld>.

Fg 2. 6FF6C$ !F 6L6C$2IC FI6L1 !/ +8$62 12!PL6$'
%- 76@%";ED =%4E" D"OPLE4 * ELE64"I6%LL< E74"%L
5- 6@%";ED =%4E" D"OPLE4 I ELE64"I6%L FIELD
6- 4=O 6@%";ED =%4E" D"OPLE4, I ELE64"I6 FIELD
Page &2 of 149
7 N 7 N 7 N 7
7 N 7 N 7 N 7 N 7 N 7
N 7 N 7 N 7 N 7 N 7
N7 N 7 N 7 N 7 N 7N 7
N 7 N 7
N 7N 7 N 7
N 7
N 7 N 7 N [
N 7
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7
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N N N 7 7 7
N N N N 7 7 7 N N N 7
7 7 77N N N N 7 7 7
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N 7 7 7
N N 7 7 N N
7 7
7 77 77
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N N N 7 7 7
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N 7 7 7
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7 7
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N NN
N NN
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N NN
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[ [[
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N N N 7 7 7
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7 7 77N N N N 7 7 7
N N N N 7 7 7 N NN 7
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7 7
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77
N NN
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7 77
7
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7 7 7
7
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NNN
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+as" +ater =Fres" +ater> In)ectonF
$"e salt content of t"e crude s essentally present n t"e (ater p"ase. 8ddton of +as"
(ater =Fres" sea(ater> contanng %uc" less concentraton of dssolBed salts (ll dlute t"e
salt concentraton n t"e e%ulsfed (ater and also (ll dssolBe any salt crystals assocated
(t" t"e crude. 'eparaton of t"e dluted (ater fro% t"e crude n 1esalter (ll result n
reducton of t"e salt content of t"e crude. $"e (ater %<ed (t" t"e crude also ta@es a(ay
fne sold partcles dstrbuted n t"e crude.
4<ngF
Proper %<ng and eBenly dstrbuton of n)ected 1e%ulsfer c"e%cal and 1luton (ater
nto t"e e%ulson by %eans of %<ng BalBes (ll ncrease t"e effcency of t"e desaltng
operaton. Ho(eBer e<cess %<ng energy used for %<ng t"e dluton (ater can cause
for%aton of stable e%ulsons. $"s (ll reEure t"at t"e pressure drop across t"e %<ng
BalBe s"all be selected to opt%;e t"e e<tent of %<ng by analy;ng perfor%ance of
1esalter at dfferent pressure drops across t"e %<ng BalBe.
GraBty 'ettlngF
1ensty of (ater droplets s "g"er t"an t"e densty of ol =contnuous p"ase>. 1ue to t"s
dfference n denstes5 (ater droplets (ll traBel do(n(ards under graBtatonal forces. $"e
"g"er t"e s;e of (ater droplets5 t"e faster (ll be t"e speed of do(n(ard %oBe%ent.
'%larly ol droplets n (ater p"ase (ll traBel up(ards due to buoyancy forces. $"s
separaton of ol and (ater =free (ater> p"ases by graBtatonal forces due to densty
dfference s called as GraBty settlng.
$"e (ater droplets coalesced n t"e electrc feld of t"e 1esalter are separated by graBty
settlng n t"e 1esalter.
$"e Belocty of s%all (ater droplets =free coalesced (ater> n !l p"ase s goBerned by t"e
follo(ng 'to@es La(.
C
t
Q 14-- < g < 1
p
2

< =
( 7
V
l
>
+"ereF
C
t
K $er%nal Belocty ft9sec
g K 8cceleraton due to graBty #2.2 ft9sec 2
1
p
K 1a%eter of lEud partcle ft
(
K LEud densty lb9ft#
l
K !l densty lb9ft#
$"e aboBe eEuaton s not applcable to Bery s%all lEud droplet s;es. Cery s%all (ater
droplets =stable e%ulson> n ol e%ulson (ll %oBe (t" e<tre%ely lo( Belocty and t"ey can
not be separated n reasonable t%e.
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:.#.: Desalters* D, 3:$ %?5
2efer to P3I1 I2 40 011 004 .8 #20 888 19&& '"t. 192 of 2
$"e crude fro% 2
nd
stage separator s pu%ped by G: #10 890 to t"e 1esalter =1' #20 890>.
$(o stages of desaltng are proBded. $"e nco%ng "ot feed s %<ed (t" recycle (ater
fro% t"e second stage and t"e oly effluent return fro% t"e oly (ater treat%ent secton.
4<ed flud s passed t"roug" a %<ng BalBe. 8fter t"e %<ng BalBe5 flud enters 1
st
stage
1esalter. $"e ol and (ater s separated under a "g" electrcal potental dfference. $"e
separated (ater s routed to t"e (as" (ater pre"eater =6C #21> and t"en to t"e (ater
treat%ent secton. !l flo(s out fro% t"e top and s t"en sent to t"e second stage 1esalter.
'eparated ol fro% t"e frst stage 1esalter s %<ed (t" pre"eated fres" (as" (ater fro%
1eaerator pu%ped by bac@ up (as" (ater pu%p =G: ,22 890> and s passed t"roug" a
%<ng BalBe and t"en routed to t"e second stage 1esalter. It s also possble to operate
1esalters n bypass and parallel %ode of operaton also. For detals of dfferent %odes of
operaton refer to procedure !IL9!P90# secton 4.#. $"e process guarantee s based on
seres operaton. In ot"er operaton %odes t %ay be reEured to lo(er t"e producton n
order to %eet t"e e<port specfcatons. 'pecfcatons of 1esalter are s"o(n n t"e follo(ng
table.
6@%"%64E"I,4I6 7I4, '%L7E
1esgn Flo( 2ate =8ctual I $9P> 7 !l %
#
9"r *40.0
1esgn Flo( 2ate =8ctual I $9P>
Produced +ater
%
#
9"r
##.0=0ased on &M
(ater cut>
'alt Content n Produced +ater g%9lt 2*,
'alt Content n +as" 'ea(ater g%9lt #*.1
Pac@age $urn 1o(n 2ato M #0
1luton +as" 'ea(ater
*M of total desgn
flo( =4a<.>
!peratng Pressure barg
9.& =frst stage>
- =second stage>
o
C ,& to -0
1esgn Pressure barg 21
1esgn $e%perature
o
C 0 9 110
!utlet 'alnty P$0 20
!utlet 0' 3 + M Col. 0.12
Cessel I1 %% #**0
Cessel $9$ lengt" %% 2**00
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$"e 1esalter operates at -7barg pressure and ,&
o
C te%perature. /ote t"at t"e electrostatc
1esalter s"ould be operated at least 1 bar aboBe t"e second stage separator pressure to
aBod any gas release fro% t"e crude5 ("c" can result n spar@ng (t"n t"e Bessel.
For t"e sa%e reason \H bleed connectons are proBded on t"e no;;les /48909C5 t"e
"g"est ponts of t"e Bessels5 to aBod any accu%ulaton of gas. $"ese bleeds s"all be
per%anently @ept open durng operaton and are connected to d9s t"e control BalBe n t"e
dsc"arge of eac" of t"e 1esalters. In case of parallel operaton of t"e 1esalters5 t"e bleeds
fro% 1esalter 8 s"all be lned up to t"e closed dran.
$"e Bessel s nsulated.
$"e Bessel s ftted (t" leBel nstru%ents to proBde nterface leBel %easure%ent besdes
adeEuate connectons for pressure 9 te%perature %easure%ent. $"e control BalBes on t"e
(ater outlet fro% t"e 1esalters controls nterface leBel n t"e 1esalter.
6ac" 1esalter s proBded (t" a P'C t"at s desgned for fre relef.
$"e 1esalter s eEupped (t" dran connectons and a utlty connecton to facltate Bessel
dranng9purgng. PostBe solaton of t"e 1esalter s ac"eBed by rotatng t"e spectacle
blnds9spades nstalled at Bessel no;;le flanges pror to %antenance 9 nspecton.
$"e Bessel s ftted (t" try7coc@s to establs" t"e ol9(ater nterface leBel durng start up.
$"e electrostatc 1esalter co%prses a set of electrodes postoned nsde t"e Bessel5 nlet 9
outlet dstrbutor "eaders5 a "g" Boltage entrance syste% and a "g" Boltage po(er unt
%ounted e<ternally.
%rran.ement of Electrodes and Inlet ? Outlet Distri2utors
$"e grds of electrodes are located )ust aboBe t"e Bessel centerlne n order to generate t"e
electrostatc feld n t"e entre cross secton of t"e 1esalter. $"e %an electrostatc feld s
generated bet(een t"e grd asse%bly.
$"e nlet "eader s ftted (t" specal dstrbutor located at t"e centerlne of t"e Bessel and
nsurng a calbrated "or;ontal flo( of e%ulson drectly n t"e electrostatc feld. $"s
arrange%ent nsures a perfect dstrbuton of t"e ol 9 (ater %<ture as (ell as a %a<%u%
resdence t%e (t"n t"e electrode area5 t"us %a<%;ng %cron and sub7%cron s;ed
(ater droplet coalescence proBdng effectBe (ater9ol separaton and an effcent
coalescence.
8s t"e (ater 9 ol %<ture enters t"e Bessel belo( t"e electrodes5 t s %%edately sub)ected
to an electrcal feld set up bet(een t"e lo(er G "ot electrodeH and t"e (ater leBel. $"s feld
s strong enoug" to coalesce and separate t"e (ater droplets. In addton5 t"s desgn
en"ances 1esalter operaton durng upset condtons and ("en slugs of (ater are
processed.
$"e crude s collected n a tray5 ("c" s nstalled along t"e top of t"e Bessel. $"us t"e
resdence t%e and eEual;ed flo( dstrbuton of t"e !l 9 (ater e%ulson n t"e "g" Boltage
feld s %a<%;ed due to t"e co%bnaton of electrode arrange%ent and nlet 9 outlet
dstrbuton "eaders.
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Interface dra(7off "eaders are proBded to allo( for re%oBal of any e%ulson t"at %ay "aBe
for%ed at t"e nterface.
8 sc"e%atc of t"e nternal arrange%ent and t"e process no;;les connected to t"ese s
s"o(n belo(F
Internals
1. Crude nlet "eader
2. Crude outlet tray
#. 6ffluent "eader
4. Interface dra(7off "eader
&. 6lectrode grds
/o;;les
/1890 Crude nlet
/2890 Crude outlet
/#8909C91 +ater outlet
/9890 Interface dra(7off
@i.h 'olta.e Entrance ,3stem
$"e "g" Boltage entrance syste% s t"e %ost %portant part of an electrostatc de"ydrator 9
1esalter unt.
It double protects t"e "g" Boltage po(er unt fro% entrance of ol by usng a pressure
bus"ng. 0ot" of t"ese bus"ngs are enclosed n an ol7flled "ousng actng as a buffer ;one.
$"e transfor%er bus"ng and entrance bus"ng can be easly re%oBed and replaced by t"e
re%oBal serBce nspecton blnds n t"e ol7flled bus"ng "ousng.
@i.h 'olta.e Po!er 7nit
$"e electrostatc 1esalter s eEupped (t" t"ree po(er unts. $"e syste% utl;es a non7
oBerloadng 100M %pedance sngle p"aseK "g" Boltage po(er unt desgned to allo( t"e
1esalter to stay n operaton eBen under upset condtons. $"s desgn also guarantees t"at
Boltage s %antaned across t"e lo(er electrode and t"e (ater leBel as (ell as bet(een t"e
t(o electrodes.
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/28 /20
/#8 /98
/18
/#0 /#C /90 /10 /#1
4 #
1
& 2
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1ry ol contanng L 0.2M by Bolu%e (ater fro% t"e 6lectrostatc 1esalter5 s routed to t"e
top of t"e 'tabl;er Colu%n.
:.#.3 =ater 6irculation Pum-s* ;& 3:$ %?5
2efer to P3I1 I2 40 011 004 .8 #20 888 19&& '"t. 1 of 2
In t"e 1esalter syste%5 fres" (as" (ater fro% bac@up (as" (ater pu%ps =G: ,22 890> s
n)ected upstrea% of t"e %< BalBe of t"e second stage 1esalter. $"e separated (ater fro%
2
nd
stage s recycled usng G: #20 890 and n)ected upstrea% of t"e %< BalBe of t"e frst
stage usng 1esalter pu%p. $"s sc"e%e leads to a greater econo%y of (ater usage.
$"e +ater crculaton pu%ps5 G: #20 8905 are "or;ontal5 sngle stage5 centrfugal process
pu%ps (t" radal splt5 centerlne %ounted and closed %peller.
6@%"%64E"I,4I6 7I4 '%L7E
,ta2ili>ed Oil Pum-s B;& 311 %?5C
Puantty 2 =1 N 1>
$ype
Hor;ontal5
centrfugal
/u%ber of 'tages 1
'ucton $e%perature
o
C -0
2ated 'ucton Pressure barg 9.&
1sc"arge +or@ng Pressure barg 1*.4
1esgn Flo( 2ate %
#
9"r &#
+or@ng Flo( 2ate %
#
9"r #*
4n%u% Flo( 2ate %
#
9"r 9
1fferental Head % ,4
/P'H 2eEured % #
/P'H 8Balable % ] &
4otor 'peed rp% 29&0
4ateral 1uple< ''
2ated Po(er @+ 22
4ec"ancal 'eal Flus"ng Plan 8PI 115 *1
$"e pu%ps are ftted (t" %ec"ancal seals5 (t" lea@ detecton syste%. $"e pu%ps are
proBded (t" %n%u% flo( recrculaton (t" auto%atc flo( control BalBe.
F8H #200 Hg" 8lar% 1' #200 1esalter .nt Z0Z +as" +ater Inlet
F8H #204 Hg" alar% G: #20890 1esalter Pu%p !utlet
F8L #200 Lo( alar% 1' #200 1esalter .nt Z0Z +as" +ater Inlet
FIC #200 Controller 1' #200 1esalter .nt Z0Z +as" +ater Inlet
FIC #204 Controller G: #20890 1esalter Pu%p !utlet
F$ #200 1P9Cell $rans%tter 1' #200 1esalter .nt Z0Z +as" +ater Inlet
F$ #204 1P9Cell $rans%tter G: #20890 1esalter Pu%p !utlet
FC #200 Control BalBe =Globe $ype> 1' #200 1esalter .nt Z0Z +as" +ater Inlet
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FC #204 Control BalBe =Globe $ype> G: #20890 1esalter Pu%p 0ypass
L18H #2028 Hg" 8lar% 1' #208 1esalter Z8Z Interface leBel
L18H #2020 Hg" 8lar% 1' #200 1esalter Z0Z Interface leBel
L18L #2028 Lo( alar% 1' #208 1esalter Z8Z Interface leBel
L18L #2020 Lo( alar% 1' #200 1esalter Z0Z Interface leBel
L1G #2048 LeBel Gauge =$ransparent> 1' #208 1esalter 8
L1G #2040 LeBel Gauge =$ransparent> 1' #200 1esalter 0
L1IC #2028 Controller 1' #208 1esalter Z8Z Interface leBel
L1IC #2020 Controller 1' #200 1esalter Z0Z Interface leBel
L1$ #2018 1splacer $rans%tter 1' #208 1esalter Z8Z LeBel
L1$ #2010 1splacer $rans%tter 1' #200 1esalter Z0Z LeBel
L1$ #2028 1splacer $rans%tter 1' #208 1esalter Z8Z Interface leBel
L1$ #2020 1splacer $rans%tter 1' #200 1esalter Z0Z Interface leBel
L1C #2028 Control BalBe =Globe $ype> 6C #21 +as" +ater Pre"eater !utlet
L1C #2020 Control BalBe =Globe $ype> G: #20890 1esalter Pu%ps !utlet
L$ #20#8 1splacer $rans%tter 1' #208 1esalter Z8Z Interface LeBel
L$ #20#0 1splacer $rans%tter 1' #200 1esalter Z0Z Interface LeBel
P1G #210 1fferental Pressure Gauge 6C #21 1P 8cross Inlet
P1G #212 1fferental Pressure Gauge 6C #21 1P 8cross !utlet
P1IC #2018 Controller 1' #208 1esalter Z8^ Inlet 1ff. Pr.
P1IC #2010 Controller 1' #200 1esalter Z0^ Inlet 1ff. Pr.
P1$ #2018 1P $rans%tter 1' #208 1esalter Z8^ Inlet 1ff. Pr.
P1$ #2010 1P $rans%tter 1' #200 1esalter Z0^ Inlet 1ff. Pr.
P1C #2018 Control BalBe =Globe $ype> 1' #208 1esalter Z8^ Inlet 1ff. Pr.
P1C #2010 Control BalBe =Globe $ype> 1' #200 1esalter Z0^ Inlet 1ff. Pr.
PG #2008 Pressure Gauge 1esalter .nt
PG #2000 Pressure Gauge 1esalter .nt
PG #20&8 Pressure Gauge G: #208 1sc"arge
PG #20&0 Pressure Gauge G: #200 1sc"arge
PG #20,8 Pressure Gauge G: #208 'ucton
PG #20,0 Pressure Gauge G: #200 'ucton
'1C #200 !n9!ff CalBe =0all $ype> 1' #208 1esaltng .nt Z8Z +ater !utlet
'1C #201 !n9!ff CalBe =0all $ype> 1' #200 1esaltng .nt Z0Z +ater !utlet
'WH #200 !pen l%t s(tc" 1' #208 1esaltng .nt Z8Z +ater !utlet
'WH #201 !pen l%t s(tc" 1' #200 1esaltng .nt Z0Z +ater !utlet
'WIH #200 Indcator 1' #208 1esaltng .nt Z8Z +ater !utlet
'WIH #201 Indcator 1' #200 1esaltng .nt Z0Z +ater !utlet
'WIL #200 Indcator 1' #208 1esaltng .nt Z8Z +ater !utlet
'WIL #201 Indcator 1' #200 1esaltng .nt Z0Z +ater !utlet
'WL #200 Close L%t '(tc" 1' #208 1esaltng .nt Z8Z +ater !utlet
'WL #201 Close L%t '(tc" 1' #200 1esaltng .nt Z0Z +ater !utlet
$G #2028 $e%perature Gauge 1esalter .nt
$G #2020 $e%perature Gauge 1esalter .nt
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$I #201 Indcator C8 #01 'tabl;aton Colu%n Inlet
$I #214 Indcator 6C #21 +as" +ater Pre"eater (ater !utlet
$'C #210 $"er%al 2elef CalBe 6C #21 0lo(do(n
$$ #201 $e%perature $rans%tter C8 #01 'tabl;aton Colu%n Inlet
$$ #214 $e%perature $rans%tter 6C #21 +as" +ater Pre"eater (ater !utlet
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2.& Sta2ili3er Section
2efer PF1F I240 011 002 88#00 888 0240 '"t 002
:.(.1 ,ta2ili>er column* 6% 31$
2efer to P3I1 I2 40 011 00# 88 #10 888 19&*
!l fro% desalter enters t"e top of t"e 'tabl;er Colu%n =C8 #10>5 ("ere any Bapor
generated flas"es fro% t"e ol. Capor fro% t"e reboler passes up(ards t"roug" t"e colu%n5
contactng (t" descendng crude on t"e trays and strppng H
2
' and lg"t "ydrocarbons
fro% t"e crude. Capacty of 'tablser s -05000 0P1 of stablsed ol producton.
'tablser colu%n "as t(o pass BalBe trays. !peratng pressure at t"e top of t"e colu%n s
1.& barg. Colu%n s desgned to %eet t"e H
2
' and 2CP specfcatons on t"e stablsed
crude.
!ff7gas fro% t"e colu%n5 ("c" contans %anly H2' and lg"t "ydrocarbons5 s Bented
drectly to t"e LP flare for dsposal under pressure control. H
2
' content n t"e stablsed ol
(ll be less t"an ,0 PP4. 2ed Bapor pressure =2CP> L -.& psa I 100J F.
$"e 'tabl;er Colu%n5 C8 #105 s a dstllaton colu%n (t" 2& nos. BalBe trays5 desgned for
#.& bar g 9 full Bacuu% and 1*&
o
C. $"e colu%n s da%eter s #1007%% and t"e "eg"t of t"e
tray secton s 24100 %%.
$"e colu%n s proBded (t" a c"%ney tray belo( t"e 2&
t"
tray to collect t"e ol flo(ng do(n
and route to stabl;er reboler. Increased da%eter at t"e botto% proBdes reEuste surge
capacty for t"e 'tabl;ed ol pu%ps =G: #11 890>. 8 s@rt proBded at t"e botto% of t"e
colu%n proBdes t"e necessary /P'H reEure%ent for t"e pu%ps. $"e lEud outlets are
proBded (t" Borte< brea@ers.
ProBson s aBalable =2H connecton on botto% of t"e colu%n> for utlty connecton for
purgng9cleanng durng %antenance 9 start up.
$"e stabl;er s proBded (t" (ater dra(7off. LEud dra(7off s proBded on tray 2 and t"e
(ater s routed to a collecton pot. $"e top of t"e collecton pot s connected bac@ to t"e
colu%n =bet(een tray 1 and 2> Ba a balancng lne. $"e collecton pot s proBded (t"
nterface leBel control =L1IC7#109>. $"e separated (ater s routed to t"e oly (ater pac@age
under nterface leBel control.
6@%"%64E"I,4I6 7I4, '%L7E
1esgn Flo( 2ate 7 !l 0P1 -05000
$urndo(n 0P1 245000 =#0 M>
!peratng Pressure barg
1.& =top>
1.- =botto%>
o
C
,*.* =top>
14#.2 =botto%>
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6@%"%64E"I,4I6 7I4, '%L7E
1esgn Pressure barg #.& 9 full Bacuu%
1esgn $e%perature
o
C 0 9 1*&
Crude outlet H
2
' content pp% L ,0
Crude !utlet 2CP I 100 JF psa -.&
$ype of trays $(o pass BalBe
/u%ber of trays 2&
Colu%n I1 %% &000 9 #100
Colu%n $9$ "eg"t %% 24100
:.(.: ,ta2ili>er "e2oiler* E6 31$
2efer to P3I1 I2 40 011 00# 88 #10 888 19&*
$"e 'tabl;er 2eboler5 6C #105 s a "or;ontal5 %ult pass =tube sde> flo(5 s"ell and tube
"eat e<c"anger proBded to %eet t"e "eat duty reEure%ents of 'tabl;er colu%n. $"e crude
fro% t"e colu%n flo( by graBty to t"e s"ell sde of t"e reboler. Part of t"e crude s
Bapor;ed n t"e reboler by t"e "eat suppled by stea% flo(ng on t"e tube sde.
6@%"%64E"I,4I6 7I4 '%L7E
,ta2ili>ation 6olumn "e2oiler BE6 31$C $ube sde '"ell sde
Puantty 1
6<c"anger $ype $648 0D.
'erBce 'tea% !l
1esgn Pressure barg 12.05 FC 4.05 FC
+or@ng Pressure barg ,.0 1.-
o
C 1,0 9* to 14#
1esgn $e%perature
o
C 192 1*&
1esgn Heat Flo( 2ate @cal9" 1&.* < 10
*
Flo( rate @g9"r #1902 &#1200
4ateral
C'
=/8C6>
C'
=/8C6>
F8H #10& Hg" 8lar% 6C #10 'tabl;aton Colu%n 2eboler 'tea% flo(
F8L #10& Lo( alar% 6C #10 'tabl;aton Colu%n 2eboler 'tea% flo(
FIC #10& Controller 6C #10 'tabl;aton Colu%n 2eboler 'tea% flo(
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FPI #101 $otal;er C8 #10 'tabl;aton Colu%n Gas !utlet to Flare Flo(
F$ #101 1P9Cell $rans%tter C8 #10 'tabl;aton Colu%n Gas !utlet to Flare Flo(
F$ #10& 1P9Cell $rans%tter 6C #10 'tabl;aton Colu%n 2eboler 'tea% flo(
FC #10& Control BalBe =0all $ype> 6C #10 'tabl;aton Colu%n 2eboler 'tea% flo(
FC #21& Control BalBe =0all $ype> C8 #10 'tabl;aton Colu%n !ly 6ffluent Inlet
L8H #101 Hg" 8lar% C8 #10 'tabl;aton Colu%n leBel
L8H #10, Hg" 8lar% 6C #10 'tabl;aton Colu%n 2eboler leBel
L8L #101 Lo( alar% C8 #10 'tabl;aton Colu%n leBel
L8L #10, Lo( alar% 6C #10 'tabl;aton Colu%n 2eboler leBel
L18L #109 Lo( alar% C8 #10 'tabl;aton Colu%n leBel
L1G #102 LeBel Gauge =$ransparent> C8 #10 +ater !utlet
L1HL #109 Hg" alar% C8 #10 'tabl;aton Colu%n leBel
L1IC #109 Controller C8 #10 'tabl;aton Colu%n leBel
L1$ #109 1splacer $rans%tter C8 #10 'tabl;aton Colu%n leBel
L1C #109 Control BalBe =Globe $ype> C8 #10 'tabl;aton Colu%n +ater !9L
LG #10& LeBel Gauge =2efle<> 'tabl;aton Colu%n
LG #10* LeBel Gauge =2efle<> 'tea% Condensate
LG91 #100 LeBel Gauge =2efle<> 'tabl;aton Colu%n
LG92 #100 LeBel Gauge =2efle<> 'tabl;aton Colu%n
LG9# #100 LeBel Gauge =2efle<> 'tabl;aton Colu%n
LIC #101 Controller C8 #10 'tabl;aton Colu%n leBel
LIC #10, Controller 6C #10 'tabl;aton Colu%n 2eboler leBel
$rans%tter =1P>
C8 #10 'tabl;aton Colu%n leBel
L$ #10# 1ap"rag% 'eal LeBel
$rans%tter =1P>
C8 #10 'tabl;aton Colu%n leBel
L$ #10, 1ap"rag% 'eal LeBel
$rans%tter =1P>
6C #10 'tabl;aton Colu%n 2eboler leBel
L$ #10- 1ap"rag% 'eal LeBel
$rans%tter =1P>
6C #10 'tabl;aton Colu%n 2eboler leBel
LC #10, Control BalBe =Globe $ype> 6C #10 2eboler !utlet ='tea% Condensate>
P8H #101 Hg" 8lar% C8 #10 'tabl;aton Colu%n Gas !utlet to Flare Pr.
P8H #104 Hg" 8lar% C8 #10 'tabl;aton Colu%n 2eboler !ly 6ffluent Inlet
P8H #10, Hg" 8lar% 6C #10 'tabl;aton Colu%n 2eboler 'tea% 'upply
P8L #101 Lo( alar% C8 #10 'tabl;aton Colu%n Gas !utlet to Flare Pr.
P8L #104 Lo( alar% C8 #10 'tabl;aton Colu%n 2eboler !ly 6ffluent Inlet
P8L #109 Lo( alar% C8 #10 'tabl;aton Colu%n Pressure
PG #100 Pressure Gauge C8 #10 'tabl;aton Colu%n
PG #10# Pressure Gauge C8 #10 !ly 6ffluent Inlet
PG #10& Pressure Gauge 6C #10 'tabl;aton Colu%n 2eboler
PG #10* Pressure Gauge 6C #10 'tea% 'upply
PI #104 Indcator C8 #10 'tabl;aton Colu%n 2eboler !ly 6ffluent Inlet
PI #10, Indcator 6C #10 'tabl;aton Colu%n 2eboler 'tea% 'upply
PI #109 Indcator C8 #10 'tabl;aton Colu%n Pressure
PIC #101 Controller C8 #10 'tabl;aton Colu%n Gas !utlet to Flare Pr.
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P$ #101 Pressure $rans%tter C8 #10 'tabl;aton Colu%n Gas !utlet to Flare Pr.
P$ #102 Pressure $rans%tter C8 #10 'tabl;aton Colu%n Gas !utlet
P$ #104 Pressure $rans%tter C8 #10 'tabl;aton Colu%n 2eboler !ly 6ffluent Inlet
P$ #10, Pressure $rans%tter 6C #10 'tabl;aton Colu%n 2eboler 'tea% 'upply
P$ #109 Pressure $rans%tter C8 #10 'tabl;aton Colu%n Pressure
PC #101 Control BalBe =Globe $ype> C8 #10 'tabl;aton Colu%n Gas !utlet
'1C #100 !n9!ff CalBe =0all $ype> C8 #10 'tabl;aton Colu%n !l !utlet
'1C #10& !n9!ff CalBe =Gate CalBe
$ype>
6C #10 'tabl;aton Colu%n 2eboler 'tea% 'upply
'WH #100 !pen l%t s(tc" C8 #10 'tabl;aton Colu%n !l !utlet
'WH #10& !pen l%t s(tc" 6C #10 'tabl;aton Colu%n 2eboler 'tea% 'upply
'WIH #100 Indcator C8 #10 'tabl;aton Colu%n !l !utlet
'WIH #10& Indcator 6C #10 'tabl;aton Colu%n 2eboler 'tea% 'upply
'WIL #100 Indcator C8 #10 'tabl;aton Colu%n !l !utlet
'WIL #10& Indcator 6C #10 'tabl;aton Colu%n 2eboler 'tea% 'upply
'WL #100 Close L%t '(tc" C8 #10 'tabl;aton Colu%n !l !utlet
'WL #10& Close L%t '(tc" 6C #10 'tabl;aton Colu%n 2eboler 'tea% 'upply
$8H #100 Hg" 8lar% C8 #10 'tabl;aton Colu%n $e%p
$8H #10# Hg" 8lar% C8 #10 'tabl;aton Colu%n Gas !utlet $e%p
$8L #100 Lo( alar% C8 #10 'tabl;aton Colu%n $e%p
$8L #110 Lo( alar% 6C #10 'tabl;aton Colu%n 2eboler Gas !utlet
$G #10& $e%perature Gauge 6C #10 'tabl;aton Colu%n 2eboler Gas !utlet
$G #10* $e%perature Gauge 6C #10 'tea% 'upply
$I #10# Indcator C8 #10 'tabl;aton Colu%n Gas !utlet $e%p
$I #110 Indcator 6C #10 'tabl;aton Colu%n 2eboler Gas !utlet
$IC #100 Controller C8 #10 'tabl;aton Colu%n $e%p
$$ #100 $e%perature $rans%tter C8 #10 'tabl;aton Colu%n $e%p
$$ #10# $e%perature $rans%tter C8 #10 'tabl;aton Colu%n Gas !utlet $e%p
$$ #104 $e%perature $rans%tter 6C #10 'tabl;aton Colu%n 2eboler Gas !utlet
$$ #110 $e%perature $rans%tter 6C #10 'tabl;aton Colu%n 2eboler Gas !utlet
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2.- Prodct crde p%ping4cooling
2efer PF1F I240 011 002 88#00 888 0240 '"t 002
:.6.1 ,ta2ili>ed Oil Pum-s* ;& 311 %?5
2efer to P3I1 I2 40 011 00& G: #11 888 19&,
$"e 'tabl;ed !l Pu%ps5 G: #11 890 are used to pu%p stabl;ed ol fro% t"e stabl;er
botto% to Product tan@ far% t"roug" a seres of e<c"angers =6C #1#5 60 #11 and 6C #12>
and e<port ol ppelne. $"e pu%ps are "or;ontal5 sngle stage5 centrfugal process pu%ps
(t" radal splt5 near centerlne %ounted casng (t" a closed %peller.
6@%"%64E"I,4I6 7I4 '%L7E
Puantty 2 =1 N 1>
$ype
Hor;ontal5
centrfugal
/u%ber of 'tages 1
'ucton $e%perature
o
C 144 =4a<.>
2ated 'ucton Pressure barg 2.1-
1sc"arge +or@ng Pressure barg 1&.&&
1esgn Flo( 2ate %
#
9"r *&&
+or@ng Flo( 2ate %
#
9"r &9&
4n%u% Flo( 2ate %
#
9"r 200
1fferental Head % 1*,
/P'H 2eEured % #
/P'H 8Balable % 4.&
4otor 'peed rp% 14-0
4ateral C' =/8C6>
2ated Po(er @+ 4-0
4ec"ancal 'eal Flus"ng Plan 8PI 115 &# 45 *1
CG Gr. 1&> suppled fro% an accu%ulator t"at s on contnuous re7crculaton durng t"e
bo< pressure.
:.6.: Feed ? 5ottoms EGchan.er* E6 313 %?5?6?D
Please refer to secton 2.#.4 for a detaled descrpton of t"s eEup%ent.

:.6.3 ,ta2ili>ed Oil cooler* E5 311 %?5?6?D
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2efer to P3I1 I2 40 011 00& 88 #10 888 19&-
'tabl;ed crude fro% reboler s partally cooled n t"e LP 'eparator Feed Pre7"eater and
t"en cooled do(n to *0
o
C by t"e stabl;ed !l Cooler before routng to t"e 'tabl;ed ol
tr% cooler.
$"e 'tabl;ed !l cooler specfcatons are aBalable n t"e follo(ng table.
6@%"%64E"I,4I6 7I4 '%L7E
,ta2ili>ed Oil cooler* E5 311
Puantty 4 unts n parallel
6<c"anger $ype Induced draft ar cooler
'erBce 'tabl;ed !l
1esgn Pressure barg 20.0
+or@ng Pressure barg 1&.#
o
C 129.& nlet 3 *0 outlet
1esgn $e%perature
o
C 1*0
1esgn Heat Flo( 2ate @cal9" 1&.& < 10
*
Flo( rate @g9"r 4,4000
4ateral C'
$e%perature control
Caryng fan blade ptc" N
by7pass
Fan %otor po(er @+ #0
6ac" cooler "as t(o fans and one of t"e% s "aBng auto%atc ptc" control for controllng
t"e outlet te%perature of t"e ol. In addton5 t"ere s a bypass lne (t" control BalBe5 ("c"
(ll auto%atcally bypass t"e reEured lEud flo( to ac"eBe t"e correct outlet te%perature.
0ot" ptc" control and bypass control s part of t"e sngle splt range loop. $"ere are
Bbraton s(tc"es proBded for eac" cooler fan.
:.6.# ,ta2ili>ed Oil 4rim 6ooler* E6 31:
2efer to P3I1 I2 40 011 00& 88 #10 888 19&-
'tabl;ed ol tr% cooler s used to cool t"e stabl;ed ol to fnal e<port te%perature of 4&
o
C.
$"e e<c"anger specfcaton s gBen belo(.
6@%"%64E"I,4I6, 7I4 '%L7E
,ta2ili>ed Oil 4rim 6ooler* E6 31:
Puantty 1
6<c"anger $ype Plate and Fra%e
'erBce !l 'ea (ater
1esgn Pressure barg 20 20
+or@ng Pressure barg 14.* &
o
C *0 to 4& #& to 4&
1esgn $e%perature
o
C 100 -0
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6@%"%64E"I,4I6, 7I4 '%L7E
1esgn Heat Flo( 2ate5 total @cal9" #.1 < 10
*
Flo( rate @g9"r 4-&000 #00000
4ateral $tanu%
6<c"anger outlet te%perature of ol s controlled by auto%atcally t"rottlng t"e sea(ater
crculaton t"roug" t"e e<c"anger. 'ucton straners are proBded on bot" nlets to preBent
any sold partcles accu%ulatng nsde t"e e<c"anger. 1fferental pressure gauges =1PG
#12# 3 1PG #124> are proBded to %easure t"e pressure drop across e<c"anger9straner.
:.6.( OFF ,PE6 Pum-s* ;& 31: %?5
2efer to P3I1 I2 40 011 00& 88 #10 888 19&-
!ff7spec pu%ps G: #12 890 are used to recycle t"e product9off spec crude bac@ to t"e 1
st
stage separator. Capacty of t"s pu%p s about 10M of t"e total ol producton capacty. $"e
specfcaton of t"e pu%p s as follo(s.
$"e pu%ps are "or;ontal5 sngle stage5 centrfugal process pu%ps (t" radal splt5
centerlne %ounted casng (t" a closed %peller.
6@%"%64E"I,4I6 7I4 '%L7E
Puantty 2 =1 N 1>
$ype
Hor;ontal5
centrfugal
/u%ber of 'tages 1
'ucton $e%perature
o
C 4&
2ated 'ucton Pressure barg 1#.1
1sc"arge +or@ng Pressure barg 2&.*#
1esgn Flo( 2ate %
#
9"r *&.&
+or@ng Flo( 2ate %
#
9"r &9.&
4n%u% Flo( 2ate %
#
9"r 9.9
1fferental Head % 14&.4
/P'H 2eEured % #
/P'H 8Balable % ] &
4otor 'peed rp% 29&0
4ateral C' =/8C6>
2ated Po(er @+ ,&
4ec"ancal 'eal Flus"ng Plan 8PI 115 &# 45 *1
CG Gr. 1&> suppled fro% an accu%ulator t"at s on contnuous re7crculaton durng t"e
bo< pressure.
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Pu%ps are proBded (t" %n%u% flo( protecton t"roug" a recycle fro% t"e pu%p
dsc"arge to stabl;er.
:.6.6 Oil EG-ort line
2efer to P3I1 I2 40 011 00& 88 #10 888 19&-
$"e stabl;ed ol s sent to t"e $an@ far% usng #.&7@% long5 14H ppelne. $"e lne s
proBded (t" 6'1C #11& at /e( plant end and 6'1C #1#* at $an@ far% end for solatng
t"e lne durng e%ergency. 'pecfcatons of t"e ppelne s as gBen belo(. $"ere s a
turbne type flo( %eter at t"e ne( plant for t"e %eterng of ol e<port
6@%"%64E"I,4I6 7I4 '%L7E
,ta2ili>ed Oil EG-ort Line
Ppe s;e Inc" 14
Ppe $"c@ness %% 4.-
Lengt" of ppe % #&00
o
C 4&
1esgn Pressure barg 21
1esgn $e%perature
o
C 100
1esgn Flo( 2ate %
#
9"r *&&
4ateral C' =/8C6>
$e%porary pggng faclty proBded for Pre7co%%ssonng5 Co%%ssonng and 1e(aterng
of t"e ppelne. Lne s protected aganst t"er%al e<panson by t"er%al relef BalBes =$'C
#11* 3 $'C #11,>.
F8H #109 Hg" 8lar% G: #11890 'tabl;ed !l pu%p !utlet
F8L #109 Lo( alar% G: #11890 'tabl;ed !l pu%p !utlet
FIC #109 Controller G: #11890 'tabl;ed !l pu%p !utlet
F$ #109 1P9Cell $rans%tter G: #11890 'tabl;ed !l pu%p !utlet
FC #109 Control BalBe =Globe $ype> G: #11890 'tabl;ed !l pu%p !utlet
PG #11-8 Pressure Gauge G: #118 'tabl;ed !l Pu%p Z8Z !9L
PG #11-0 Pressure Gauge G: #110 'tabl;ed !l Pu%p Z0Z !9L
PG #1208 Pressure Gauge G: #118 'tabl;ed !l Pu%p Z8Z I9L
PG #1200 Pressure Gauge G: #110 'tabl;ed !l Pu%p Z0Z I9L
P$ #11,8 Pressure $rans%tter G: #118 'tabl;aton !l Pu%p Inlet Pressure
P$ #11,0 Pressure $rans%tter G: #110 'tabl;aton !l Pu%p Inlet Pressure
P$ #1198 Pressure $rans%tter G: #118 'tabl;aton !l Pu%p !utlet Pressure
P$ #1190 Pressure $rans%tter G: #110 'tabl;aton !l Pu%p !utlet Pressure
C$ #1208 to C$
#12,8
Cbraton $rans%tter G: #118 'tabl;aton !l Pu%p Z8Z Pu%p94otor
Cbraton
C$ #1#00 to C$
#1#,0
Cbraton $rans%tter G: #110 'tabl;aton !l Pu%p Z0Z Pu%p94otor
Cbraton
F8H #11& Hg" 8lar% 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
F8L #11& Lo( alar% 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
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F6 #11* !rfce Plate G: #12890 !ff spec !l Pu%p !utlet
FI #11& Indcator 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
FIC #11* Controller G: #12890 !ff spec !l Pu%p !utlet
FPI #11& $otal;er 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
F$ #11& $urbne Flo( 4eter 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
F$ #11* 1P9Cell $rans%tter G: #12890 !ff spec !l Pu%p !utlet
FC #11* Control BalBe =Globe $ype> !ff 'pec !l $o C8 #10
H' #110 'elector '(tc" H' dBerts LIC #101 !9P $o LC9C #101
LC98 #101 Control BalBe =0all $ype> 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
LC90 #101 Control BalBe =0all $ype> 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
LC9C #101 Control BalBe =Globe $ype> !ff 'pec !l $o 1' #01
P1G #12# 1fferental Pressure
Gauge
6C #12 1P 8cross !l 'upply
P1G #124 1fferental Pressure
Gauge
6C #21 1P 8cross +ater 2eturn
PG #1218 Pressure Gauge G: #128 !ff 'pec Pu%p 1sc"arge
PG #1210 Pressure Gauge G: #120 !ff 'pec Pu%p 1sc"arge
PG #1228 Pressure Gauge G: #128 !ff 'pec Pu%p 'ucton
PG #1220 Pressure Gauge G: #120 !ff 'pec Pu%p 'ucton
P$ #11& Pressure $rans%tter 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
'1C #114 !n9!ff CalBe =0all $ype> 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
'6C #114 'olenod CalBe 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
'WH #114 !pen l%t s(tc" 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
'WIH #114 Indcator 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
'WIL #114 Indcator 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
'WL #114 Close L%t '(tc" 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
$8H #111 Hg" 8lar% 60 #11 'tabl;ed !l Cooler !utlet
$8H #11& Hg" 8lar% 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
$8H #119 Hg" 8lar% 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
$8L #111 Lo( alar% 60 #11 'tabl;ed !l Cooler !utlet
$8L #11& Lo( alar% 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
$I #119 Indcator 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
$IC #111 Controller 60 #11 'tabl;ed !l Cooler !utlet
$IC #11& Controller 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
$$ #111 $e%perature $rans%tter 60 #11 'tabl;ed !l Cooler !utlet
$$ #11& $e%perature $rans%tter 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
$$ #11* $e%perature $rans%tter 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
$$ #119 $e%perature $rans%tter 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
$C #111 Control BalBe =0all $ype> 60 #11 'tabl;ed !l Cooler 0ypass
$C #11& Control BalBe =0all $ype> 6C #12 'tabl;ed !l $r% Cooler +ater 2eturn
$W98 #111 Carable Fan 0lade Ptc" 60 #11 'tabl;ed !l Cooler Fan 1a%per
$W9C #111 Carable Fan 0lade Ptc" 60 #11 'tabl;ed !l Cooler Fan 1a%per
PG #12&8 Pressure Gauge G: #128 !ff 'pec Pu%p seal
PG #12&0 Pressure Gauge G: #120 !ff 'pec Pu%p seal
PI #1248 Indcator G:#128 !ff spec Pu%p 4ec"ancal 'eal pressure
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PI #1240 Indcator G:#120 !ff spec Pu%p 4ec"ancal 'eal pressure
P$ #11*8 Pressure $rans%tter 6<stng Lne to and fro% 'torage $an@
P$ #11*0 Pressure $rans%tter 6<stng Lne to and fro% 'torage $an@
P$ #11*C Pressure $rans%tter 6<stng Lne to and fro% 'torage $an@
P$ #1248 Pressure $rans%tter G:#128 !ff spec Pu%p 4ec"ancal 'eal pressure
P$ #1240 Pressure $rans%tter G:#120 !ff spec Pu%p 4ec"ancal 'eal pressure
$G #1248 $e%perature Gauge G: #128 !ff 'pec Pu%p seal
$G #1240 $e%perature Gauge G: #120 !ff 'pec Pu%p seal
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2.5 Oily "ater *reat%ent Section
2efer to PF1 I2 40 011 88400 888 0242
2efer to P3I1 _sF
- I2 40 012 1'400 888 19,0
- I2 40 012 1'401 888 19,1
2efer to Bendor P3I1sF
- I2 40 0#044 012 .8400 888 002#
- I2 40 0#044 012 .8400 888 0024
- I2 40 0#044 012 .8400 888 002&
- I2 40 0#0&2 012 .0401 888 000#
Influent to t"e oly (ater treat%ent pac@age %anly conssts of produced (ater and oly (as"
(ater fro% t"e follo(ng untsF
Produced (ater fro% test separator =1' #00>5
Produced (ater fro% 1
st
stage separator =1' #01>5
nd
!ly effluent fro% desaltng pac@age =.8 #20>
$"e pac@age s ntended to lo(er t"e ol content of t"e oly (ater strea%s to appro<%ately
1& PP45 before dsc"arge to t"e sea. $"e desgn ol concentraton n t"e nlet to t"e
pac@age s 2000 %g9lt. 1e7olng of oly (ater s ac"eBed n a t(o7stage treat%ent
co%prsng of degassng and flotaton. 0ul@ of ol s re%oBed n degassng stage along (t"
sour Bapours and so%e (ater Bapour. 2est of t"e ol s separated fro% (ater (t" t"e ad of
fuel gas =as flotaton %edu%> n flotaton unt.
.pstrea% of t"e oly (ater treat%ent pac@age5 scale n"btor and reBerse de%ulsfer are
n)ected to t"e produced (ater strea%s fro% t"ree7p"ase graBty separators as (ell as to t"e
oly (ater return fro% t"e desaltng pac@age. Produced (ater flo(s by graBty t"roug" t"e
1egasser '@%%er Bessel and Flotaton Bessels (t" t"e de7oled (ater leBel n t"e Flotaton
Bessel beng controlled by t"e outlet control BalBe LCC7400,. $"e Bessels also operate
under a co%%on postBe pressure %antaned Ba pressure controller PIC740015 actng on
t"e nlet gas BalBe PC9274002 and outlet Bent BalBe PC9174001. 8 f<ed (er postoned
to(ards t"e end of t"e Bessel %antans t"e (ater leBel n t"e flotaton Bessel. 8n nternal
oBerflo( ppe %antans t"e (ater leBel n t"e 1egasser '@%%er Bessel. '@%%ed ol s
collected fro% t"e 1egasser '@%%er Bessel and Flotaton Bessel n t"e '@%%ed !l Ppe
("c" proBdes sutable resdence for t"e !l '@% 2eturn Pu%ps.
De.assin. ,Dimmer 'essel D,-#$$
!ly (ater and eBolBed gas enter t"e Bessel nto an nlet c"a%ber ("ere t s dBerted so t"at
t"e (ater flo(s across t"e Bessel and t"roug" a plate pac@. $"e co%bnaton of t"e lo(
crossflo( Belocty and nclned surface area of t"e plate pac@ allo( ol droplets to coalesce
and rse to t"e surface. Perforated baffles on t"e nlet and outlet of t"e plate pac@ "elp to
%antan opt%u% flo( dstrbuton nto and out of t"e plate pac@ and preBent any s"ort7
crcutng.
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1ue to t"e lo( Belocty5 "g" surface area and nclned plates5 ol droplets settle on t"e
plates5 coalesce to for% larger droplets and rse to t"e surface. $"e rsng ol droplets for%
an ol pad on top of t"e de7oled (ater strea%. $"e dept" of t"s ol pad s partly dependent
on t"e a%ount of nco%ng ol but can also be controlled by t"e ol (er at a f<ed ol
collecton bo< across t"e cross secton of t"e Bessel. $"e ol (er s set "g"er t"an t"e de7
oled (ater oBerflo( (er. $"e ol rc" p"ase oBerflo(s nto t"e ol buc@et and flo(s by
graBty to t"e '@%%ed !l Ppe.
$"e (ater and ol p"ases leaBe t"e cross flo( plate pac@ and enter t"e end part of t"e
Bessel. $"e f<ed ol collecton bo< across t"e cross secton of t"e Bessel allo(s (ater to
flo( underneat" before oBerflo(ng an upstand ppe to t"e Flotaton Bessel. $"e ol pad
collects on t"e upstrea% sde of t"e collecton bo< and oBerflo(s t"e ol (er as descrbed
aboBe.
6@%"%64E"I,4I6 7I4, '%L7E
DE;%,,E" ,0I//E" 'E,,EL D,-#$$
#
9"r 29#
!peratng Pressure barg 0.*
o
C #9 to ,0
1esgn $e%perature
o
C 11 9 -&
Cessel I1 %% 2*00
Cessel $9$ lengt" %% ,900
Flotation 'essel D,-#$1
Partally de7oled (ater enters t"e IGF Bessel 1'7401 nlet c"a%ber and flo(s t"roug" t"e
four actBe flotaton cells to(ards t"e end of t"e Bessel. 8 f<ed oBerflo( (er at t"e end of
t"e Bessel %antans t"e (ater leBel n t"e flotaton cells. 1e7oled (ater oBerflo(s t"e (er
nto t"e fnal (ater co%part%ent to allo( any entraned gas to escape. +ater e<ts t"e
Bessel Ba t"e leBel control BalBe LCC7400,. $"e %a)orty of t"e entraned ol accu%ulates as
an ol7rc" frot" layer n eac" of t"e flotaton cells. $"s layer s re%oBed contnuously by t(o
floatng s@%%ers ("ere t flo(s to t"e '@%%ed !l Ppe.
8ny resdual ol n t"e fnal (ater co%part%ent floats to t"e surface ("ere t s nter%ttently
draned a(ay to t"e '@%%ed !l Ppe Ba a s%all ol buc@et and %anual BalBe. $"s s an
operator functon.
$"e IGF Bessel utlses %ec"ancally nduced gas bubbles to effectBely separate ol and
solds fro% (ater by flotaton. 6ac" flotaton cell s eEupped (t" a Cycloturbne unt5 ("c"
by forcng t"e gas nto t"e (ater as Bery s%all bubbles creates an nt%ate %<ture bet(een
lEud and gas by %ec"ancal effect. !l droplets and sold partcles ad"ere to t"e surface of
t"ese bubbles. 8s t"e bubbles rse t"oug" t"e (ater t"ey coalesce to for% larger bubbles5
encouragng flocculaton of t"e ol and flotaton to t"e surface.
Page ,1 of 149
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6@%"%64E"I,4I6 7I4, '%L7E
FLO4%4IO 'E,,EL D,-#$1
#
9"r 29#
!peratng Pressure barg 0.*
o
C #9 to ,0
1esgn $e%perature
o
C 11 9 -&
Cessel I1 %% 21#4
Cessel $9$ lengt" %% 9-&4
,Dimmed Oil Pi-e and Oil ,Dim "eturn Pum-s
2ecoBered ol7rc" lEud fro% t"e 1egasser '@%%er Cessel and Flotaton .nt flo(s by
graBty to t"e '@%%ed !l Ppe fro% ("ere t s pu%ped to t"e 1't stage 1esalter Bessel
nlet by t"e !l '@% 2eturn Pu%ps. $"e pu%ps =duty9standby> operate under auto%atc
control (t" Barable speed %otors beng controlled by t"e lEud leBel n t"e '@%%ed !l
Ppe.
6@%"%64E"I,4I6 7I4, '%L7E
,0I//ED OIL PIPE
#
9"r 2*.4
!peratng Pressure barg 0.* O 0.-
o
C #9 to ,0
1esgn code 8/'I 01*.&
Cessel I1 %% 924
Cessel $9$ lengt" %% &000
6@%"%64E"I,4I6 7I4 '%L7E
Oil ,Dim "eturn Pum-s B;& #$$ %?5C
Puantty 2 =1 N 1>
$ype ProgressBe caBty
o
C #9 to ,0
'ucton Pressure barg 0.* to 2.&
1sc"arge +or@ng Pressure barg 1#.&
1esgn Flo( 2ate %
#
9"r 2*.4
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6@%"%64E"I,4I6 7I4 '%L7E
4n%u% Flo( 2ate %
#
9"r &.2
2ated Po(er @+ #,
=ater Flash 'essel and Ejector ,3stem
$"e oly (ater out of 1'7401 (ll be routed to an eleBated (ater flas" Bessel 1'74025 ("c"
operates at 0.- 0ara. $"e Bacuu% pressure condton s ac"eBed by t"e t(o7stage e)ector
syste% .07401. $"e e)ectors use LP fuel gas as %otBe gas. 1ssolBed gas =%anly H
2
' and
C!
2
> (ll eBolBe fro% t"e produced (ater and s dsc"arged t"roug" t"e e)ector syste% to
t"e LP flare. $"e pressure n 1'7402 s controlled by a pressure controller PIC74022 nsde
t"e e)ector syste%5 ("c" controls t"e %otBe gas flo(. $"e (ater fro% 1'7402 flo(s under
leBel control to t"e 2etenton Pt Ba a lEud seal. In addton5 t"e Bessel 1' 402 s located
suc" t"at t"e lEud seal bet(een 1'7401 and 1'7402 s %antaned. H
2
' content n treated
(ater leaBng 1' 402 s e<pected to be ,0071&00 PP4.
6@%"%64E"I,4I6 7I4, '%L7E
=%4E" FL%,@ 'E,,EL D,-#$:
#
9"r 29#
!peratng Pressure barg 70.2
o
C #9 to ,0
1esgn $e%perature
o
C 11 9 -&
Cessel I1 %% 2200
Cessel $9$ lengt" %% *&00
6ontrol & /onitorin. ,chedule
FI 4010 Flo( Indcator 1' 401 Flotaton unt !9L
FI 4011 Flo( Indcator 1' 401 Flotaton unt !9L
L8H 400, Hg" 8lar% 1' 401 Flotaton unt LeBel
L8H 4010 Hg" 8lar% '@%%ed ol ppe leBel
L8H 4011 Hg" 8lar% '@%%ed ol ppe leBel
L8L 400, Lo( alar% 1' 401 Flotaton unt LeBel
L8L 4011 Lo( alar% '@%%ed ol ppe leBel
LCC 400, Control BalBe 1' 401 Flotaton unt outlet
LG 4004 LeBel Gauge =2efle<> '@%%ed !l Ppe leBel
LG 400, LeBel Gauge =2efle<> '@%%ed !l Ppe leBel
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LG 4010 LeBel Gauge =2efle<> '@%%ed !l Ppe leBel
LG 4012 LeBel Gauge=2efle<> 1' 401 floataton unt
LIC 400, Controller 1' 401 Flotaton unt LeBel
LIC 4011 Controller '@%%ed ol ppe leBel
L$ 4002 1P $ype LeBel $rans%tter 1' 400 1egasser 9'@%%er 1ru%
L$ 400, 1P $ype LeBel $rans%tter 1' 401 Flotaton unt LeBel
L$ 400- 1P $ype LeBel $rans%tter 1' 401 Flotaton unt LeBel
L$ 4010 1P $ype LeBel $rans%tter '@%%ed ol ppe leBel
L$ 4011 1P $ype LeBel $rans%tter '@%%ed ol ppe leBel
P8H 4001 1' 400 1egassng 1ru% Pressure
P8L 4001 1' 400 1egassng 1ru% Pressure
PG 40118 Pressure Gauge G: 4008 2e)ect !l +ater 2eturn Pu%p
PG 40110 Pressure Gauge G: 4000 2e)ect !l +ater 2eturn Pu%p
PIC 4001 Controller 1' 400 1egassng 1ru% Pressure
P$ 4001 Pressure $rans%tter 1' 400 1egassng 1ru% Pressure
P$ 4002 Pressure $rans%tter 1' 400 1egassng 1ru%
PC91 4001 Control BalBe =0utterfly
$ype>
1' Gas !utlet $o 1' 401
PC92 4001 Control BalBe =0utterfly
$ype>
1' 400 1egassng 1ru% Gas !utlet $o Flare
'1C 4000 !n9!ff CalBe =0all $ype> Fuel Gas $o LP Flare 8nd 1' 401
'1C 4001 !n9!ff CalBe =0all $ype> G: 400890 !ly 2e)ect (ater pu%p outlet
'1C 4002 !n9!ff CalBe =0all $ype> 1' 401 Floataton unt outlet
$$ 401#8 $e%perature $rans%tter G:4008 !l s@% return pu%p !9L $e%p
$$ 401#0 $e%perature $rans%tter G:4000 !l s@% return pu%p !9L $e%p
PIC92 402# Controller G0 402 6)ector Inlet Pressure.
P$ 402# Pressure $rans%tter G0 402 6)ector Inlet Pressure.
PC 402# Control BalBe =0utterfly
$ype>
G0 402 6)ector Inlet Pressure.
$I 4021 $e%perature Gauge .0 401 6)ector Fuel Gas 'upply
$I 4022 $e%perature Gauge 1' 402 +ater Flas" Cessel !9L
$I 402# $e%perature Gauge .0 401 6)ector Fuel Gas !9L
$I 4024 $e%perature Gauge G0 402 6)ector72 Fuel gas !9L
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2.6 ,ydrate %itigation
:.9.1 @3drate 4endenc3
$"e predcted "ydrate for%aton te%perature and pressure curBe s s"o(n n Fgure -.15
based on t"e gBen (ell flud co%poston =.e. G!2 of 1-40 scf9stb> gBen n table under
c"apter 1 n t"s %anual secton 1.4.
FI;7"E :.9.1
@<D"%4E FO"/%4IO P"E,,7"E %D 4E/PE"%47"E
B2ased on .i+en com-osition !ith ;O" of 19#$ scf?st2C
0
10
20
#0
40
&0
*0
,0
-0
7* 74 72 0 2 4 * - 10 12 14 1* 1- 20 22 24
4E/PE"%47"E BH6C
P
"
E
,
,
7
"
E

B
2
a
r
a
C
8Berage 4n. 8%bent
:.9.: /inimum Flo! for Production Lines
8s seen fro% Fgure -.15 t"e flud te%perature at t"e producton ppelne outlet needs to be
%antaned at aboBe 1-JC for t"e outlet pressure of 21 bara durng nor%al producton5 to
el%nate potental "ydrate rs@ (t"out t"e use of "ydrate n"btor. For t"e LP %ode of
operaton at pressure 12.4 barg5 t"e "ydrate for%aton te%perature (ll be around 10 JC.
2.6.2.1 'ini%% Flow for ,P %ode
$"e ppelne outlet te%perature Bares (t" producton condtons5 ncludng flo( rate5
a%bent te%perature as (ell as G!2 and +C. $"e predcted outlet te%peratures for t"e
producton lnes are s"o(n n t"e follo(ng fgures5 coBerng t"e e<pected operaton
enBelope and ta@ng nto account of Baratons n a%bent te%perature. $"e "ydrate
te%perature s super%posed on t"e fgures to underlne t"e l%t.
Fgure 2.9.2a !utlet $e%perature of 1-H /6 Producton Lne =G!2 1000 scf9stb>
Fgure 2.9.2b !utlet $e%perature of 1-H /6 Producton Lne =G!2 #000 scf9stb>
Fgure 2.9.#a !utlet $e%perature of 1-H 'out" Prod. Lne =G!2 1000 scf9stb>
Fgure 2.9.#b !utlet $e%perature of 1-H 'out" Prod. Lne =G!2 #000 scf9stb>
It s"ould be noted t"at t"e te%perature profles for t"e 1-H /+ ppelne are s%lar to t"at of
t"e /6 producton lne5 and are t"erefore not repeated.
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Fi.ure :.9.:a
Outlet 4em-erature of 19I E Production Line B;O" 1$$$ scf?st2C
0
10
20
#0
40
&0
*0
&5000 105000 1&5000 205000 2&5000 #05000 #&5000 405000 4&5000 &05000
LIA7ID P"OD764IO B2-dC
O
74
LE
4
4E
/
PE
"%
47
"E
Bd
e.
6C
2& deg C a%bet 3 0M +C
11 deg C a%bent 3 0M +C
2& deg C a%bent 3 #0M +C
11 deg C a%bent 3 #0M +C
Hydrate $e%perature
Fi.ure :.9.:2
Outlet 4em-erature of 19I E Production Line B;O" 3$$$ scf?st2C
0
10
20
#0
40
&0
*0
&5000 105000 1&5000 205000 2&5000 #05000 #&5000 405000 4&5000 &05000
O
74
LE
4
4E
/
PE
"
%4
7
"E
Bd
e.
6C
2& deg C a%bet 3 0M
+C
11 deg C a%bent 3 0M
+C
0 deg C a%bent 3 0M
+C
2& deg C a%bent 3 #0M
+C
11 deg C a%bent 3 #0M
+C
0 deg C a%bent 3 #0M
+C
Hydrate
$e%perature
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Fi.ure :.9.3a
Outlet 4em-erature of 19I ,outh Production Line B;O" 1$$$ scf?st2C
0
10
20
#0
40
&0
*0
&5000 105000 1&5000 205000 2&5000 #05000 #&5000 405000 4&5000 &05000
O
74
LE
4
4E
/
PE
"%
47
"E
Bd
e.
6C
Hydrate $e%perature
Fi.ure :.9.32
Outlet 4em-erature of 19I ,outh Production Line B;O" 3$$$ scf?st2C
0
10
20
#0
40
&0
*0
&5000 105000 1&5000 205000 2&5000 #05000 #&5000 405000 4&5000 &05000
O
74
LE
4
4E
/
PE
"%
47
"E
Bd
e.
6C
Hydrate $e%perature
$"e follo(ng conclusons are obtanedF
$"ere s no %n%u% l%t on producton rate f t"e a%bent te%perature s at or aboBe t"e
"ydrate te%perature of 1-JC5 as far as "ydrate rs@ s concerned.
I%pact of a%bent te%perature on ppelne outlet te%perature s sgnfcant5 as e<pected for
unnsulated ppelnes.
For a f<ed lEud rate5 "g"er (ater cut and "g"er G!2 results n "g"er ppelne outlet
te%peratures5 due to "g"er t"er%al %ass.
For a f<ed lEud rate5 t"e outlet te%perature s %uc" "g"er for t"e 'out" producton lne
due to s"orter lengt".
In Be( of t"e aboBe Fgures 2.-.2a9b O 2.-.#a9b5 %n%u% flo(s for t"e producton lnes are
reco%%ended as gBen n $able 2.-.15 n order to el%nate t"e potental "ydrate rs@ for
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nor%al operaton. '"ould t"e producton fall belo( t"e reco%%ended flo(5 contnuous
n)ecton of "ydrate n"btor (ould be necessary to %tgate "ydrate rs@.
4a2le :.9.1 /inimum LiEuid Flo! B2-dC for Production Lines to Eliminate
@3drate "isD in @P mode
G!2 8%bent ]Q 1-JC 8%bent Q 11JC 8%bent QL 0JC
=scf9stb> #0 7 0M +C #0 7 0M +C #0 7 0M +C
/6 3 /+ 1000 /o %n. l%t 14500071,5000 225&00 O 2-5000
'out" 1000 /o %n. l%t &5000 O ,5000 95000 O 125000
/6 3 /+ #000 /o %n. l%t 105000 O 125000 1,5&00 O 195000
'out" #000 /o %n. l%t 45000 O &5000 ,5&00 O -5000 bpd
2.6.2.2 'ini%% Flow for 7P 'ode
In t"e LP %ode t"e "ydrate for%aton te%perature =10 JC> s slg"tly belo( t"e %n%u%
a%bent te%perature of 11 JC. Hence ("en n t"e operatng n t"e LP %ode5 t"ere s
t"eoretcally no rs@ for "ydrate for%aton at any flo(rate. Ho(eBer5 n case of %n%u%
a%bent te%perature t"e %argn s only s%all and s reco%%ended to obserBe at least t"e
%n%u% flo( l%ts adBsed for aBodng "ydrodyna%c sluggng =see secton 2.10.1>
:.9.3 /inimum Flo! for 4est Lines
2.6.3.1 'ini%% Flow for ,P 'ode
$"e predcted outlet te%peratures for t"e test lnes are s"o(n n t"e follo(ng fgures5
coBerng t"e e<pected operaton enBelope and ta@ng nto account of Baratons n a%bent
te%perature. $"e "ydrate te%perature s super%posed on t"e fgures to underlne t"e l%t.
Fgure 2.-.4a !utlet $e%perature of 10H /6 $est Lne =G!2 1000 scf9stb>
Fgure 2.-.4b !utlet $e%perature of 10H /6 $est Lne =G!2 #000 scf9stb>
Fgure 2.-.&a !utlet $e%perature of 10H 'out" $est Lne =G!2 1000 scf9stb>
Fgure 2.-.&b !utlet $e%perature of 10H 'out" $est Lne =G!2 #000 scf9stb>
It s"ould be noted t"at t"e te%perature profles for t"e 10H /+ test lne are s%lar to t"at of
t"e /6 test lne5 and are t"erefore not repeated.
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Fi.ure :.9.#a
Outlet 4em-erature of 1$I E 4est Line B;O" 1$$$ scf?st2C
0
&
10
1&
20
2&
#0
#&
40
4&
&0
25000 #5000 45000 &5000 *5000 ,5000 -5000 95000 105000 115000 125000
O
74
LE
4
4E
/
PE
"%
47
"E
Bd
e.
6C
2& deg C a%bent 3 &0M +C
11 deg C a%bent 3 &0M +C
Hydrate $e%perature
Fi.ure :.9.#2
Outlet 4em-erature of 1$I E 4est Line B;O" 3$$$ scf?st2C
0
&
10
1&
20
2&
#0
#&
40
4&
&0
25000 #5000 45000 &5000 *5000 ,5000 -5000 95000 105000 115000 125000
O
74
LE
4
4E
/
PE
"%
47
"E
Bd
e.
6C
2& deg C a%bent 3 &0M +C
Hydrate $e%perature
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Fi.ure :.9.(a
Outlet 4em-erature of 1$I ,outh 4est Line B;O" 1$$$ scf?st2C
0
&
10
1&
20
2&
#0
#&
40
4&
&0
25000 #5000 45000 &5000 *5000 ,5000 -5000 95000 105000 115000 125000
O
74
LE
4
4E
/
PE
"
%4
7
"E
Bd
e.
6C
11 deg C a%bent 3 0M
+C
2& deg C a%bent 3 &0M
+C 11 deg C a%bent 3 &0M
+C
0 deg C a%bent 3 &0M
+C
Hydrate
$e%perature
Fi.ure :.9.(2
Outlet 4em-erature of 1$I ,outh 4est Line B;O" 3$$$ scf?st2C
0
&
10
1&
20
2&
#0
#&
40
4&
&0
25000 #5000 45000 &5000 *5000 ,5000 -5000 95000 105000 115000 125000
O
74
LE
4
4E
/
PE
"%
47
"E
Bd
e.
6C
2& deg C a%bent 3 &0M
+C 11 deg C a%bent 3 &0M
+C
Hydrate
$e%perature
In Be( of t"e aboBe Fgures 2.-.4a9b O 2.-.&a9b5 %n%u% flo(s for t"e test lnes are
reco%%ended as gBen n $able 2.9.25 n order to el%nate t"e potental "ydrate rs@ ("en
used et"er for (ell test or producton. '"ould t"e flo( fall belo( t"e reco%%ended rate5
contnuous n)ecton of "ydrate n"btor (ould be necessary to %tgate "ydrate rs@.
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4a2le :.9.: /inimum LiEuid Flo! B2-dC for 4est Lines to Eliminate @3drate
"isD in @P /ode
G!2 8%bent ]Q 1-JC 8%bent Q 11JC 8%bent QL 0JC
=scf9stb> &0 7 0M +C &0 7 0M +C &0 7 0M +C
/6 3 /+ 1000 /o %n. l%t 95#007125000 Hydrate In"btor
'out" 1000 /o %n. l%t #5-00 O &5400 *5#00 O 95000 bpd
/6 3 /+ #000 /o %n. l%t -5000 O 95&00 Hydrate In"btor
'out" #000 /o %n. l%t #5#00 O #5,00 &5400 O *5000 bpd
For t"e /6 and /+ test lnes5 (ell test s"ould be aBoded5 f possble5 at t"e e<tre%e cold
(nter te%peratures. It s also reco%%ended t"at t"e test lnes s"ould be utl;ed for
producton ("le not used for (ell test5 at t"e aboBe7reco%%ended rate at least to %antan
t"e te%perature aboBe t"e "ydrate te%perature. +"en t"e /6 and /+ test lnes are used
for producton at t"e e<tre%e cold (nter te%peratures5 contnuous n)ecton of "ydrate
n"btor s"ould be used to %tgate "ydrate rs@.
2.6.3.2 'ini%% Flow for 7P 'ode
In t"e LP %ode t"e "ydrate for%aton te%perature =10 JC> s slg"tly belo( t"e %n%u%
a%bent te%perature of 11 JC. Hence ("en n t"e operatng n t"e LP %ode5 t"ere s
t"eoretcally no rs@ for "ydrate for%aton at any flo(rate. Ho(eBer5 n case of %n%u%
a%bent te%perature t"e %argn s only s%all and s reco%%ended to obserBe at least t"e
%n%u% flo( l%ts adBsed for aBodng "ydrodyna%c sluggng =see secton 2.10.1>
:.9.# ,hutdo!n 6onditions
For a producton s"utdo(n at bot" t"e cluster and 1orood # ends5 t"e est%ated ppelne
settle out pressure s crca 20 0ara n HP %ode. $"e correspondng "ydrate te%perature s
1, JC as s"o(n n Fgure -.1. +t"out any t"er%al nsulaton5 t"e flud te%perature n t"e
ppelnes (ll reac" a%bent te%perature Bery Euc@ly5 especally for t"e gas flled sectons.
$"e predcted cool do(n t%e =.e. t"e t%e to reac" a%bent te%perature> s less t"an 1
"our5 sub)ect to t"e flo(ng condtons pror to s"utdo(n.
Lne pac@ng (ll ta@e place n case of 1orood # s"utdo(n only5 untl t"e ppelne pressure s
eEual;ed (t" t"e (ell"ead P'HH set pressure. $"e rate of pac@ng depends on reserBor
condtons and co%pleton detals5 as (ell as ppelne flo(ng condtons pror to s"utdo(n.
$"e ppelne cool do(n rate %ay be slo( ntally5 because of lne pac@ng. $"s could e<tend
t"e oBerall cool do(n t%e to reac" a%bent te%perature5 sub)ect to pac@ng rate. GBen t"at
t"e ppelne s not nsulated and not bured5 t s e<pected to reac" a%bent te%perature
relatBely Euc@ly follo(ng t"e s"utdo(n n cold enBron%ent5 regardless of s"utdo(n
scenaros.
'"ould t"e a%bent te%perature fall belo( t"e "ydrate for%aton te%perature for t"e
correspondng ppelne settle7out pressure5 t"e ppelne (ould be %posed on potental
"ydrate rs@. GBen t"at t"e %n%u% aBerage te%perature s 11JC5 t"e "ydrate rs@ e<sts
follo(ng a s"utdo(n n (nter season. Ho(eBer5 t"e lo( te%perature %ay only last for fe(
"ours at ng"tt%e5 and t %ay rse to aboBe t"e "ydrate te%perature t"roug"out t"e day.
Hydrate for%ed n t"e ppelne5 f any %ay (ell dsassocate durng dayt%e. $"e effect of
a%bent te%perature cyclng on "ydrate for%aton and9or dsassocaton needs to be
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consdered to establs" t"e l@el"ood of "ydrate bloc@age n t"e ppelnes for prolonged
s"utdo(n n (nter season.
$o %tgate "ydrate rs@5 "ydrate n"btor s"ould be n)ected for any planned long7ter%
s"utdo(n n (nter season. For unplanned s"utdo(n n (nter season5 ppelne
depressur;aton s"ould be consdered. For t"e %n%u% a%bent te%perature of 11JC5 t"e
ppelnes need to be depressur;ed to belo( - 0ara5 as s"o(n n Fgure 2.9.1.
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2.8 $he%ical !njection for Oil Syste%
Producton and test %anfolds are protected aganst corroson by n)ectng corroson n"btor
drectly nto t"e flo( lnes at t"e clusters and also upstrea% of t"e /e( Plant %anfold
=syste% -#,5 -#- 3 -#9>. 1ue to "g" leBels of "ydrogen sulfde and carbon do<de n t"e
gas strea%s fro% separaton Bessels5 corroson n"btor s n)ected to t"e gas strea%s fro%
t"e separators to reduce t"e corroson rate of do(nstrea% carbon steel eEup%ent.
$o reduce foa% for%aton n t"e separators5 antfoa% s added to t"e producton flud
enterng test separator =1' #00> and t"e 1
st
stage separator =1' #01>. 8nt foa% s also
n)ected to t"e ol strea% enterng 2
nd
stage separator. $o strea%s carryng produced (ater5
scale n"btor s added to reduce scale for%aton n t"e lnes5 and processng Bessels.
1e%ulsfer s appled to ol9(ater %<tures to assst ac"eBng a better ol9(ater separaton n
t"e separators and t"e desaltng Bessels.
C"e%cal n)ecton reEure%ents for t"s syste% are defned as follo(sF
'yste% -2-7Corroson n"btor $ype71 n)ecton toF
Producton and test %anfolds5
Gas leaBng test separator =1' #00>5 1
st
stage separator =1' #01>5 and 2
nd
stage
separator =1' #02>.
'yste% -2&7'cale n"btor n)ecton toF
Producton flud enterng test separator =1' #00> and 1
st
!l enterng 2
nd
!l enterng 1
st
stage desaltng unt =1' #208>5
Produced (ater leaBng test separator =1' #00>5 1
st
stage separator =1' #01>5 and
2
nd
'ea(ater upstrea% of sand fltraton pac@age =.0 ,11>5 as e<planed n 'ecton 2.1.
ProBson of %ultple n)ecton pont s proBded to %antan t"e necessary c"e%cal
concentraton n t"e syste%.
'yste% -2971e%ulsfer n)ecton toF
st
!l enterng 2
nd
!l enterng 1
st
stage desaltng unt =1' #208>.
'yste% -2,78ntfoa% $ype72 n)ecton toF
st
!l enterng 2
nd
!l enterng stabl;aton colu%n =C8 #10>.
ProBson of %ultple n)ecton ponts s proBded to %antan t"e necessary c"e%cal
6hemical injection reEuirements for the oil3 !ater treatment section is as follo!s1
'yste% -#07reBerse de%ulsfer n)ecton toF
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Produced (ater fro% test separator =1' #00>5 1
st
stage separator =1' #01>5 and 2
nd
st
stage desaltng unt =1' #028>.
'yste% -2* surfactant n)ecton s proBded for n)ecton to t"e co%bned oly (ater.
$"e est%ated c"e%cal dosng rates for !l syste% s specfed n t"e follo(ng tables.
4a2le :.).1 Estimated 6hemical 6onsum-tion "ates for Oil & ;as 4reatment %rea
'yste% C"e%cal In)ecton Locaton
Flud Flo(
/ote 1
1osage5 PP4
/ote 1 /or%al
Consu%pton
2ate5 lt9"r
/
o
t
e
s
Crude5
%
#
9"r
Prod
+ater
%
#
9"r
Gas5
44'CF1 /or% 1esgn
-2-
Corroson
In"71
Gas fro% $est 'eparator
Gas fro% 1
st
'eparator
Gas fro% 2
nd
'eparator
$est 4anfold
Producton 4anfold
0.0
0.0
0.0
40
*00
0.0
0.0
0.0
40
200
` #*
242
` 1*
242
#*
2&0
2&0
2&0
20
20
&00
&00
&00
2&
2&
0.4
2.&
0.2
0.-
4.0
2
2
2
#
#
-2&
'cale
In"btor
Prod Flud nto $est 'ep.
Prod Flud nto 1
st
'ep.
!l nto 2
nd
'eparator
!l nto 1esaltng .nt
Prod +ater fro% $est 'ep.
Prod +ater fro% 1
st
'ep.
Prod +ater fro% 2
nd
'ep
40
*00
*00
*00
0.0
0.0
0.0
40
200
*0
10&
40
200
120
` #*
242
0.0
0.0
0.0
0.0
0.0
20
20
10
&
&
&
&
#0
#0
#0
#0
#0
#0
#0
0.-
4.0
0.*
0.&
0.2
1.0
0.*
#
#
#
#
#
#
#
-29 1e%ulsfer
Prod Flud nto 1
st
'ep.
!l nto 2
nd
'eparator
!l nto 1esaltng .nt
40
*00
*00
*00
40
200
*0
10&
` #*
242
0.0
0.0
20
20
&
&
#0
#0
10
10
1.*
1*.0
#.#
#.&
4
4
4
4
-2, 8ntfoa%72
Prod Flud nto 1
st
'ep.
!l nto 2
nd
'eparator
!l nto 'tabl;aton Col.
40
*00
*00
*00
40
200
*0
1
` #*
242
0.0
0.0
#.0
#.0
2.0
1.0
&.0
&.0
&.0
&.0
0.2
2.4
1.#
0.*
4
4
4
4
-#,
Corroson
In"71
/. 6. Cluster 200 ,0 ` -0 &0 100 #.& #
-#-
Corroson
In"71
/. +. Cluster 200 ,0 ` -0 &0 100 #.& #
-#9
Corroson
In"71
'. Cluster 200 ,0 ` -0 &0 100 #.& #
/otesF
1. 8ll dosage rates correspond to 100M soluton. 8ll flo( rates nclude 10M oBer t"e nor%al
flo(.
2. 1osage rate corresponds to %l944'CF of gas flo(.
#. 1osage rate s based on produced (ater flo(.
4. 1osage rate s based on crude and produced (ater flo( rates.
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4a2le :.).: Estimated 6hemical 6onsum-tion "ates for Oil3 =ater 4reatment %rea
'yste% C"e%cal In)ecton Locaton
!ly
+ater Flo(5
%
#
9"r
/ote 1
1osage5
PP4
/ote 1
/or%al
Consu%pt
on 2ate5
lt9"r

/
o
t
e
s
/or%
1esg
n
-#0
2eBerse
1e%ulsfer
$est 'eparator Prod +ater
1
st
'eparator Prod +ater
2
nd
'eparator Prod +ater
1
st
1esalter Prod +ater
40
200
120
10&
20
20
10
&
#0
#0
#0
#0
0.-
4.0
1.4
0.&
-24 'urfactant Co%bned !ly +ater 290 & 10 1.&
/otesF 8ll dosage rates correspond to 100M soluton. 8ll flo( rates nclude 10M oBer t"e
nor%al flo(.
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2.19,ydrodyna%ic $onsideration for the Pipelines and the New
plant
H8W!P 8cton te% no. 20.#
8s part of t"e pro)ect scope $ransent perfor%ance of t"e ntegrated producton and
recepton facltes s eBaluated5 ncludng # producton ppelnes5 HP separator =1' #01> and
t"e assocated control syste%. 'tartng fro% t"e (orst case condton5 a seEuence of
transent eBents s %odeled5 ncludng s"utdo(n9restart. $"e follo(ng s t"e su%%ary of t"e
study applcable for t"e operaton of t"e /e( plant.
:.1$.1 @3drod3namic slu..in.
$"e follo(ng are t"e @ey ponts relates to "ydrodyna%c sluggng n ppe lnesF
7 $"e /65 /+ and 'out" producton lnes are predcted to operate n slug flo( reg%e5
oBer a (de range of flo(rates5 G!2s and +Cs.
7 For t"e producton lnes5 typcal slug freEuency s around *07-0 seconds (t" slug s;e of
&7*%
#
. For t"e test lnes5 typcal slug freEuency s around 1007120 seconds (t" slug
s;e of around 1%
#
.
7 $erran effect beco%es do%nant as flo( rate s reduced5 resultng n unstable flo(.
Larger slug of 1#71&%
#
s predcted (t" longer freEuency of 1&071*0 seconds n t"e
producton lnes.
7 !peratng n unstable flo( reg%e s not desrable and s"ould be aBoded. $"e follo(ng
t"res"old lEud rates are reco%%ended for t"e producton and test lnes5 fro% stable
operaton pont of Be( for t"e ndBdual lnes. $"e lo(er Balue of t"e t"res"olds s
applcable to "g" G!2 and9or lo( +C condtons5 t"e "g"er Balue to lo( G!2 and9or
"g" +C condtons.
10500071&5000 bpd for t"e 1-H /6 and /+ producton lnesK
&500071&5000 bpd for t"e 1-H 'out" producton lneK
25000745000 bpd for all t"ree 10H test lnes.
+"en t"e producton fro% ndBdual clusters falls belo( t"e reco%%ended t"res"olds
%entoned aboBe5 t s suggested t"at t"e test lne s"ould be used5 nstead of producton
lne5 to %n%;e t"e terran %pact on lEud sluggng and to ensure stable flo( to t"e
recepton facltes.
:.1$.: ,hutdo!n and "estart
Follo(ng a producton s"utdo(n5 bot" at t"e cluster and 1orood # nlet5 gas and lEud n
t"e ppelne start to separate. $"e lEud s draned to(ards lo( ponts along t"e ppelne5
("ereas t"e gas s flo(ed to(ards t"e top.
For t"e /6 and /+ clusters5 %ost of t"e lEud s draned bac@ to t"e cluster end5 (t" t"e
rest settled n t"e lo( ponts close to 1orood # after 20 %nutes of s"utdo(n. $"e startng
secton of t"e ppelne5 fro% &00 to 12&0 % at t"e cluster end s flled (t" lEud5 due to t"e
nature of t"e terran. .nl@e t"e /6 and /+ ppelne5 due to t"e topology of t"e ppe lne5 t"e
lEud content n t"e 1-H 'out" producton lne s (dely dstrbuted oBer a nu%ber of local
lo( ponts after s"utdo(n.
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It s relatBely easer to start7up t"e 'out" producton lne5 n co%parson to t"e /6
and /+ producton lnes5 due to lo(er lEud content. Follo(ng a total producton
s"utdo(n5 t s reco%%ended to start7up t"e 'out" producton lne frst to %n%;e
t"e start7up lEud sluggng and t"e %pact to t"e HP 'eparator.
H8W!P 8cton te% ,8.*
$"e predcted start7up lEud slug s bet(een 27- %
#
for 'out" Producton lne5 and 12714 %
#
for t"e /6 and /+ producton lnes. $"e start7up process s relatBely steady. /o e<cessBe
lEud surge s predcted for t"e Euc@ start7up scenaro =.e. 2 (ells per "our or 1 (ell per 0.&
"our>5 n co%parson to start7up 1 (ell per "our.
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3 P"O6E,, 6O4"OL
3.1 $ontrol Syste% Description
$"e follo(ng s a bref descrpton of t"e process control syste% at 1orood # faclty.
$"e control and %ontorng of t"e 1orood ne( plant facltes (ll be %ade aBalable to t"e
operators fro% sngle ne( control buldng. Process control functons =PC'> and t"e Process
s"utdo(n functons =P''> are perfor%ed n t"e 1C'.
$"e syste% selected for t"s pro)ect s 16L$87C suppled by 6%erson Process
4anage%ent.
'afety s"utdo(n syste% ='''> and Fre 3 gas syste% functons are perfor%ed n one
co%%on 'afety PLC suppled by IC' $2IPL6: (t" $42 arc"tecture and s certfed 'IL#
as per I6C *1&0-.
For t"e )etty fre control applcatons a separate redundant 16L$8 C controller A6$$?7FC. s
proBded.
3.1.1 Process B-roductionC 6ontrol Functions BP6,C
$"e PC' functons (ll %anly nclude t"e control of t"e process and utltes producton
=ncludng data fro% pac@ages>.
In t"s plant PC' s dBded nto 4 %a)or sectons as follo(ed.
PC'71F .tltes
PC'72F +ater
PC'7#F !l
PC'74F Process9Fuel gas co%presson and treat%ent.
3.1.: Process B-roductionC ,hutdo!n Functions BP,,C
$"e P'' functons %anly ncludes t"e control and t"e %anage%ent of t"e process and
utltes s"utdo(n logcs of t"e follo(ng leBels9typeF
In t"s plant P'' s dBded nto 4 %a)or sectons as follo(ed.
P''71F .tltes
P''72F +ater
P''7#F !l
P''74F Process9Fuel gas co%presson and treat%ent.
$"e P'' controllers are redundant.
3.1.3 P6,?P,, ,3stem ;eneral descri-tion
=8lso refer to t"e 642 docu%ent PC'9P'' Hard(are desgn specfcatons
G 'yste%s 8rc"tecture /o I240 0#001 F12 /H000 11D 01&,>
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$"e syste% %anly conssts of t"e follo(ng 44I ele%ents located n t"e 1!2!!1 ne(
Control 2oo%F
Four !perator Control statons =!C'>5
!ne applcaton staton
!ne log prnter5
!ne report prnter
!ne C1. dsplays "ard coper5
8 s%plfed s@etc" of t"e syste% arc"tecture s s"o(n n fgure #.1.1 at t"e end of t"s
secton. $"e syste% also ncludes t"e follo(ng ele%ent nstalled n t"e 1!2!!1
Instru%ent $ec"ncal 2oo% and 'ea(ater Pu%png 'taton /e( s"elterF
PC' and P'' syste% cabnets "ousng controller unts5 po(er supply unts5 I9!
cards5 nterfacng9co%%uncaton %odules5
4ars"allng cabnets dedcated to PC'9P'' sgnal =8t I$2 only>.
$"e 'yste% also co%prsesF
!ne %antenance9 engneer (or@staton toget"er (t" a prnter5
8 redundant 1ata "g"(ay for co%%uncatons bet(een Barous ele%ents of t"e
dstrbuted arc"tecture.
ProBded !C's s"all be used for !perators access to bot" PC'9P'' syste% functons and
'''9FG' syste% functons.
1ata to be e<c"anged t"roug" seral ln@s (t" foregn eEup%ent and syste%sF
$"e data e<c"ange bet(een t"e PC'9P'' syste% and foregn control eEup%ent and
syste%s s"all be ac"eBed5 unless f specfed ot"er(se5 by %eans of seral ln@s5 type 2'
4-& or 2' 2#2 or 2' 422 full duple<5 19200 bauds. PartyF !115 ProtocolF 4!10.'.
$"e foregn syste%s (t" ("c" t"e /e( 1orood PC' 9 P'' "as been nterfaced are as
follo(sF
+ater n)ecton $urbo pu%p5 G?7,#08
+ater n)ecton $urbo pu%p5 G?7,#00
+ater n)ecton $urbo pu%p5 G?7,#0C
Fuel gas co%pressor5 D:7-018
Fuel gas co%pressor5 D:7-010
4P9HP71 $urbo7Co%pressor tran5 D?7&009&019&10
HP72 $urbo Co%pressor5 D?7&11
LP 'tea% 0olers5 .8 9&08909C
$6G 2egeneraton unt5 .87*10
'ea(ater 'and Flter5 167,11
Instru%ent ar co%pressors. .07-&0890
/trogen Pac@age5 .07-*0890
Fres" (ater pac@age5 .8 910
Po(er generator5 P? 9-0 8909C
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$"e '''9FG' "as also been nterfaced to t"e PC'9P'' t"roug" a redundant seral ln@.
3.1.# ,,, ,75 ,<,4E/
$"e functon of t"e 'afety '"utdo(n 'ub 'yste% ='''> s to protect people5 process
facltes and enBron%ent of t"e nstallatons fro% accdental stuatons.
$"e %an tas@s of t"e ''' 'ub7'yste% s"all be as follo(sF
4ontorng of alar%s and actons assocated (t" e%ergency s"utdo(n =6'1 1>
4ontorng9alar%ng n case of n"bt co%%and of a s"utdo(n nput or oBerrdng
co%%and of '"utdo(n actons.
6'1 logc ac"eBe%ent.
Frst out alar% %anage%ent.
6%ergency depressur;aton and blo(do(n.
6lectrcal solaton.
3.1.( FI"E & ;%, ,75 ,<,4E/. BF;,C
4an functons of FG' s"all be as follo(sF
4ontor all desgnated areas for fre5
4ontor all areas ("ere fla%%able9to<c Bapours %g"t be present n nor%al
operaton5
4ontor all ar loc@s 9HC8C ar nta@es to buldngs for to<c and fla%%able gas5
ProBde a faclty for rasng an alar%5
8lert personnel n Control 2oo% of any fre5 gas =to<c or fla%%able> e%ergency
stuaton5
8ctBate t"e auto%atc fre7fg"tng syste% and 6'15
Close fre da%pers to facltes ("ere gas s detected. '"utdo(n of HC8C syste%
s"all be ntated by 6'15
8lert personnel n Control 2oo% of any fault detected by self7test facltes.
3.1.&.1 SSS 4 FGS $ON*+O7 +OO' '.*+!:;P.N(7
$"ere are t(o separate 4atr< panels for ''' 3 FG'. $"ese are "ard(red panels located
n 1orood ne( control roo%.
It co%prses of
6%ergency s"utdo(n =6'1 0 or 0lac@ out> pus" button5
General producton s"utdo(n =GP'1> pus" button5
0lac@ start co%%ands5
0lo(do(n co%%ands5
6'11 pus" button.
Pus" button =s> for openng co%%and of t"e deluge BalBes5
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Pus" button =s> for openng 9close co%%and of t"e 0lo(do(n BalBes5
Fre pu%ps start co%%and pus" button5
Fre pu%ps status5
L6L detecton co%%on alar% per ;one =Lo( 3 Hg" concentraton>5
H2' detecton co%%on alar% per ;one5
Fre detecton co%%on alar% per ;one5
La%p $est pus" button5
8lar% 8c@no(ledge%ent pus" button.
3.1.6 Electrical et!orD /ana.ement ,3stem
$"s s part of t"e 1C'. $"s syste% conssts of # controllers. Po(er generators P?9-0
8909C are "aBng a seral nterface (t" t"ese controllers. 8 separate PLC for c"ange oBer
logc s part of t"s syste%. $"s PLC s of 'c"nder %a@e.
8 separate PC =G8$6 +8?> s aBalable for '%art relay %antenance for H.C.'(tc" gear.
In addton an 6/4' operator console s also part of t"s syste%.
8 s%plfed s@etc" of t"e syste% arc"tecture s s"o(n n fgure #.1.2 at t"e end of t"s
secton.
3.1.8 D6, 4rainin. ,imulator
8 1C' tranng s%ulator s suppled along (t" t"e syste%. $"s s a standalone syste%5
("c" s not part of t"e net(or@.
$"e purpose of t"s s%ulator s to assst n tranng t"e operators on t"e ne( plant operatng
process capabltes.
# (or@statons are proBded5 1 for t"e teac"er and 2 for t"e operators.
$"e process s%ulaton s l%ted to ol secton only.
3.1.9 Jett3 P6,?P,,
8 separate )etty PC'9P'' s located n t"e seas"ore area t"at controls and %ontors t"e
operaton of t"e sea(ater lft staton eEup%entF
'ea(ater lft pu%ps =G:7,00 8909C91>5
Fre (ater pu%ps =G?7920 890>5
Fre (ater )oc@ey pu%ps =G:7921 890>5
Poc@et flters =IF7,10 8909C>5
6lectro7c"lornaton pac@age =.87,00>.
8 s%plfed s@etc" of t"e syste% arc"tecture s s"o(n n fgure #.1.#.
Fre(ater pu%ps and )oc@ey pu%ps "aBe t"er ndependent local panels. $"e c"lornaton
pac@age "as a dedcated PLC.
8ll "ard (rng related to t"e aboBe eEup%ent at t"e seas"ore are contaned nsde t"e )etty
P'C9P'' roo%. $"e co%%uncaton bet(een t"e )etty PC'9P'' and t"e /e( Plant Control
2oo% s ac"eBed t"roug" fber optc ln@.
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3.1.) /an /achine Interface
$"e /e( Plant Control 2oo% s per%anently %anned and used for all re%ote daly routne
control actBtes and start7up.
Control and %ontorng s perfor%edF
0y %eans of !perator Control 'tatons =!C's> (t" C1.s and @eyboard =Four
!C's5 s"all be nstalled>. 8ll !C' s"all "aBe access to co%plete control database.
$"e 1C' s"all proBde t"e follo(ng facltes to t"e operatorsF
Process and utlty producton dyna%c control5 data acEuston5 set pont
c"ange5 start9stop %an eEup%ent5 data calculaton5 Barous %easure%ent
trend curBe5 a5 etc5 dsplayed on C1.s.
Control and %ontor process and utlty producton.
Control and %ontor t"e '"utdo(n and t"e Fre and Gas detecton.
1yna%c producton feld control and status dsplay Be(s and trend curBes.
8ut"or;e9Co%%and 6'1C5 01C Plant BalBes re7openng or closure after
'"utdo(n.
0y %eans of dedcated '''9FG' "ard(red %atr< panel faclty.
4ontor co%%on alar%s related to Fre 3 Gas detecton =Fre5 L6L5 H2'
detecton5 a>5 by %eans of a %atr< panel n con)uncton (t" t"e C1.. $"e
purpose of t"e %atr< panel s t"at5 t (ould be operatonal n case of a
co%%uncaton falure bet(een t"e FG'9''' and C1.s. 8 panel as s%ple as
possble s"all be proBded so t"at t"e operator can ta@e a Euc@ acton on
detecton of fre or gas.
Infor%aton and actons aBalable on t"e panel (ll be.
o Gas and fre detecton alar% per ;one =grouped sensors>
o 4ontor t"e Fre fg"tng eEup%ent statuses by %eans of status lg"t.
o Fre pu%p start
o Intate 6'105 6'115 and general blo(do(n by %eans of an e%ergency
pus" button.
0y %eans of t(o Prnters to perfor%F
8lar%s =pre7alar%5 s"utdo(n> loggng5
'tatus c"anges loggng5
Frst7out type trppng defect5
Producton balance s"eets.
0y %eans of one Colour Hard7coper to perfor% Bdeo dsplay capture.
!ne Publc 8ddress 4anual 8nnounce%ent 8ccess .nt for alar%5 (arnng and
%usterng broadcast facltes n case of e%ergency stuatons =fre5 ol9gas
lea@age5 %usterng> s"all be nstalled on t"e operator control des@.
$"e operators (ll use t"e consoles to control and co%%and t"e nstallaton.
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$"e console allo(s t"e operator toF
C"an fro% one %%c dsplay to anot"er5
In"bt sgnals5
'tart9stop eEup%ent5
!pen9close BalBes5
8c@no(ledge alar%s5
4odfy para%eters5
2eset 6'15
2eset and test safety BalBes5
Install and re%oBe bypasses.
3.2 Process $ontrol Narrati)e
$"e ob)ectBe of t"s secton s to defne an operatng and control p"losop"y t"at (ll %eet
t"e defned operatonal and control ob)ectBes of t"e 1orood # faclty. $"e p"losop"y
ensures t"at t"e desgn of t"e plant %eets t"e operatng ob)ectBes of t"e 1orood # faclty
(t" respect to safety5 productBty and asset protecton.
!peraton and control of t"e 1orood # facltes s perfor%ed n suc" a %anner to %eet t"e
follo(ng ob)ectBesF
Protecton of personnel and publc
Protecton of t"e enBron%ent
Protecton of assets
4a<%;e 9 !pt%;e producton
4n%;e operatng costs
PreBentBe %easures aganst "a;ardous operatng condtons and e%ergency stuatons s
ta@en by contnuous operator %ontorng of t"e facltes and by t"e control actons of t"e
Process Control 'yste% =PC'> 3 Process '"utdo(n 'yste%. Ho(eBer5 ("ere suc"
condtons cannot be adeEuately controlled5 fnal protecton s proBded by t"e 'afety
'"utdo(n syste% ='''> and t"e Fre and Gas 'yste% =FG'>.
For process control of eac" pac@age5 refer to t"e correspondng pac@age operaton and start
up %anual.
3.:.1 Production =ellheads* Flo! lines and /anifolds
8s part of 1!2 # pro)ect5 1# ne( producton (ells (ll be routed to t"e ne( treat%ent
facltes. $"ese are dBded nto # clusters5 ("c" areF
/ort"east Cluster F 4 (ells
/ort"(est Cluster F 4 (ells
'out" Cluster F & (ells
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$"e (ells n t"e ndBdual clusters are routed to et"er a 10H test "eader or an 1-H
producton "eader. 6ac" cluster s proBded (t" dedcated test and producton "eaders. $"e
producton control for eac" (ell s ac"eBed by a %anual c"o@e BalBe proBded at t"e (ell
"ead.
1edcated (ell"ead control panels are proBded for eac" cluster to %ontor t"e status of t"e
(ells and flo( lnes. Ho(eBer5 t"ere s no co%%uncaton bet(een (ell"ead and t"e /e(
plant control roo%.
$"e producton "eaders fro% eac" clusters are co%bned at t"e producton %anfold n t"e
ne( plant and feed to t"e frst stage separator. '%larly5 t"e test "eaders fro% eac" cluster
are co%bned at t"e test %anfold and feeds to t"e test separator. 2outng of t"e (ells to a
producton "eader or to a test "eader s carred out by operatng t"e %anual solaton BalBes
proBded. $est separator (ll be contnuously used for producton to preBent "ydrate rs@ and
reduce start up t%e. $"e test separator can also be used for producton ("en t"e Frst
stage separator =1' #01> s under s"utdo(n. Ho(eBer5 t"e operatng reg%e (ll be l%ted
by t"e releBng capacty of t"e test syste%.
3.:.: ,e-arator ,ection
3.2.2.1 *est Facilities
8s part of t"e 1!2 # 1eBelop%ent5 one test separator s proBded for t"e faclty. Producton
fro% any gBen (ell can be routed to t"e $est 4anfold. +ell producton s dBerted to t"e
$est9Producton 'eparator by %anual operaton of BalBes at t"e Producton and $est
4anfolds.
Fro% t"e $est 4anfold5 producton s routed nto t"e $est 'eparator5 1' #005 ("c" s
desgned5 for t"ree7p"ase separaton. 8ssocated gas s flas"ed fro% t"e ol and routed to
t"e 4P %anfold. Pressure control of t"e Bessel s ac"eBed by regulatng t"e flo( of e<cess
assocated gas to t"e flare. !peratng te%perature s not controlled.
1urng operaton of t"e test separator5 t"e follo(ng para%eters are %ontored n t"e ne(
plant control roo% =C2>F

Cessel operatng pressure
Cessel operatng te%perature =n gas outlet>.
+ater Flo( fro% separator =flo( total;er proBded>
!l flo( fro% t"e separator =flo( total;er proBded>.
$otal Bapor flo( fro% t"e separator =flo( total;er proBded>.
LEud leBel
Interface leBel
$"e flo( %eters on $est separator (ll "aBe a turndo(n of 1F1&
Process control (ll be as follo(sF
!peratng pressure s controlled n t"e follo(ng %annerF PIC 19#00# %odulates t"e BalBe
PC917#00# on t"e Bapor lne to slug catc"er. PIC 29#00# %odulates t"e control BalBe =PC2
#00#> on t"e lne gong to t"e flare. $"us durng t"e nor%al operaton5 by controllng t"e flo(
Page 94 of 149
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to t"e slug catc"er5 t"e pressure (ll be controlled. 8ny e<cess gas (ll result n ncrease n
pressure5 ("c" (ll be routed to t"e HP flare.
!l7(ater nterface leBel s detected by leBel nterface trans%tter =Capactance type> $"e
nterface leBel (ll be controlled =L1IC O #002> by %odulatng t"e control BalBe on t"e
produced lne (ater fro% t"e separator.
!l leBel n t"e dru% s %easured by a leBel trans%tter =1P type>. $"s LEud leBel s
controlled by =LIC #00&> by %odulatng t"e control BalBe on ol lne fro% t"e separator.
8 (er e<tendng (ell aboBe t"e nterface leBel preBents bul@ (ater carry oBer to t"e ol
strea%
3.2.2.2 Oil Prodction *rain
Fro% t"e producton %anfold n t"e ne( plant5 producton s routed to a sngle 1
st
stage
separator. $"e 1
st
'tage 'eparator5 1' #015 (ll operate as a t"ree7p"ase separaton of ol5
gas and (ater. Produced (ater separated n t"e 1
st
stage Inlet 'eparators (ll be routed to
t"e +ater $reat%ent 'yste% for re%oBal of entraned ol.
$"e follo(ng para%eters are %ontored.
!peratng pressure
!peratng te%p
Produced (ater flo( rate
8ssocated gas flo( rate
LEud leBel
Interface leBel
$"e follo(ng para%eters are controlled to ensure a proper functonng of t"e eEup%entF
'eparator pressure s controlled by PIC 29#0125 ("c" %odulates PC928 #012 and PC920
#012 to Bary t"e gas flo( to 4P staton. PC92 8 #012 BalBe (ll be on lne ("en HP %ode of
operaton s selected. 1urng t"e LP %ode5 bot" t"e BalBes (ll be on lne. $"e e<cess gas
(ll be routed to HP flare by PIC 19#012 by %odulatng t"e control BalBe PC91 #012. PIC
19#012 set pont (ll be "g"er t"an PIC 29#012. $"us durng t"e nor%al operaton5 by
controllng t"e flo( to t"e slug catc"er5 t"e pressure (ll be controlled. 8ny e<cess gas5
("c" (ll result n ncrease n pressure of t"e separator5 (ll be routed to t"e HP flare.
!l (ater nterface leBel s controlled by regulatng t"e produced (ater flo( by L1IC7#012.
!l leBel s controlled by LIC7#01& by regulatng t"e ol outlet flo( to t"e 2
nd
stage separator.
$80L6 O1 LeBel settngs for 'eparators fro% 0otto% $L O $L
LE'EL ,E44I;, D, 3$$ D, 3$1 D, 3$:
OIL ,IDE
L'HH 1200 21&0 #210
HLL 1000 1-40 #020
LLL ,00 1200 1100
L'LL *00 1000 -00
=%4E" ,IDE
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HLL &00 ,,0 &00
LLL #00 400 #00
L'LL 200 200 200
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Fg.1 '6P828$!2 C!/$2!L 'CH646
$"e dru% s proBded (t" "g" 9 lo( leBel s(tc"es for t"e ol leBel and lo( leBel s(tc" for
nterface. $"ese s(tc"es actBate safety trps5 detals of ("c" can be found n '"utdo(n
logc dagra%. $"s preBents t"e Bessel fro% gas blo(7by and ol carryunder n (ater etc.
$"e separated ol fro% t"e 1st stage separator and test separator s co%bned and s routed
to LP separator Feed Pre7"eater 6C7#1#. In t"s e<c"anger5 t"e "ot stabl;er botto% flud
"eats t"e ol. 4odulatng t"e flo( of t"e "ot flud t"roug" t"e e<c"anger controls t"e outlet
te%perature of t"e 2
nd
stage separator feed by $IC #1#4. $"e "eated ol s t"en routed to 2
nd
separator 1'7#02.
1' #02 operatng pressure s controlled =PIC7#022> by regulatng t"e flo( of eBolBed gas to
t"e HP flare.
$"e lEud leBel control n t"s Bessel s controlled by LIC7#02&5 ("c" gBes a set pont to
FIC7#21& n t"e dsc"arge of t"e !l 0ooster Pu%ps5 ("c" n ts turn controls FC7#21& n
t"e nlet to t"e stabl;er. 2egulatng t"e leBel of t"e ol9(ater nterface =L1IC7#022> controls
t"e flo( of (ater fro% t"e Bessel =L1C #022>. Produced (ater s sent to t"e !ly +ater
degasser for furt"er treat%ent.
Page 9, of 149
$$
F2
P$
P
C
P
C
2
$! FL826
$! P2!C6''
$$
L1I
C
L$
!IL
+8$62
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"e+ $1
3.:.3 Desalter
'eparated ol fro% 1' #02 s pu%ped to 1esalter usng pu%p G: #10 890 =2<100M pu%ps
proBded (t" auto c"ange7oBer>. 8 control BalBe FC7#1105 controlled by FC7#110 s proBded
on t"e %n%u% flo( recrculaton lne of t"e pu%p.
,eries o-eration
$(o stages of desaltng are proBded. $"e nco%ng "ot feed s %<ed (t" recycle (ater
fro% t"e second stage and (t" t"e oly effluent fro% !+$ pac@age. 4<ed flud s passed
t"roug" a %<ng BalBe. $"e pressure drop across t"s BalBe s controlled at around 1.& bar5
by P1IC #2018. 8fter t"e %<ng BalBe5 flud enters 1
st
stage 1esalter7#208. $"e ol and
(ater s separated under a "g" electrcal potental dfference. $"e separated (ater s routed
to t"e (as" (aster pre"eater and t"en to t"e (ater treat%ent secton. !l flo(s out fro% t"e
top and s sent to t"e ne<t 1esalter. !l (ater nterface leBel (ll be controlled by L1IC7
#2028.
'eparated ol fro% t"e frst stage s %<ed (t" pre"eated fres" (as" (ater and s passed
t"roug" a %<ng BalBe and t"en routed to t"e second stage 1esalter 1'7#200. $"e
pressure drop across t"e %<ng BalBe s %antaned at around 1.& bar by P1IC7#2010. !l
(ater separaton s ta@ng place n t"e 2
nd
stage 1esalter also. $"e separated (ater s
recycled to 1
st
stage 1esalter. $"e ol flo(s fro% t"e top to t"e 'tabl;er colu%n. Flo( rate
of ol s controlled by t"e leBel controller of 2
nd
stage separator LIC7#02&. 'eparated (ater
fro% t"e second stage 1esalter s recycled to t"e frst stage usng pu%p G:7#20 890.
4n%u% flo( t"roug" t"e pu%p s controlled by FIC7#204 and FC7#2045 ("c" recycles
(ater bac@ to t"e 2
nd
stage 1esalter.
$"e (as" (ater flo(rate s controlled by FIC7#200 and FC7#200 at t"e n)ecton pont
bet(een t"e 1
st
and 2
nd
stage 1esalters.
Parallel o-eration
'Ingle stage desaltng s proBded n t(o parallel Bessels. $"e nco%ng "ot feed s %<ed
(t" t"e oly effluent fro% !+$ pac@age and t"en splt n t(o strea%s. 6ac" strea% s %<ed
(t" sea (ater fro% t"e (as" (ater pu%p pror to passng t"roug" a %<ng BalBe. $"e
pressure drop across t"s BalBe s controlled at around 1.& bar5 by P1IC #201890. 8fter t"e
%<ng BalBe5 flud enters 1esalter7#20890. $"e ol and (ater s separated under a "g"
electrcal potental dfference. $"e separated (ater s routed to t"e (as" (aster pre"eater
and t"en to t"e (ater treat%ent secton. !l flo(s out fro% t"e top and s sent to t"e top of
t"e 'tabl;er.
!l (ater nterface leBel (ll be controlled by L1IC7#202890. $"e separated (ater fro% bot"
t"e 1esalters s sent to t"e !ly +ater Pac@age. Fro% 1esalter 8 Ba L17#202 =flo(ng Ba
6C7#21>. Fro% 1esalter 05 (ater s dsc"arged Ba G:7#20 890 and L1C7#200. $"e 4H ball
BalBe n t"e lne to t"e oly (ater pac@age s to be opened5 ("le t"e 4H ball BalBe n t"e
recycle lne to t"e nlet of 1esalter 8 s to be closed. 4n%u% flo( t"roug" t"e pu%p s
controlled by FIC7#204 and FC7#2045 ("c" recycles (ater bac@ to t"e 1esalter 0.
$"e (as" (ater flo(rate s controlled by FIC7#200 and FC7#200 upstrea% t"e pont ("ere
t"e (as" (ater strea% splts n t(o to t"e nlets of t"e t(o 1esalters.
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Page 99 of 149
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FIG 2 16'8L$62 C!/$2!L 'CH646 ='62I6' !P628$I!/>
Page 100 of 149
F2!4 2
/1
'$8G6
'6P828$!2
1
'$
'$8G6
16'8L$62
1' #20 8
2
/1
'$8G6
16'8L$62
1' #20 0
$! '$80ILIW62
$! !+$
P8CD8G6
G: #20
+8'H +8$62
+8'H +8$62
P26H68$62
6C #21
F2!4 !+$
P8CD8G6
L1IC
L1IC
P1C
P1C
FC
FC
Doc. o. I"#$-%11-&$$-%%%$$$-P"'-($1)*
"e+ $1
FIG # 16'8L$62 C!/$2!L 'CH646 =P828LL6L !P628$I!/>
3.:.# ,ta2ili>er
1ry ol contanng L 0.2M by Bolu%e (ater fro% t"e 1esalter5 s routed to t"e top of t"e
'tabl;er Colu%n. Pre"eated ol enters t"e top of t"e 'tabl;er Colu%n5 C87#105 ("ere any
Bapor generated due to pressure reducton flas"es fro% t"e ol. !l flo(s do(n t"e colu%n5
contactng on t"e trays (t" "ot Bapor generated n t"e Crude 'trpper 2eboler5 6C #10.
Capor fro% t"e reboler passes up(ards t"roug" t"e colu%n5 contactng (t" descendng
crude on t"e trays and strppng H2' and lg"t "ydrocarbons fro% t"e crude. 'tabl;ed
crude fro% t"e reboler drops nto t"e colu%n botto%s secton fro% ("ere t s pu%ped out
by t"e Crude ol transfer Pu%ps5 G: #11 890. LIC7#101 controls t"e leBel n t"e stabl;er by
%odulatng control BalBe LC7#101 do(nstrea% t"e 'tabl;ed !l $r% Cooler 6C7#12. Pu%p
s protected aganst gong belo( t"e %n%u% flo( by proBdng a recycle control BalBe FC7
#1015 ("c" recycles t"e stabl;ed ol to t"e colu%n under control of FIC7#019 n t"e
dsc"arge of t"e pu%p. $"e 'tabl;er Colu%n s controlled as follo(s.
'trpped gases are released to flare on pressure control. $"e colu%n pressure s controlled
by PIC7#101. H2' strpper colu%n botto% te%perature (ll be %antaned by $IC #1005
("c" sets t"e desred stea% flo( to t"e reboler =FIC7#10&>. $"s (ll ac"eBe t"e desred
Page 101 of 149
F2!4 2
/1
'$8G6
'6P828$!2
1
'$
'$8G6
16'8L$62
1' #20 8
2
/1
'$8G6
16'8L$62
1' #20 0
$! '$80ILIW62
$! !+$
P8CD8G6
G: #20
+8'H +8$62
+8'H +8$62
P26H68$62
6C #21
F2!4 !+$
P8CD8G6
L1IC
L1IC
P1C
P1C
FC
FC
$! !+$
P8CD8G6
Doc. o. I"#$-%11-&$$-%%%$$$-P"'-($1)*
"e+ $1
$CP and H2' specfcaton n t"e e<port crude ol =,07pp% by (t>. 8 condensate pot (t"
leBel control s proBded for condensate re%oBal fro% reboler.
$"e (ater dra(7off fro% t"e colu%n s controlled by nterface leBel controller L1IC7#109 on
t"e dra(7off collecton pot5 ("c" sends t"e dra(7off (ater to t"e oly (ater pac@age Ba
L1C7#019.
$"e H2' strppng process s senstBe to t"e reboler te%perature and t"e operatng
pressure. Hg"7pressure s(tc" =P'HH #102> and t"e re7boler return te%perature s(tc"
=$'HH #104> are proBded. $"ese alar% set ponts s"all be carefully %ontored n control
roo%.
3.:.( Product -um-in.?coolin.
'tabl;ed crude fro% t"e 'tabl;er Colu%n s pu%ped =usng G: #11 890> to t"e LP
separator pre"eater =6C #1#>. In t"s e<c"anger5 ol co%ng fro% t"e frst stage separator s
"eated to about -0 JC by t"e stabl;ed crude as %entoned aboBe. Cool5 stabl;ed crude
fro% t"s e<c"anger s routed to stabl;ed ol cooler 60 #11 and t"e 'tabl;ed ol tr% cooler
6C #12. $"e outlet te%perature of 607#11 s controlled at *0 JC by $IC7#111 Ba splt range
control. Pr%ary control s on t"e by7pass around t"e coolers and t"e secondary control s on
t"e fan ptc" control on t"at s proBded on one of t"e t(o fans on eac" of t"e 4 cooler
ban@s. !n9off control on t"e ot"er fan on eac" ban@ s %anual by t"e operator. Fnal ol
te%perature s controlled =$IC #11&> by t"rottlng t"e sea (ater flo( t"roug" t"e tr% cooler.
$"e te%perature s relayed to t"e control roo%. In addton5 t"e "g" te%peratures alar%
$8H7#11& and t"e Hg" Hg" $rp =$'HH #11*>.
'tabl;er botto% leBel s controlled by LCC #101 on t"e ol e<port lne. $"s BalBe s proBded
(t" a co%plete spare control BalBe n t"e bypass.
4etered crude s routed to t"e ne( ol ppelne for e<port. $"e operatng pressure at t"e
delBery pont of ppelne s %ontored and relayed to t"e Control 2oo%. 8 lo( lo(7pressure
s(tc" =P'LL7#11&> s nstalled on t"e e<port "eader.
$"ere s a faclty to recycle part of t"e stabl;ed ol to t"e frst stage separators. $"s s used
durng start up or ot"er upset condtons. 'eparate off spec pu%ps =G: #12 890> s proBded
for t"s functon. $"e pu%p ta@es sucton fro% t"e ol e<port lne upstrea% of t"e LC9890
#101. 8 control BalBe s proBded on t"e dsc"arge of t"s pu%p. 1urng t"e recycle %ode of
operaton5 t"s control BalBe (ll be controlled by t"e LIC #101 ='tabl;er colu%n botto%
leBel>. For t"s5 a selector s(tc" (ll be proBded on t"e control sgnal fro% t"e LIC #1015
("c" can select et"er ol e<port or recycle %ode of operaton. In t"e ol e<port %ode5 leBel
control (ll Bary t"e ol flo( rate gong to t"e e<port ppelne. In t"e recycle %ode of
operaton5 t"e control sgnal (ll Bary t"e recycle flo( rate gong to t"e 1
st
stage separator. In
case of part recyclng5 LC98907#101 s to be selected on 8.$! and LC9C7#101 s to be ta@en
on %anual.
8ll pu%ps are proBded (t" 8uto start facltes (t" local9re%ote and auto9%anual selecton
aBalable n t"e 1C'.
3.:.6 Oil3 =ater 4reatment ,3stem
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Produced (ater fro% t"e 1
st
stage 'eparators5 t"e $est 'eparator and t"e 2
nd
'tage
'eparator s routed to t"e degassng s@%%er. Fro% t"e s@%%er5 (ater (t" ol traces5 s
sent to flotaton unt 1' 4015 ("ere product ol specfcaton n (ater s ac"eBed =as per
Du(at Protocol>. 1' 401 operates at about 0.270.# barg. +ater fro% 1' 401 flo(s to 1'
4025 (ater flas" Bessel t"at operates at about 0.- bara Bacuu%.
Cacuu% n 1' 402 s %antaned by an e)ector syste% operatng (t" fuel gas as t"e %otBe
flud. $"e flas" gases and %otBe fluds are dspatc"ed to LP gas flare. $"e (ater fro% 1'
4025 after flas" re%oBal of H2'5 s sent to retenton pool Ba lEud seal. In addton5 t"e
Bessel 1' 402 s located suc" t"at t"e lEud seal bet(een 1'7401 and 1'7402 s
%antaned.
Flo( t"roug" t"e syste% s by graBty oBer a seres of f<ed (ers. $"e f<ed (ers control t"e
%an (ater leBels n 1'7400 and 1'7401. 8d)ust%ent reEures ta@ng t"e Bessels off7lne and
Bessel entry.
$"e (ater leBel n t"e fnal co%part%ent of t"e flotaton Bessel 1'7401 s controlled by BalBe
LC7400,. 2sng (ater leBel opens LC7400, and Bce Bersa. $"e BalBe s %antaned at ts
set7pont by t"e leBel controller LIC7400, t"at derBes tZs nput fro% L$7400,.
L$7400- proBdes HH and LL alar%s t"at ntate actons n accordance (t" t"e Cause 3
6ffect dagra%. L$74002 proBdes an ndependent "g"7"g" alar% for t"e 1egasser '@%%er
Cessel 1'7400. 8 flooded Bessel (ll result n poor de7olng effcency ("lst an e%pty Bessel
(ould allo( gas to escape do(nstrea%.
In nor%al operaton t"e gas pressure of t"e Bessels (ll be controlled by Bent BalBe PC917
4001 as suffcent gas enters (t" t"e (ater p"ase. LP fuel gas nlet BalBe PC9274002 opens
f t"e pressure begns to fall belo( t"e set pont ("lst t"e outlet BalBe PC9174001 opens f
t"e gas pressure s aboBe t"e set pont. $"e BalBes are %antaned at t"er set ponts by
PIC74001 t"at derBes ts nput fro% P$74001. Pressure trans%tter P$74002 proBdes HH
and LL alar%s ("c" (ll ntate actons n accordance (t" t"e Cause 3 6ffect dagra%. 8
"g" pressure (ll result n less gas beng lberated fro% t"e (ater p"ase ("le a lo(
pressure %ay result n lEud bac@up fro% do(nstrea%.
"e s@%%ed ol pu%ps are to operate on a duty standby bass to dsc"arge t"e contents of
t"e s@%%ed ol ppe to t"e upstrea% 1esalter. $"e pu%ps are drBen by an electrc %otor
("ose speed s controlled by an nBerter5 ln@ng t"e pu%p speed to t"e Bolu%e contaned
(t"n t"e '@%%ed !l Ppe. Falure of t"e duty pu%p (ll auto%atcally start t"e standby
pu%p.
Page 10# of 149
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# %L%"/,* 4"IP,* E,D %D EA7IP/E4
P"O4E64IO
#.1 P$S .lar% Set Point
4a. o Function ? Location ,et-Point
=ell head and
6luster manifold
Oil and Inlet
/anifold
P8H71020 /ort" 6ast Cluster $est Inlet 4anfold Pressure
Hg"
2# bar=g>
P8H7102# /ort" 6ast Cluster Inlet 4anfold Pressure Hg" 2# bar=g>
P8H7102* /ort" +est Cluster $est Inlet 4anfold Pressure
Hg"
2# bar=g>
P8H7102, /ort" +est Cluster Inlet 4anfold Pressure Hg" 2# bar=g>
P8H7102- 'out" Cluster $est Inlet 4anfold Pressure Hg" 2# bar=g>
P8H71029 'out" Cluster Inlet 4anfold Pressure Hg" 2# bar=g>
P8L71020 /ort" 6ast Cluster $est Inlet 4anfold Pressure Lo( 9 bar=g>
P8L7102# /ort" 6ast Cluster Inlet 4anfold Pressure Lo( 9 bar=g>
P8L7102* /ort" +est Cluster $est Inlet 4anfold Pressure
Lo(
9 bar=g>
P8L7102, /ort" +est Cluster Inlet 4anfold Pressure Lo( 9 bar=g>
P8L7102- 'out" Cluster $est Inlet 4anfold Pressure Lo( 9 bar=g>
P8L71029 'out" Cluster Inlet 4anfold Pressure Lo( 9 bar=g>
,e-arator
,ection
4est ,e-arator
F8L7#001 1' #00 $est 'eparator +ater !utlet Flo( lo( #9 %#9"
L8H7#00& 1' #00 $est 'eparator leBel Hg" 1000 %%
L8L7#00& 1' #00 $est 'eparator leBel Lo( ,00 %%
LI8H7#002 1' #00 $est 'eparator7 Interface LeBel Hg" #00 %%
LI8L7#002 1' #00 $est 'eparator7 Interface LeBel Lo( 200 %%
P8H7#00# 1' #00 $est 'eparator Pressure Hg" 22.& bar=g>
P8L7#00# 1' #00 $est 'eparator Pressure Lo( 9 bar=g>
1st ,ta.e
,e-arator
F8H7#010 1' #00 1st 'tage 'eparator Gas !utlet Flo( Hg" #00000 '%#9"
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F8L7#010 1' #00 1st 'tage 'eparator Gas !utlet Flo( Lo( 1&000 '%#9"
F8L7#011 1' #00 1st 'tage 'eparator +ater !utlet Flo( Lo( &0 %#9"
L8H7#01& 1' #01 1st 'tage 'eparator LeBel Hg" 1-40 %%
L8L7#01& 1' #01 1st 'tage 'eparator LeBel Lo( 1200 %%
LI8H7#012 1' #01 1st 'tage 'eparator 7 Interface LeBel Hg" ,,0 %%
LI8L7#012 1' #01 1st 'tage 'eparator 7 Interface LeBel Lo( 400 %%
P8H7#012 1' #01 1st 'tage 'eparator Pressure Hg" 22.& bar=g>
P8L7#012 1' #01 1st 'tage 'eparator Pressure Lo( 9 bar=g>
$8L7#011 1' #01 1st 'tage 'eparator Gas !utlet $e%p Lo( 22 1eg C
LP se-arator
Feed Preheater
$8H7#1#4 6C #1# LP separator feed pre"eater !l !utlet $e%p.
Hg"
90 1eg C
$8L7#1#4 6C #1# LP separator feed pre"eater !l !utlet $e%p.
Lo(
,0 1eg C
:nd ,ta.e
,e-arator
L8H7#02& 1' #02 2nd 'tage 'eparator LeBel Hg" #020 %%
L8L7#02& 1' #02 2nd 'tage 'eparator LeBel Lo( 1100 %%
LI8H7#022 1' #02 2nd 'tage 'eparator7 Interface LeBel Hg" &00 %%
LI8L7#022 1' #02 2nd 'tage 'eparator7 Interface LeBel Lo( #00 %%
P8H7#022 1' #02 2nd 'tage 'eparator Pressure Hg" ,.& bar=g>
P8L7#022 1' #02 2nd 'tage 'eparator Pressure Lo( 4.& bar=g>
Oil 5ooster
Pum-s
F8H7#110 G: #10890 !l 0ooster Pu%p Z890Z !utlet Flo( Hg" *90 %#9"
F8H7#21& 1' #20 890 1esalter Inlet Flo( Hg" *90 %#9"
F8L7#110 G: #10890 !l 0ooster Pu%p Z890Z !utlet Flo( Lo( 2#0 %#9"
Desalter
F8H7#200 1' #200 1esalter .nt Z0Z +as" +ater Inlet Flo(
Hg"
4, %#9"
F8H7#204 G: #20890 1esalter Pu%p !utlet Flo( Hg" &# %#9"
F8L7#200 1' #200 1esalter .nt Z0Z +as" +ater Inlet Flo(
Lo(
12 %#9"
LI8H7#2028 1' #208 1esalter Z8Z Interface leBel Hg" 10,& %%
LI8H7#2020 1' #200 1esalter Z0Z Interface leBel Hg" 10,& %%
LI8L7#2028 1' #208 1esalter Z8Z Interface leBel Lo( ,,& %%
LI8L7#2020 1' #200 1esalter Z0Z Interface leBel Lo( ,,& %%
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,ta2ili>er
F8H7#10& 6C #10 'tabl;aton Colu%n 2eboler 'tea% flo(
Hg"
#&000 @g9"
F8L7#10& 6C #10 'tabl;aton Colu%n 2eboler 'tea% flo(
Lo(
9*00 @g9"
L8H7#101 C8 #10 'tabl;aton Colu%n leBel Hg" ##00 %%
L8L7#101 C8 #10 'tabl;aton Colu%n leBel Lo( -00 %%
LI8H7#109 C8 #10 'tabl;aton Colu%n Interface leBel Hg"
LI8L7#109 C8 #10 'tabl;aton Colu%n Interface leBel Lo(
P8H7#101 C8 #10 'tabl;aton Colu%n Gas !utlet to Flare
Pressure Hg"
2 bar=g>
P8H7#104 C8 #10 'tabl;aton Colu%n 2eboler !ly 6ffluent
Inlet Pressure Hg"
1# bar=g>
P8H7#10, 6C #10 'tabl;aton Colu%n 2eboler 'tea% 'upply
Pressure Hg"
-.& bar=g>
P8L7#101 C8 #10 'tabl;aton Colu%n Gas !utlet to Flare
Pressure Lo(
1 bar=g>
P8L7#104 C8 #10 'tabl;aton Colu%n 2eboler !ly 6ffluent
Inlet Pressure Lo(
- bar=g>
P8L7#109 C8 #10 'tabl;aton Colu%n Pressure Lo( 1.0 bar=g>
$8H7#100 C8 #10 'tabl;aton Colu%n $e%p Hg" 1&0 1egC
$8H7#10# C8 #10 'tabl;aton Colu%n Gas !utlet $e%p Hg" 100 1egC
$8L7#100 C8 #10 'tabl;aton Colu%n $e%p Lo( 110 1egC
$8L7#110 6C #10 'tabl;aton Colu%n 2eboler Gas !utlet
$e%p Lo(
10& 1egC
,ta2ili>ed Oil
Pum-
F8H7#109 G: #11890 'tabl;ed !l pu%p !utlet Flo( Hg" *&0 %#9"
F8L7#109 G: #11890 'tabl;ed !l pu%p !utlet Flo( Lo( 2&0 %#9"
C8H7G:#1181 G:#118 4otor Bbraton (arnng
C8H7G:#1182 G:#118 Pu%p Bbraton (arnng
C8H7G:#1101 G:#110 4otor Bbraton (arnng
C8H7G:#1102 G:#110 Pu%p Bbraton (arnng
Product 6oolin.
F8H7#11& 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far% Flo(
Hg"
*12 %#9"
F8L7#11& 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far% Flo(
Lo(
1*, %#9"
$8H7#111 60 #11 'tabl;ed !l Cooler !utlet $e%p. Hg" *& 1egC
$8H7#11& 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
te%p. Hg"
&& 1egC
$8H7#119 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
te%p. Hg"
&& 1egC
$8L7#111 60 #11 'tabl;ed !l Cooler !utlet $e%p. Lo( &0 1egC
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$8L7#11& 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far%
te%p. Lo(
40 1egC
Oil3 !ater
-acDa.e
L8H74011 '@%%ed ol ppe leBel ,00 %%
L8H74021 1' 402 +ater Flas" Cessel LeBel 1&00 %%
L8L74011 '@%%ed ol ppe leBel 4&0 %%
L8L74021 1' 402 +ater Flas" Cessel LeBel *00 %%
P8H74001 1' 400 1egassng 1ru% Pressure 0.-
P8L74001 1' 400 1egassng 1ru% Pressure 0.4
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#.2 (SD *rip .lar% Set Point
/anifold %rea
P'HH71010 /ort" 6ast Cluster $est Inlet 4anfold &0 bar=g>
P'LL71010 /ort" 6ast Cluster $est Inlet 4anfold , bar=g>
P'HH7101* /ort" +est Cluster $est Inlet 4anfold &0 bar=g>
P'LL7101* /ort" +est Cluster $est Inlet 4anfold , bar=g>
P'HH7101- 'out" Cluster $est Inlet 4anfold &0 bar=g>
P'LL7101- 'out" Cluster $est Inlet 4anfold , bar=g>
P'HH71012 /ort" 6ast Cluster Inlet 4anfold &0 bar=g>
P'LL71012 /ort" 6ast Cluster Inlet 4anfold , bar=g>
P'HH7101, /ort" +est Cluster Inlet 4anfold &0 bar=g>
P'LL7101, /ort" +est Cluster Inlet 4anfold , bar=g>
P'HH71019 'out" Cluster Inlet 4anfold &0 bar=g>
P'LL71019 'out" Cluster Inlet 4anfold , bar=g>
4est ,e-arator
L1'LL7#001 1' #00 $est 'eparator7 Interface LeBel Lo(
Lo(
200 %%
L'HH7#004 1' #00 $est 'eparator LeBel Hg" Hg" 1200 %%
L'LL7#004 1' #00 $est 'eparator LeBel Lo( Lo( *00 %%
P'HH7#002 1' #00 $est 'eparator Pressure Hg" Hg" 24 bar=g>
For HP !peraton
P'HH7#002 1' #00 $est 'eparator Pressure Hg" Hg" 1&.4 bar=g>
For LP !peraton
P'LL7#002 1' #00 $est 'eparator Pressure Lo( Lo( , bar=g>
1st ,ta.e ,e-arator
L1'LL7#011 1' #01 1st 'tage 'eparator7 Interface LeBel
Lo( Lo(
200 %%
L'HH7#014 1' #01 1st 'tage 'eparator LeBel Hg" Hg" 21&0 %%
L'LL7#014 1' #01 1st 'tage 'eparator LeBel Lo( Lo( 1000 %%
P'HH7#011 1' #01 1st 'tage 'eparator Pressure Hg"
Hg"
24 bar=g>
For HP !peraton
P'HH7#011 1' #01 1st 'tage 'eparator Pressure Hg"
Hg"
1&.4 bar=g>
For LP !peraton
P'LL7#011 1' #01 1st 'tage 'eparator Pressure Lo( Lo( , bar=g>
:nd ,ta.e ,e-arator
L1'LL7#021 1' #02 2nd 'tage 'eparator7 Interface LeBel 200 %%
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L'HH7#024 1' #02 2nd 'tage 'eparator LeBel Hg" Hg" #210 %%
L'LL7#024 1' #02 2nd 'tage 'eparator LeBel Lo( Lo( -00 %%
P'HH7#021 1' #02 2nd 'tage 'eparator Pressure Hg"
Hg"
-.& bar=g>
P'LL7#021 1' #02 2nd 'tage 'eparator Pressure Lo(
Lo(
4.0 bar=g>
5ooster and ,ta2ili>ed Oil Pum-s
P'HH7#1118 G: #108 !l 0ooster Pu%p !utlet Pressure Hg" Hg" 19.0
bar=g>
P'LL7#1118 G: #108 !l 0ooster Pu%p !utlet Pressure Lo( Lo( 10.0
bar=g>
P'HH7#1110 G: #100 !l 0ooster Pu%p !utlet Pressure Hg" Hg" 19.0
bar=g>
P'LL7#1110 G: #100 !l 0ooster Pu%p !utlet Pressure Lo( Lo( 10.0
bar=g>
P'LL7#11#8 G: #108 !l 0ooster Pu%p Inlet Pressure Lo( Lo( 4.0 bar=g>
P'LL7#11#0 G: #100 !l 0ooster Pu%p Inlet Pressure Lo( Lo( 4.0 bar=g>
P'LL8907#1#18 G:#108 !l 0ooster Pu%p 'eal Pressure Lo( Lo(
P'LL8907#1#10 G:#100 !l 0ooster Pu%p 'eal Pressure Lo( Lo(
Desalter %rea
L1'HH7#2018 1' #208 1esalter Z8Z Interface LeBel 122& %%
L1'LL7#2018 1' #208 1esalter Z8Z Interface LeBel *2& %%
L1'HH7#2010 1' #200 1esalter Z0Z Interface LeBel 122& %%
L1'LL7#2010 1' #200 1esalter Z0Z Interface LeBel *2& %%
L'LL7#20#8 1' #208 1esalter Z8Z LeBel
L'LL7#20#0 1' #200 1esalter Z0Z LeBel
P'LL7#20-8 G: #208 1esalter Pu%p 8 I9L Pressure Lo( Lo( & bar=g>
P'LL7#20-0 G: #200 1esalter Pu%p 0 I9L Pressure Lo( Lo( & bar=g>
,ta2ili>ation
L1'LL7#110 C8 #10 'tabl;aton colu%n !9L to 1'400 #00 %%
L'HH7#10# C8 #10 'tabl;aton Colu%n leBel #-00 %%
L'LL7#10# C8 #10 'tabl;aton Colu%n leBel #00 %%
L'LL7#10- 6C #10 'tabl;aton Colu%n 2eboler leBel 92.2 M
P'HH7#102 C8 #10 'tabl;aton Colu%n Gas !utlet 2.4 bar=g>
P'LL7#102 C8 #10 'tabl;aton Colu%n Gas !utlet 0.& bar=g>
$'HH7#104 6C #10 'tabl;aton Colu%n 2eboler Gas !utlet 1&- 1eg
C
,ta2ili>ed Oil Pum-s
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P'LL8907#1#08 G: #118 'tabl;ed !l Pu%p Z8Z 'eal Pressure Lo( Lo( &.&
P'LL8907#1#00 G: #110 'tabl;ed !l Pu%p Z8Z 'eal Pressure Lo( Lo( &.&
P'LL7#11,8 G: #118 'tabl;ed !l Pu%p Inlet Pressure Lo( Lo( 0.& bar=g>
P'LL7#11,0 G: #110 'tabl;ed !l Pu%p Inlet Pressure Lo( Lo( 0.& bar=g>
P'HH7#1198 G: #118 'tabl;ed !l Pu%p !utlet Pressure Hg" Hg" 1, bar=g>
P'HH7#1190 G: #110 'tabl;ed !l Pu%p !utlet Pressure Hg" Hg" 1, bar=g>
$'HH7#1208 G: #118 'tabl;ed !l Pu%p Z8Z 4otor +ndng $e%p.
Hg" Hg"
1&0
1egC
Hg" Hg"
1&0
1egC
Hg" Hg"
1&0
1egC
$'HH7#12*8 G: #118 'tabl;ed !l Pu%p Z8Z 4otor 0earng $e%p.Hg"
Hg"
9& 1egC
$'HH7#12,8 G: #118 'tabl;ed !l Pu%p Z8Z 4otor 0earng $e%p.Hg"
Hg"
9& 1egC
$'HH7#12-8 G: #118 'tabl;ed !l Pu%p Z8Z Pu%p 0earng
$e%p.Hg" Hg"
9& 1egC
$'HH7#1298 G: #118 'tabl;ed !l Pu%p Z8Z Pu%p 0earng
$e%p.Hg" Hg"
9& 1egC
$'HH7#1#00 G: #110 'tabl;ed !l Pu%p Z0Z 4otor +ndng $e%p.
Hg" Hg"
1&0
1egC
Hg" Hg"
1&0
1egC
Hg" Hg"
1&0
1egC
$'HH7#1#*0 G: #110 'tabl;ed !l Pu%p Z0Z 4otor 0earng $e%p.
Hg" Hg"
9& 1egC
$'HH7#1#,0 G: #110 'tabl;ed !l Pu%p Z0Z 4otor 0earng $e%p.
Hg" Hg"
9& 1egC
$'HH7#1#-0 G: #110 'tabl;ed !l Pu%p Z0Z Pu%p 0earng $e%p.
Hg" Hg"
9& 1egC
$'HH7#1#90 G: #110 'tabl;ed !l Pu%p Z0Z Pu%p 0earng $e%p.
Hg" Hg"
9& 1egC
C'HH7G: #1181 G: #118 'tabl;ed !l Pu%p Z8Z 4otor Bbraton Hg" Hg"
C'HH7G: #1182 G: #118 'tabl;ed !l Pu%p Z8Z Pu%p Bbraton Hg" Hg"
C'HH7G: #1101 G: #110 'tabl;ed !l Pu%p Z0Z 4otor Bbraton Hg" Hg"
C'HH7G: #1102 G: #110 'tabl;ed !l Pu%p Z0Z Pu%p Bbraton Hg"
Hg"
Product 6oolin. and EG-ort
P'LL7#11& 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far% Pressure
Lo( Lo(
9.0 bar=g>
P'LL7#1248 G:#128 !ff spec Pu%p 4ec"ancal 'eal pressure Lo(
Lo(
*.1
P'LL7#1240 G:#120 !ff spec Pu%p 4ec"ancal 'eal pressure Lo(
Lo(
*.1
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$'HH7#11* 6C #12 'tabl;ed !l $r% Cooler $o $an@ Far% $e%p.
Hg" Hg"
*0 1ec C
C'HH7#11&8 60 #1181 'tabl;ed !l Cooler Fan Z81Z Cbraton Hg"
Hg"
Hg"
C'HH7#11&C 60 #11C1 'tabl;ed !l Cooler Fan ZC1Z Cbraton Hg"
Hg"
Hg"
C'HH7#11,8 60 #1182 'tabl;ed !l Cooler Fan Z82Z Cbraton Hg"
Hg"
C'HH7#11,0 60 #1102 'tabl;ed !l Cooler Fan Z02Z Cbraton Hg"
Hg"
C'HH7#11,C 60 #11C2 'tabl;aton !l Cooler Fan ZC2Z Cbraton Hg"
Hg"
C'HH7#11,1 60 #1112 'tabl;aton !l Cooler Fan Z12Z Cbraton Hg"
Hg"
Oil3 =ater PacDa.e
L'LL74002 1' 400 1egasser 9'@%%er 1ru% LeBel Lo( Lo( 2200 %%
P'HH74002 1' 400 1egassng 1ru% Pressure Hg" Hg" #.0
L'LL74010 '@%%ed ol ppe LeBel Lo( Lo( 2&0 %%
L'HH7400- 1' 401 Flotaton unt LeBel Hg" Hg" 1,90 %%
L'LL7400- 1' 401 Flotaton unt LeBel Lo( Lo( 4&0 %%
$'HH7401#8 G:4008 !l s@% return pu%p !9L $e%p Hg" Hg"
$'HH7401#0 G:4000 !l s@% return pu%p !9L $e%p Hg" Hg"
L'HH74022 1' 402 +ater Flas" Cessel LeBel Hg" Hg" 1-&0
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#.3 Fire <Gas Syste%
$"e Fre 3 Gas detector Layouts s"o( t"e locatons and types of Fre 3 Gas detector
nstalled. 2eferF I2 40 011 F0 88 000 80 . 04*, '"t 1720.
'ettngs are as follo(sF
DE4E64O" 4<PE LO= LE'EL
,E4 POI4
@I;@ LE'EL
,E4 POI4
H
2
' detectors & pp% 4& pp%
Hydrocarbon =pont type> atF
7 6ngne enclosures =ncl. 8r nlets>
7 0uldngs =ncl. HC8C ar nlets>
1&M L6L 2&M L6L
Hydrocarbon =pont type> atF
7 Processng areas
20M L6L &0M L6L
Hydrocarbon =open pat" bea%> 1L6L.% 2.& L6L.%
2ate of rse detectors 1 JC9%n

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#.# +elief /al)es
P,' o. ,et
Pressure*
2ar.
P&ID o. Location ? "emarDs
P'C 1000 890 12, 1940 'H$ 1 !/ CL.'$62 $6'$ LI/6' I/ 48/IF!L1
P'C 1002 8909C 12, 1940 'H$ 2 !/ CL.'$62 P2!1.C$I!/ LI/6 I/
48/IF!L1
P'C 100* 890 12, 1940 'H$ 1 !/ CL.'$62 $6'$ LI/6' I/ 48/IF!L1
P'C 100, 8909C 12, 1940 'H$ 2 !/ CL.'$62 P2!1.C$I!/ LI/6 I/
48/IF!L1
P'C 100- 890 12, 1940 'H$ 1 !/ CL.'$62 $6'$ LI/6' I/ 48/IF!L1
P'C 1009 8909C 12, 1940 'H$ 2 !/ CL.'$62 P2!1.C$I!/ LI/6 I/
48/IF!L1
P'C #000 890 2, 19&0 !n $est 'eparator 1' #00
P'C #011 8909C91 2, 19&1 !n Producton 'eparator 1' #01
P'C #020 8909C 10 19&# 'H$ 2 !n 2
nd
stage 'eparator 1' #02
P'C #100 890 #.& 19&* '$80ILI'62 C!L.4/
P'C #1#0 890 20 19&# 'H$ 2 6C7#1# P2!$6C$I!/
P'C #2008 21 19&& 'H$ 1 16'8L$62 8
P'C #2000 21 19&& 'H$ 2 16'8L$62 0
P'C 4020 #.& 19,1 !/ 1' 402
#.& Blow down /al)es
4%; O. P&ID o. ,IJE F%IL7"E
PO,I4IO
LO6%4IO ? "E/%"0,
01C #00# 888 19&0 #^ F! !n $est 'eparator 1' #00
01C #01* 888 19&1 *^ F! !n 1st 'tage 'eparator 1' #01
01C #02# 888 19&# 9 2 4^ F! !n 2nd 'tage 'eparator 1' #02
Page 11# of 149
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#.- (%ergency Shtdown /al)es
4%; O. P&ID o. ,IJE F%IL7"E
PO,I4IO
LO6%4IO ? "E/%"0,
6'1C 1000 888 194091 10^ FC !l lne fro% /ort" 6ast Cluster $est Lne
6'1C 1002 888 194092 1-^ FC !l lne fro% /ort" 6ast Cluster Producton
Lne
6'1C 100* 888 194091 10^ FC !l lne fro% /ort" +est Cluster $est Lne
6'1C 100, 888 194092 1-^ FC !l lne fro% /ort" +est Cluster Producton
Lne
6'1C 100- 888 194091 10^ FC !l lne fro% 'out" Cluster $est Lne
6'1C 1009 888 194092 1-^ FC !l lne fro% 'out" Cluster Producton Lne
6'1C 101* 888 194091 2^ FC !l lne fro% /ort" +est Cluster $est Lne
6'1C 101- 888 194091 2^ FC !l lne fro% 'out" Cluster $est Lne
6'1C 1020 888 194091 2^ FC !l lne fro% /ort" 6ast Cluster $est Lne
6'1C 1022 888 194092 2^ FC !l lne fro% /ort" 6ast Cluster Producton
Lne
6'1C 102, 888 194092 2^ FC !l lne fro% /ort" +est Cluster Producton
Lne
6'1C 1029 888 194092 2^ FC !l lne fro% 'out" Cluster Producton Lne
6'1C 10-1 888 1,1191 10^ FC Flo( lne fro% /ort" 6ast Cluster (ell 17
1[[P/61
1[[P/62
6'1C 10-# 888 1,1191 10^ FC Flo( lne fro% /ort" 6ast Cluster (ell 17
1[[P/6#
1[[P/64
6'1C 1091 888 1,1192 10^ FC Flo( lne fro% /ort" +est Cluster (ell 17
1[[P/+4
1[[P/+#
6'1C 109# 888 1,1192 10^ FC Flo( lne fro% /ort" +est Cluster (ell 17
1[[P/+2
1[[P/+1
6'1C 1101 888 1,119# 10^ FC Flo( lne fro% 'out" Cluster (ell 171[[P'11
6'1C 1102 888 1,119# 10^ FC Flo( lne fro% 'out" Cluster (ell 171[[P'10
6'1C 110# 888 1,119# 10^ FC Flo( lne fro% 'out" Cluster (ell 171[[P'9
6'1C 1104 888 1,119# 10^ FC Flo( lne fro% 'out" Cluster (ell 171[[P'-
6'1C 110& 888 1,119# 10^ FC Flo( lne fro% 'out" Cluster (ell 171[[P',
6'1C #11& 888 19&- 14^ FC !l 6<port Ppelne
6'1C #11* 888 19&- 14^ FC !l 6<port Ppelne
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( ,%FE4<
$"s 'afety secton brefs about t"e safety features of t"e 1orood /e( Plant facltes ("c"
proBdes safety syste%s to protect personnel5 enBron%ent and assets fro% t"reats of
producton "a;ards. $"e safety of t"e plant facltes s %antaned to a %n%u% rs@ leBel by
adaptng t"e follo(ng safety desgn aspectsF
8Bodng e<posure to potental "a;ards5
4n%sng t"e potental =freEuency> for "a;ardous occurrences =release of
"ydrocarbons5 "ydrocarbon fla%%able gases and any ot"er abnor%al "a;ardous
eBent>5
Contanng and %n%sng t"e conseEuence =fre5 e<ploson and to<c gas
releases> of t"e "a;ards5
ProBdng t"e %eans of escape and eBacuaton fro% suc" "a;ards5
ProBng a safe (or@ng enBron%ent for ste personnel and t"e surroundng
populaton.
8Bodng e<posure to potental "a;ards durng constructon5 co%%ssonng and
operatons.
&.1 Plant 7ayot
$"e Plant layout s based on t"e follo(ng desgn consderatonsF
Hydrocarbon contanng eEup%ent s postoned do(n(nd t"e preBalng (nd drecton.
$"e poston of flares and Bents are ta@en nto account preBalng (nds to aBod as far as
possble drftng Hydrocarbon9$o<c clouds.
Furnaces s preferably located at t"e e<tre%ty of unts and at least 1&% fro% ad)acent
eEup%ent ("c" %g"t proBde a potental source of "ydrocarbon lea@age =IP Code #>.
$"e processng plant facltes are grouped nto processng syste%s5 separatng "g"
pressure fro% lo( pressure5 (t" "g"7pressure eEup%ent as far as possble fro% %anned
areas and do(n (nd of t"e preBalng (nd drecton to assst n t"e protecton aganst
"ydrogen sulp"de.
Control roo%s5 tec"ncal roo%s and ot"er buldngs are located n non7"a;ardous areas.
8ccess and space for e<ecuton of %antenance5 fre7fg"tng and s%ultaneous operatons s
proBded.
Lftng and %antenance reEure%ents on eEup%ent are ta@en nto account n layout.
'afety dstances are respected and all safety dstances bet(een eEup%ent5 plant areas and
buldngs "aBe been Berfed by conseEuence %odellng usng credble accdent scenaros.
8ccess to t"e buldng areas =doors5 etc> are located and openng onto t"e sde opposte
fro% t"e process. 1oors are orentated n t"e drecton of escape.
$"e plant and flare per%eters are fenced.
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4uster areas for t"e /e( Plant are around t"e plant but outsde of t"e boundary fencng.
Cable trays5 ppe rac@s and flare "eader are postoned to suffer %n%u% da%age fro% )et
fres5 e<ploson effects or Be"cle collsons.
Ce"cle collson effects are ta@en nto account. +"ere roads run beneat" ppe rac@s
defensBe sold fra%es s postoned to preBent oBers;ed Be"cles fro% passng beneat".
'upports are placed outsde t"e %aneuBer area ="eg"t and (dt"> of Be"cles =and truc@s>
t"at (ll operate on t"e producton facltes.
Locaton of roads carryng general traffc around process bloc@s s n non7"a;ardous areas.
4n%u% of 2 entry ponts per process unt s proBded. 0arrer control at %an ons"ore
facltes entrance s proBded. Clear "eadroo% of at least 4.&% (t" suffcent (dt" to
enable long Be"cles to turn s reEured.
6scape routes and open areas are proBded.
Good pedestran access s proBded. 4n%u% "eadroo% reEured s 2.1 %.
+nd drecton ndcators are proBded across t"e plant5 to assst personnel escape n t"e
eBent of a to<c gas release.
8lt"oug" t"e Layout P"losop"y s defned n t"s secton t s recognsed t"at D"arg Island s
a congested ndustral and %ltary area and t"erefore t"e actual faclty layout s constraned
by t"e d%ensons of t"e plant plot.
&.2
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&.3 (%ergency Shtdown Syste%
(.3.1 O2jecti+e
$"e ob)ectBe of t"e 6%ergency '"utdo(n 'yste% sF
$o preBent undesrable eBents t"at could deBelop nto stuatons5 ("c" could cause rs@
to personnel and eEup%ent.
$o s"utdo(n t"e producton unts ("ere upset condtons are detected.
$o preBent an escalaton of upset condtons.
6%ergency '"ut 1o(n =6'1> s"all %n%se t"e conseEuences of a loss of contan%ent
stuaton n t"e "ydrocarbon processng strea%s. $"e "ydrocarbon process eEup%ent s
proBded (t" an auto%atc s"utdo(n and 0lo( 1o(n =01> syste% t"at n t"e eBent of an
accdental eBent beng detected ntates t"e protectBe actons and predeter%ned alar%s to
(arn personnel of a fre or gas ncdent.
In addton to t"e auto%atc s"utdo(n and blo(do(n syste% for "ydrocarbon process
strea%s t"e 6'1 syste% (ll also be reEured to ntate alar%s or e<ecutBe actons as
approprate for confr%ed detecton of fre n utlty areas and syste%s
(.3.: ,3stem %rchitecture
$"e 6'1 control s e%bedded n t"e 'afety 'afeguardng 'yste% ='''>. $"e ''' s"are a
Central Processng .nt =CP.> (t" t"e Fre 3 Gas 'yste% =FG'>5 "o(eBer t"e FG' and
6'1 logc are co%pletely ndependent soft(are pac@ages. $"e 6'1 and FG' logc s"are
only nput and output sgnals as defned n t"e 6'1 Logc 1agra%s and t"e FG' Logc
1agra%s.
$"e 6'1 syste% drBen by t"e ''' s"all be clearly dstngus"ed fro% te Process Control
'yste% =PC'> and t"e Process '"utdo(n Functon =P''>. $"e purpose of t"e PC' and t"e
P'' s to control t"e nor%al operaton of process and utlty syste%s. $"e 6'1 functons
drBen by t"e ''' "aBe prorty oBer t"e P'' and t"e PC'5 and t"e P'' "as prorty oBer
t"e PC'. $"e actBe 6'1 deBces =l@e 6'1Cs and 01Cs> are dedcated and ndependent
fro% t"e P'' control deBces =l@e '1Cs>.
(.3.3 ;eneral Princi-les
4ontorng5 control and status of 6'1 syste% and functons and 01 operatons s n t"e
Control 2oo%.
8 syste% of 4anual 8lar% Call ponts =48Cs> n any plant area are operator ntated nputs
to t"e FG'. !peraton of a 48C (ll ntate a co%%and to t"e 6'1 logc control t"at s
eEuBalent to confr%ed fre.
6'1Cs are proBded at all plant boundares. 01Cs are proBded on all pressur;ed
"ydrocarbon contanng syste%s.
$"e 6'1 syste% s desgned n accordance (t" fal7safe prncples.
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!n confr%ed detecton of a loss of contan%ent5 t"e 6'1 syste% s"all ntate auto%atc to
brng t"e plant to a safe status and to %n%;e t"e conseEuences of a release. $"s %ay
consst ofF
Isolatng nco%ng or outgong ol or gas strea%s
6%ergency depressur;aton of t"e facltes
6l%nate potental sources of gnton by solatng po(er supply fro% electrcal eEup%ent.
Intate alar%s n t"e Control 2oo% and Plant 8rea
$"e 6'1 syste% at t"e plant "as been desgn around t"ree pr%ary safety s"utdo(n leBelsF
8n ult%ate 6'1 leBel =E,D $> t"at can be trggered only %anually fro% t"e control roo% by
a pus" button. $"s s"ould be ntated n an "a;ardous eBent t"at "as t"e potental to
escalate rapdly nto an uncontrolled e%ergency stuaton.
E,D-1& B%*5*6C (ll be trggered auto%atcally Ba t"e F3G detecton n t"e producton
areas. $"ese 6'1 leBels apply on a process area bass. Certan process upset
condtons (ll also trgger t"ese s"utdo(n leBels.
E,D-: (ll be trggered by gas detecton n a non7process area and ntates only an alar%
to t"e control roo%.
$"e 'ea(ater nta@e area n ncluded n t"e plant 6'1 syste%. $"e clusters "aBe no ln@
(t" t"e plant 6'1 syste%. $"ey are proBded (t" t"er o(n ndependent safety cabnets.
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(.3.# E,D 6ontrol Lo.ic
$"e 6'1 control logc s presented n a s%plfed %anner n t"e table belo(. Full detals can
be found n t"e '"utdo(n Logc 1agra% for 6'1 3 GP1'5 I240 011 :00 88000 888 &0*-.
$"s (ll descrbe also ("at po(er sources re%an lBe and ("c" are solated at eac" 6'17
18 and 6'170.
E,D-$
6%7,E %64IO
Pus" button n control roo% 8bandon plant alar% Ba P8G8
8l%ost all electrcal po(er solated e<cept
for Lube ol rundo(n pu%ps and
Hydraulc 2atc"et pu%ps for turbnes
6'1718
E,D-1%
6%7,E %64IO
6'170
Confr%ed "g" leBel gas detecton n any
plant area
$o<c gas detected alar% Ba P8G8
$rp G$G5 61G auto start up
Isolate non7e<plosBe proof electrcal
eEup%ent n open plant areas
'"utdo(n buldng HC8C
Isolate .P' supples 2#0 C 8C5 4-C 1C and
%an HC and LC boards
6'1710
E,D-15
6%7,E %64IO
6'1718
Fre n ol area
Fre n %anfold area
Fre n gas area
Fre n dranage area
General alar% Ba P8G8
0lo(do(n all plant facltes
6'171C
E,D-16
6%7,E %64IO
6'1710
Fre n 4et"anol storage area
Fre at Flare D! dru%
HP or LP Flare D! dru% "g" "g" leBel
HP or LP Flare D! dru% "g" "g" pressure
Flare plots falure
Isolate Plant nlet 3 outlet =close all 6'1Cs>
Isolate nstru%ent ar "ose statons
GP'1718 co%%and to P''
E,D-:
6%7,E %64IO
Fre n safe areas
Fre at sea (ater nta@e
(.3.( Process ,hutdo!n Lo.ic
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8 General Process '"ut 1o(n =GP'1> s trggered for abnor%al condtons t"at present a
potental for deBelopng nto a loss of contan%ent eBent. $"s leBel s ln@ed to t"e plant
operatng process condtons and causes a producton s"utdo(n of releBant facltes. $"e
GP'1 control logc s presented n a s%plfed %anner n t"e table belo(. Full detals can be
found n t"e '"utdo(n Logc 1agra% for 6'1 3 GP1'5 I240 011 :00 88000 888 &0*- '"t
1.
;P,D-1%
6%7,E %64IO
6'171C
Pus" button n t"e control roo%
Instru%ent ar pressure lo(7lo(
$rp sea(ater lft 3 fltraton syste%
$rp sea(ater n)ecton syste%
$rp 'tea% generaton syste%
GP'1710
;P,D-15
6%7,E %64IO
GP'1718
8cd flare D! dru% leBel "g"7"g"
Closed dran dru% leBel "g"7"g"
LP fuel gas syste% pressure lo(7lo(
$rp ol syste%
$rp flare syste%
$rp gas s(eetenng
6'171C
E,D-16
6%7,E %64IO
GP'1710
/trogen syste% pressure lo(7lo(
$ube rupture 4P 0oosted Gas Cooler
$rp fuel gas syste%
$rp oly (ater syste%
$rp gas n)ecton syste%
Isolate ntrogen "ose statons
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(.3.6 6luster ,hutdo!n Lo.ic
$"e cluster s"utdo(n logc s ac"eBed t"roug" t"e (ell"ead control panels =+HCPs> and
6'1C panels. $"ere are t"ree leBels of s"utdo(nF
E,D-1. $"e "g"est leBel of e%ergency s"utdo(n of t"e co%plete cluster =ncludng closure
of t"e do(n "ole BalBes> t"at (ll be ntated n case of fre only.
E,D-:. /or%al e%ergency s"utdo(n of t"e ("ole cluster
E,D-3. '"utdo(n of a sngle (ell
$"e logc s represented n t"e table belo(. Full detals can be found n t"e '"utdo(n Logc
1agra% for Clusters5 I240 011 :00 88000 888 &0*- '"t *.
E,D-1
6%7,E %64IO
Pus" button on +HCP
8ny pus" button on escape route
Fusble plug loop
Confr%ed gas detecton
Close 'C''Cs on all ol and gas (ells
6'172
E,D-:
6%7,E %64IO
6'171
Pus" button on +HCP
4anfold pressure "g"7"g" =2 oo # Botng>
Close ''Cs on all (ells
Close all 6'1Cs
6'17# of all (ells
E,D-3
6%7,E %64IO
6'172
Flo(lne pressure "g"7"g"
Flo(lne pressure lo(7lo(
Close ''C of concerned (ell
Close 6'1C n gas n)ecton "eader =only n
case of 6'17# on gas n)ecton (ell>
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&.# Fire < Gas Syste%
(.#.1 O2jecti+e
$"e ob)ectBe of t"e fre and gas detecton s to proBde an early (arnng to personnel of
potentally dangerous stuatons suc" as fla%%able or to<c =H
2
'> gas at%osp"eres or fres
and to enable auto%atc ntaton of re%edal actons to aBod or %n%se escalaton of
eBents5 e.g. ntate releBant s"utdo(ns.
.
$"e early (arnng sgnal (ll enable personnel9and or t"e syste% to ta@e re%edal actons to
reduce escalaton effects of t"e dangerous stuaton and5 certanly at least as %portant5
personnel are %ade a(are of a dangerous stuaton. $"s s partcularly %portant for H2'
releases5 ("ere rapd personnel response s essental to reduce t"e "a;ard potental.
$"e functon of t"e F3G 'yste% s toF
4ontor all desgnated areas for fre
4ontor all areas ("ere fla%%able9to<c Bapours %g"t be present n nor%al operaton.
4ontor all ar loc@s 9HC8C ar nta@es to buldngs for to<c and fla%%able gas
ProBde a faclty for rasng an alar%
8lert personnel n Control 2oo% of any fre5 gas =to<c or fla%%able> e%ergency
stuaton
8ctBate t"e auto%atc fre7fg"tng syste% and 6'1
Close fre da%pers ("en gas s detected. '"utdo(n of HC8C syste%.
8lert personnel n Control 2oo% of any fault detected by self7test facltes.
(.#.: F&; ,u2-,3stem Descri-tion
$"e Fre 3 Gas 'yste% =FG'> s"all be proBded to perfor% t"e follo(ng dutesF
$o eBaluate sgnals fro% F3G detecton syste%5 usng Botng tec"nEues ("ere
necessary
$o actBate Bsual and audble alar%s
$o %ontor t"e actBaton of auto%atc fre fg"tng syste%s ntated on t"e confr%ed
detecton of fre Ba a fusble loop.
$o auto%atcally actBate approprate fre7fg"tng syste%s ("ere ntaton s not
auto%atc Ba t"e fusble loop.
$o allo( %anual ntaton by operator fro% Control 2oo% of re%otely operated fre
fg"tng facltes.
$o proBde start faclty =%anual and auto%atc> for fre(ater pu%ps
$o sgnal 6'1 syste% for furt"er auto%atc acton
$o actBate fre da%per closure n HC8C
$o %ontor state and aBalablty of t"e fre7fg"tng syste%s
$o ndcate any acton ta@en n Control 2oo%
$o log all F3G sub7syste% actons.
8ll F3G detector syste% output s"all be connected to t"e faclty dedcated F3G sub7
syste%. $"s for%s part of t"e faclty '''9FG' syste% ("c" s located n t"e
Instru%entaton $ec"ncal 2oo%.
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$"e detecton syste% arc"tecture s"all be based on area dentfcaton and not at detector
leBel. $"e syste% desgn s"all be based on fal7safe prncples5 (t" fault reBealng facltes
for detectors. 8ll of t"e non fal7safe F3G nputs and outputs s"all be lne %ontored.
F3G detectors (ll be proBded n all areas (t" a sgnfcant fre or gas "a;ard5 and t"ey (ll
be selected and located to %a<%se t"e speed and relablty of response.
8ll t"e F3G sensors for t"e process plant s"all be ln@ed drectly to t"e F3G sub7syste% to
be located n t"e processng plant Instru%entaton $ec"ncal 2oo%. Cluster F3G sensors
s"all be local only.
$"e oBerall F3G sub7syste% (ll be %ontored fro% t"e process plant Control 2oo%. Full
dsplay ncludng alar%s5 faults5 detecton etc s"all be proBded.
(.#.3 4he ,election and Location of F&; Detectors
1etectors (ould be selected out of t"e follo(ng types for locatng t"e% n approprate areas
at reEured EuanttyF
Ion;aton and optcal type s%o@e detectors
2ate !f 2se type t"er%al detectors
Fusble plug type t"er%al detectors
I29I2 type fla%e detectors
'pot I29I2 Fla%%able gas detectors
'pot $o<c gas detectors
0ea% type Fla%%able gas detectors
Hydrogen gas detectors
4anual 8lar% Call Ponts =48C>
General selecton crtera for eac" type of detector (ould be as follo(sF
S%o=e detectors for enclosed areas ("ere do%estc type fres =Class 8>5 fla%ng lEud
fres and electrcal fres =Class C> are e<pected and ("ere Euc@ detecton of suc" fres are
reEured et"er due to t"e areas un%anned nature or for proBdng early (arnng to enable
t"e personnel to protect t"e plant5 processes and eEup%ents.
$o%2sti2le gas detectors and to>ic gas detectors for areas ("ere lea@age of suc"
gases s possble and can escalate to cause "ar% to personnel and 9or affect plant5 process
and eEup%ents.
+"ereBer gas release leads to t"e presence of to<c gas and9or fla%%able gas n t"e sa%e
area5 only to<c gas detectors need to be proBded as to<c gas detecton notfcaton ta@es
precedence. $"e e<cepton to t"s s t"e cluster area ("ere fla%%able gas detectors "aBe
been gBen precedence5 "o(eBer to<c gas detectors are also present.
Fla%%a2le gas 2ea% detectors to be used n open plant process area to detect
fla%%able gas presence oBer t"ose locatons.
,ydrogen gas detectors ("ere "ydrogen gas release and accu%ulaton s possble.
Fla%e detectors to be proBded n t"e open plant areas ("ere "ydrocarbon fre rs@ s
predo%nant.
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Fsi2le plgs to be proBded near crtcal eEup%ent located n open areas for detectng t"e
fre n t"e Bcnty.
6<cept for buldngs5 generally5 "a;ardous area classfcaton dra(ngs of t"e plant to be t"e
bass for dentfyng t"e areas ("ere gas lea@s are possble and t"e gas concentraton can
for% gntable %<ture durng nor%al operaton of t"e plant.
Fire
Spot type !oni3ation s%o=e detectors for enclosed areas ("ere s%o@e due to fre do not
contan large partcles =less t"an 100 %crons> or ("ere products of co%buston are nBsble
suc" as cable trenc"es5 Baults ("ere electrcal cables pose t"e %a)or fre rs@. =Cable
Bods9trenc"es>. 1etectors nstalled n floor Bods and trenc"es9Baults (ll "aBe re%ote
ndcaton n t"e roo% aboBe t"e %ontored space to ndcate t"er status.
Spot type optical s%o=e detectors for enclosed areas ("ere s%o@e "as large partcles
=larger t"an 100 %crons> suc" as n t"e case of s%oulderng fres =!ffces5 +are "ouses5
publc areas5 tec"ncal roo%s5 control roo%s5 laboratores etc>.
+ate of +ise detectors 0+O+1 for enclosed areas ("ere s%o@e detectors can not be used
or are not effectBe and ("ere Euc@ te%perature rse due to fre s e<pected. $"ese could
also be used n con)uncton (t" s%o@e detectors n enclosed areas l@e (or@s"ops and
(are"ouses ("ere et"er type of fre s possble.
!+4!+ fla%e detectors for open plant areas ("ere lEud "ydrocarbon fres %ay occur5
proBdng ;one coBerage. In areas ("ere fla%ng fres are e<pected and are not eEupped
(t" any ot"er type of detectors to %ontor upset condtons5 I29I2 fla%e detectors can be
nstalled. +"ere nstalled t"ey s"all be utlsed n place of fusble plug syste%s. I29I2 fla%e
detectors s"all be proBded n t"e Gas '(eetenng 8rea5 $6G .nt5 Co%presson 8rea5
4et"anol $an@ 8rea5 1esel $an@ 8rea5 2etenton Pt 8rea5 4anfold 8rea5 !l Producton
8rea5 +ater In)ecton 8rea5 Gas Co%presson 8rea5 Gas $reat%ent 8rea5 +are"ouse5 !ffce
buldng and Laboratory n t"e /e( Plant. I29I2 fla%e detectors are also proBded n t"e
cluster area n t"e Bcnty of producton and gas re7n)ecton (ells5 and by t"e ol %anfolds
and t"e flare to(er area.
Fsi2le plg loop ("ere lne type =contnuous> coBerage and %ontorng for fre s reEured
for areas and eEup%ents.
Fusble plug syste%s s"all be t"e %an fre detecton syste% n place for t"e %a)or
"ydrocarbon lEud nBentores on t"e 1orood /e( Plant facltes. 1eluge7(ater spray
syste%s for t"e !l 'tablsaton and !l 'eparaton 8rea s"all be auto%atcally actBated5
upon confr%ed fre detecton5 by frangble bulbs %ounted on a (et plot syste% connected
to t"e deluge BalBe. .pon fre detecton5 actBated by a P'LL on t"e (et plot syste% t"e
sgnal s trans%tted to t"e F3G sub7syste% and an 6'1 ntated.
For t"e HP and LP Flare D! 1ru%s a pneu%atc fusble plug loop s proBded. Fusble plugs
s"all be located as close as possble to t"e potental source of gnton of t"e eEup%ent t"ey
protect (t"out %pedng %antenance actBtes e.g. pu%ps etc.
!nfra;red fla%e detectors 0!+FD1 s"all be nstalled ("ereBer fusble plug detecton syste%s
cannot be nstalled5 and9or fast response s reEured.
'anal .lar% $all 0'.$1 point of pull rotate type ("c" s ntegrated (t" t"e F3G syste%
(ll be proBded along all escape routes at eBery &0% nterBal and at open plant areas ("ere
%a<%u% traBel dstance to nearest 48C e<ceeds #0%. 0rea@ Glass type 48Cs (ll be
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proBded at eBery buldng e<ts =nsde>. 48C actBaton s"all "aBe t"e sa%e effect as
confr%ed fre detecton n t"e area of 48C ntaton. 8 pus" button =pull7rotate type> to
ntate 6'170 s proBded n t"e Control 2oo%.
8t t"e clusters 48C pus"buttons =pull7rotate type> are proBded at t"e entrance9e<ts to eac"
cluster ste. 8ctBaton of t"e 48C annuncates as confr%ed fre to t"e local FG' Panel
("c" ntates audble and Bsual alar%s oBer t"e cluster ste.
4oGic and Flamma2le ;as
Spot type ,2S detectors ("ere flud "andled "as H2' and ("ere Bentlaton nlets and
entrances to occuped areas are located.
Spot type ,2 detectors ("ere H2 gas e%sson s e<pected suc" as battery roo%s "aBng
Lead 8cd batteres and c"argng facltes.
Spot type $,# detectors ("ere "ydrocarbon Bapour9gas lea@ s t"e sole gas "a;ard and at
ar nta@es of %ac"nes and Bentlaton nlets. Preference s"all be gBen to t"e use of
nfrared type "ydrocarbon gas detectors to aBod H2' posonng of catalytc types =I2G1>.
$,# Bea% detectors ("ere "ydrocarbon Bapour release can for% t"e gas "a;ard.
,elected t3-es and locations
$"e Fre 3 Gas detector Layout s"o( t"e locatons and types of Fre 3 Gas detector
nstalled. 2eferF I2 40 011 F0 88 000 80 . 04*, '"t 1720.
(.#.# 'otin. Lo.ic and %ctions
8ll loops and detectors are arranged suc" t"at any arsng "a;ard can be easly located. /o
loop coBers %ore t"an one fre area.
1etecton n at least 2 loops s generally reEured n order to ntate an e<ecutBe acton.
1etecton n one loop proBdes an alar% only. 8 faled detector s"all be consdered as a
detector "g" alar%.
$"e Botng logc s generally as per t"e table belo(F
Lo.ic o. of detectors
o+er limit
Lo! le+el
B.as detctionC
@i.h le+el B.as detectionC
or fire
1oo1 1 8lar% 8lar%
2oo2 1 8lar% 8lar%
2oo2 2 8lar% Protecton acton
2oo# 1 8lar% 8lar%
#oo# 2 or # 8lar% Protecton acton
1oo/ 1 8lar% 8lar%
2oo/ 2 of %ore 8lar% Protetcon acton
$"e aboBe does not apply for fusble plug loops5 ("c" ntate acton at any sngle detecton.
$"e alar%s t"at are beng generated Ba t"e P8G8 are defned n secton &.9.2. 8ctons t"at
are generated t"roug" t"e 6'1 syste% are defned n sectons &.2.& 3 &.2.*. !n confr%ed
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fre detecton5 t"e fre(ater pu%p (ll be started. Furt"er detals can be found n t"e F3G
Cause 3 6ffect %atrces I240 011 F1# 88 000 'P . 0412
&.& +elief and Depressrisation Syste%s
6%ergency 1epressursaton =61P> syste%s are proBded to rapdly depressurse all
producton Bessel Bapour nBentores. 61P syste%s s desgned n accordance (t" 8PI 2P
&21 and so t"at t"ey do not nduce "ar%ful stuatons for t"e operatng personnel5 t"e
natural enBron%ent5 and t"e eEup%ent on t"e producton unts. 2adaton and gas
dsperson calculatons are produced to substantate t"e desgn of t"e 61P syste%.
8ll eEup%ent treatng "ydrocarbons and ot"er fla%%able or to<c fluds s"all be conBeyed
to t"e flares located at a safe dstance fro% t"e operatng plant.
$"e desgn of t"e blo(do(n syste%s s based on ac"eBng a pressure of , barg or &0M of
desgn pressure5 ("c"eBer s t"e lo(er5 (t"n 1& %n of ntaton.
&.- Flare Syste%s
Flarng s nor%ally reEured to safely dspose of t"e produced gas t"at s not used for fuel
gas or re7n)ected durng nor%al operatons. In addton t"e flare s a process safeguard t"at
s used to depressurse t"e process plant under e%ergency condtons and to receBe
dsc"arges fro% relef BalBes.
$"e flare s postoned at a safe locaton (t" respect to t"e ne( plant5 ot"er ndustral areas
and t"e publc. Flare s postoned at a safe locaton (t" respect to possble gnton by t"e
flare of fla%%able gases accdentally released fro% t"e producton facltes.
1etaled descrpton can be found n secton 2.- of t"e .tltes !peratng 4anual.
&.5 Drainage and Spill $ontain%ent
ProBsons s defned for controllng possble splls fro% t"e process 9 utltes eEup%ent by
collectng and dranng t"e% to dedcated unt=s> O dran retenton pts.
Derbs or drp pans s proBded under potental lea@ sources5 e.g. sa%ple ponts and pu%ps
to contan any spllage of to<c or fla%%able lEuds.
'egregaton of "a;ardous5 non7"a;ardous5 ran(ater and santary drans s appled as far as
possble to aBod "a;ardous stuatons or enBron%ental polluton. !pen and closed drans s
co%pletely segregated. 8 detaled descrptons of t"e closed and open dran syste%s are
gBen n sectons 2.9 and 2.10 respectBely of t"e .tltes !peratng 4anual.
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&.6 Fire Protection Syste%
(.9.1 %cti+e Fire Protection
In t"e desgn of t"e fre protecton syste%s precedence "as been gBen to aBodng a release
of "ydrocarbon t"en to %n%se gnton probablty and fnally to aBod escalaton t"roug"
t"e separaton of plant %a)or nBentores. Ho(eBer ("ere addtonal protecton "as been
dee%ed necessary5 actBe fre protecton =8FP> "as been gBen precedence oBer passBe fre
protecton =PFP> syste%s. 8ctBe Fre Protecton reEure%ents nclude Hydrants5 4ontors5
Hose 2eels5 1eluge CalBes (t" (ater spray syste% for 'eparators 3 1esalter 8reas and
Foa% 4ontors eEupped (t" 1eluge CalBes for 4et"anol5 1esel and 2etenton Pool. 8
detaled descrpton of t"e fre fg"tng syste%s proBded s gBen n secton 2.14 of t"e
.tltes !peratng 4anual.
(.9.: Passi+e Fire Protection
Load bearng structural steel s e<pected to fal (t"n 10 %nutes f drectly e<posed to a
"ydrocarbon fre. $"erefore any structural steel ("c" s reEured to retan ts load bearng
capacty5 and s at rs@ fro% e<posure fro% a "ydrocarbon fre5 (ll be protected usng
passBe fre protecton %aterals. $"e ntenton of t"s p"losop"y s to prepare a syste% of
passBe fre protecton t"at (ll offer stablty to crtcal structures and eEup%ent durng a
"ydrocarbon fre5 for a perod of 1 "our. $"s (ll l%t escalaton5 enable personnel to safely
leaBe t"e area and allo( fre7fg"tng operatons to proceed n a controlled %anner.
8ll aboBe ground dry G2P ppe used for t"e fre protecton syste% %ust be proBded (t" a
PFP coatng for a duraton of *0 %nutes. +et G2P ppng5 carbon steel or cupronc@el
ppng does not reEure PFP.
$"e applcaton of passBe fre protecton reduces t"e de%ands on t"e fre(ater syste%5
allo(ng frefg"tng efforts to be drected at t"e source of t"e fre and also to proBde coolng
(ater protecton to eEup%ent e<posed to "g" radaton
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&.8 (%ergency? ()acation and +esce 0((+1 Philosophy
(.).1 ;oals
$"e 662 p"losop"y s based on t"e follo(ng goalsF
ProBdng a F3G detecton and alar% syste% so t"at personnel are rapdly %ade a(are
of any "a;ardous ncdent.
ProBdng personnel (t" escape breat"ng %as@s5 escape breat"ng apparatus or self
contaned breat"ng apparatus to enable t"e% to be protected aganst t"e effects
of H2'.
ProBdng clear and dBerse escape routes to enable personnel to rapdly leaBe t"e
scene of an ncdent.
ProBdng a 4uster Pont e<ternal to t"e /e( Plant area (t" suffcent protecton for t"e
t%e needed to effect a controlled eBacuaton ("ere personnel asse%ble to decde
on course of acton to ta@e.
(.).: Esca-e "outes
2efer t"e follo(ng 'afety LayoutsF
I240 011 F1# 88 000 80. 04*09*19*2 OClusters
I240 011 F1# 88 000 80. &40* t"ru &41# O Plant
I240 011 F1# 88 000 80. &41* O 'ea +ater Lftng 'taton
8ll areas of t"e ons"ore facltes are proBded (t" 2 separate and dBerse escape routes5
("c" s readly accessble and unobstructed. 6scape routes s arranged suc" t"at fro%
eac" unt5 escape s possble n 2 drectons. 6scape routes s as strag"t as possble and
(t"out obstructon.
For nternal areas =roo%s> t"e traBel lengt" to an e<t s"ould be under ,%5 "o(eBer n all
nstances at least 2 e<ts s nstalled f t"e lengt" of an enclosed area s ],%. 1ead end
corrdors s"all not e<ceed &%. For outsde areas5 escape routes s located at t"e outer
edges of "a;ardous unts.
4an escape routes s at least 1.2% (de (t" clear "eadroo% of 2.1%5 %an escape routes
are s;ed for t"e passage of stretc"ers. 6scape9access routes leadng to %an escape
routes s"all "aBe a %n%u% (dt" of 0.-%.
8t least one %an escape route s"all re%an passable for long enoug" to allo( personnel to
reac" a safe area (t"out ncurrng n)ury.
1oors t"at open on to t"e route s"all not reduce t"e (dt" of t"e escape route. 1oors fro%
enclosed areas s"all open out(ards5 n drecton of escape. 6%ergency doors fro% buldng
are eEupped (t" ant7panc bars. 4n%u% door d%ensons are 200& %% "eg"t and -00
%% (dt". /o loc@ng facltes are proBded for doors along escape routes.
8ll escape routes s of non7slp fns" and %ar@ed (t" arro(s pontng to t"e safe area.
'treet lg"tng and plant e%ergency lg"tng ("c" are po(ered fro% t"e e%ergency
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generator durng 6'1718 (ll proBde adeEuate escape lg"tng. 8ll personnel enterng t"e
/e( Plant 8rea after sunset s"ould carry an 6<d rated torc"5 for n case 6'170 (ould be
ntated. Personnel gong to off7ste areas s"ould also carry an 6<d torc".
';ng of escape routes especally star(ays and starcase s"all ta@e nto consderaton
transt of stretc"ers and persons (earng breat"ng apparatus.
6scape routes s clear of any Bent fro% "a;ardous areas.
1recton sgns are strategcally postoned along escape routes n bot" 6ngls" and Fars.
'gns s"all lead personnel to t"e %uster area or e%ergency e<ts. $"e colour code s ("te
on green bac@ground.
Plans s"o(ng locatons of %a)or te%s of safety eEup%ent s pro%nently dsplayed nsde
t"e plant.
(.).3 /uster %rea
8 %uster area s proBded outsde of t"e /e( Plant per%eter boundary fence of t"e ne(
ons"ore facltes5 ("ere personnel can be up(nd and protected fro% t"e effects of an
ncdent by t"er p"yscal separaton.
In assgnng an outsde %uster area5 t s assu%ed t"at t"e %an 6%ergency 2esponse
Centre s n t"e Control roo%5 "eaded by traned personnel. 8ll t"ose personnel not nBolBed
n 62 actBtes s"all go to et"er t"e %an %uster area or t"e nearest e%ergency e<t5
follo(ng orders gBen oBer t"e Publc 8ddress9General 8lar% syste%.
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&.19+adio $o%%nication and P.G. Syste%
2ado Co%%uncaton syste% are proBded for 8reas of t"e ne( facltes t"at (ll rapdly
alert personnel to t"e presence of a "a;ard5 for detals refer to Publc 8ddress and General
8lar% 'pecfcaton5 /o I24078017:007880007'PL71*00.
(.1$.1 ;eneral -rinci-les
$"e P8G8 syste% can be used to send Bocal %essages5 and general alar%s as a functon
of t"e "a;ard dentfed by t"e F3G detecton syste%.
In areas ("ere a%bent nose e<ceeds -& d0=8> a nu%ber of Bsble (arnng deBces
=flas"ng beacons> (ll supple%ent t"e loudspea@ers. $"e flas"ng beacons (ll not replace
t"e loudspea@ers n t"ose areas5 but (ll %proBe safety (arnngs durng perods of "g"
nose.
$"e co%bned Publc 8ddress9General 8lar% 'yste% s"all ntegrate t(o separate and
dentcal sub syste% =830> feedng loudspea@ers and Bsual alar% loops. $(o dfferent cable
routngs s used by t"e loops connected to t"e t(o sub syste%s.
8ll loudspea@ers and flas"ng beacons5 ncludng t"ose nstalled ndoors5 s certfed for use
n "a;ardous areas =;one15 group II 0 class $#>.
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(.1$.: 43-es of %larms
$"ere (ll be t"ree type of 8udble alar%s are follo(ed5 suc" as 8bandon Plant 8lar% $o<c
Gas 8lar% General 8lar% and Publc 8ddress 8nnounce%ent faclty.
%2andon Plant %larm
Intaton of t"e 8bandon Plant alar% fro% t"e P8G8 syste% s Ba t"e '''9FG' syste%
follo(ng %anual ntaton of 6'170 by pus"button n t"e Control 2oo%. $"e abandon plant
alar% (ll be reset %anually n t"e Control 2oo%.
$"e alar% tone s an unnterrupted sgnal (t" s(eepng freEuency fro% 1200 H; to &00 H;
(t" s(eep perod of 1 second co%ple%ented by red flas"ng lg"ts ("ere necessary.
4oGic ;as %larm
$o<c gas alar% s actBated auto%atcally Ba t"e '''9FG' syste% by confr%ed to<c gas
detecton n t"e /e( Plant 8rea or %anually Ba t"e P.8.G.8 access unt.
$"e alar% s 1000 H; tone co%ple%ented by red flas"ng lg"ts ("ere necessary.
$"e auto%atc or %anual alar% s reset only fro% t"e P.8.G.8 access unt of t"e control
roo%.
;eneral %larm
8uto%atc ntaton of a General alar% fro% t"e P8G8 syste% s Ba t"e '''9FG' syste%
follo(ng confr%ed fla%%able gas detecton or confr%ed fre detecton. 8ctuaton of a
48C (ll "aBe t"e sa%e effect as confr%ed fre. 8 General 8lar% can also be actBated
%anually Ba t"e P.8.G.8 access unt.
$"e alar% tone to be 1000 H; snusodal5 1second !n91second !ff co%ple%ented by
?ello(7flas"ng lg"ts ("ere necessary.
$"e auto%atc or %anual alar% s reset only fro% t"e P.8.G.8 access unt of t"e control
roo%.
Pu2lic %ddress %nnouncement1
8nnounce%ent s possble fro% bot" control roo% and guard s"elter access unts.
$"e syste% consst of %essages preceded auto%atcally by a dstnctBe pagng c"%e tone.
It s possble to send %essages or pre7recorded %essages pror to or after an alar%
broadcast.
8lar%s s"all "aBe "g"er prorty t"an announce%ent and ntaton of actons fro% Control
2oo% P8 access unt s"all "aBe prorty on t"ose ntated fro% t"e guard s"elter.
8ctons to be ta@en on eac" of t"e alar%s are descrbed n t"e e%ergency response plan.
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(.1$.3 Pro+isions at Off-sites
6luster %reas1
$"e clusters (ll be proBded (t" audble and Bsble alar%s5 ("c" (ll be ntated drectly
fro% t"e cluster FG' on confr%ed fre or gas detecton. 6ac" cluster (ll "aBe separate
to<c gas and general alar%s toget"er (t" assocated Bsual alar%s.
Flare and ,ea =ater IntaDe %reas1
$"e flare and 'ea +ater Inta@e areas (ll not be proBded (t" a P.8.G.8 'yste%. $"ere (ll
be no Bsble or audble alar%s n t"ese areas. Ho(eBer5 confr%ed fre detecton n et"er
t"e flare area =ntated by 48C> or sea(ater nta@e area (ll ntate t"e General 8lar% n t"e
/e( Plant Ba t"e P.8.G.8. syste%.
&.11Safety Signs < Personnel Protection
(.11.1,afet3 ,i.ns
'afety sgns (ll be proBded t"roug"out t"e facltes. $e<t s n Fars and 6ngls". 'afety
sgns are n accordance (t" 0' &#,-.
6%ergency sgns s"all be proBded to nfor% personnel of escape routes5 e%ergency e<ts5
fre7fg"tng and rescue eEup%ent locatons. 8ll e%ergency sgns are p"oto lu%nescent and
Bsble by t"e nor%al lg"tng suppled by t"e G$G po(er or t"e e%ergency lg"tng
descrbed for 6'17185 untl f necessary 6'170 s %anually actuated.
6nclosures protected by C!
2
s"all "aBe at t"er entrance (arnng sgns t"at nfor%
personnel of %%nent C!
2
dsc"arge as (ell as nstructon to n"bt t"e syste% before
enterng t"e area.
Hg" Bsblty (ndsoc@s s"all be proBded on ste to enable personnel to deter%ne t"e (nd
drecton and to select an approprate escape route.
(.11.:Personnel Protection
Personnel protecton s proBded aganst t"e follo(ng "a;ardsF
Hot surfaces9fluds
'lps5 trps and falls
+or@ng n closed enBron%ents
6<tre%e enBron%ental condtons
+or@ng (t" c"e%cals
8deEuate personnel protecton s proBded n t"e for% ofF
'afety "el%ets and gloBes
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6ye protectBe spectacles5
'afety s"oes5
6ar protecton5
Fre protecton suts5
6scape %as@s
0reat"ng apparatus5 $rolley %ounted (t" 4 cylnders and "ose.
$orc" 2ec"argeable =6<d type>
Fre%ans Dt
6Eup%ent for * fre%en s proBded.
Frst 8d 6Eup%ent
8 Frst ad bo< s proBded n t"e offce buldng =frst ad roo%>.
6lectrcal 'afety Dt 7 8n electrcal safety @t s proBded nsde t"e electrcal roo% and
t"e sea(ater pu%p tec"ncal s"elter
4oGic ;as Esca-e /asDs* 5reathin. %--aratus and 5reathin. %ir 6om-ressor
8deEuate nu%ber of 0reat"ng apparatus unts s"all be proBded nsde t"e central plant for
t"e e%ergency response tea% and personnel attendng t"e clusters. $"ese 08 sets s"all
"aBe an autono%y of #0 %nutes.
$o facltate co%%uncaton durng an e%ergency eBent5 08 "eadsets (ll "aBe t"e proBson
to attac" rado co%%uncaton to nterface (t" e<stng rado syste%s. 8deEuate nu%ber of
escape breat"ng apparatus unts s"all be @ept n t"e central plant for ot"er personnel. $"ey
s"all "aBe autono%y of greater t"an 10 %nutes.
8deEuate nu%ber of $o<c escape gas %as@s (t" an H2' protecton cartrdge s @ept n t"e
central plant for all personnel.
$"e 6scape breat"ng apparatus s located n t"e tec"ncal roo%5 (are"ouse and at t"e
offces. 0reat"ng apparatus s located n t"e control roo% and at t"e offces. $"e to<c
escape gas %as@s s located n t"e tec"ncal roo%5 (are"ouse and at t"e offces. $o enable
t"e c"argng of t"e cylnders on ste5 a s%all breat"ng ar co%pressor sutable for use s
proBded.
,afet3 ,ho!ers and E3e!ash ,tations
Integrated safety s"o(er and eye(as" statons s"all be nstalled n t"e laboratory and (ater
treat%ent area ("ere "andlng of c"e%cals ta@es place. 6ye(as" bottles s"all be proBded
n t"e battery roo% and laboratory. 8deEuate nu%ber of eye (as" bottles s @ept n t"e
central plant for personnel Bstng t"e clusters.
Other ,afet3 eEui-ment
$"e follo(ng safety eEup%ent n addton to t"e aboBe (ll be proBded at strategc locaton
n t"e plantF
'tretc"er
Hydrogen 'ulp"de Cartrdges
8r 'upply $rolley
Personal gas alar%s =H
2
'>
Personal gas alar%s ='!
2
>
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Fre e<tngus"er and fre fg"tng eEup%ent s descrbed n secton 2.14 of t"e .tltes
!peratng 4anual.
Auantities -ro+ided B@OLDC
6Eup%ent /o. 7 Plant /o. 7 Clusters
=$otal>
/o. 7 Aetty $otal
/edical EEui-ment1
'afety s"o(ers (t" eye(as"s # 0 0 #
6ye(as"s 2 # 0 &
Frst 8d @t 1 # 0 4
'tretc"ers 1 1 =n fre truc@> 0 2
Personnel ,afet3 EEui-ment
Fre%ans !utfts * 0 0 *
$o<c gas escape %as@ =$G4> 40 0 0 40
H
2
' cartrdges 200 0 0 200
0reat"ng apparatus =82I> 12 # =n fre truc@> 0 1&
Personal gas alar% 24 * 0 #0
6scape breat"ng apparatus
=608>
*0 0 0 *0
Lfe buoys 0 0 2 2
$rolley of 8r 'upply =$8'> * 0 0 *
0reat"ng 8r Co%pressor =08C> 1 0 0 1
&.12(%ergency Power Syste%
!ne e%ergency 1G of *40@+ (ll be nstalled to supply essental9e%ergency loads of t"e
plant.
$"s 1G set (ll be used durng plant start7up to po(er t"e startng %otor of t"e G$G as (ell
as to cater to c"argng of t"e batteres of Barous 8C and 1C .P' syste%s.
!n total po(er loss fro% t"e G$Gs5 t"s 1G set (ll be started auto%atcally and (ll co%e
on lne to c"arge t"e e%ergency bus of t"e LC '(tc"board P1 99072 ("c" caters to all t"e
crtcal9essental loads. Ho(eBer5 all t"e essental9e%ergency loads5 ("c" drop out durng
t"e loss of G$G supply5 need to be re7started %anually.
$"e 1G set (ll be suppled5 "oused n an acoustc enclosure eEupped (t" all t"e
assocated 1G au<lary syste%s suc" as startng battery5 fuel tan@5 Bentlaton fans5 fre 3
gas detecton5 C!
2
syste% and nternal lg"tng.
For t"e planned lBe transfer of essental 9e%ergency loads5 f reEured any t%e5 fro% t"e
1G set to G$G po(er and Bce7Bersa5 sync"ronsng facltes are proBded n t"e aboBe
referred generator control panel.
Furt"er detals can be found n secton 2.1#.1 of t"e .tltes !peratng 4anual.
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&.137ighting
0attery bac@ed up =autono%y t%e of #0 %nutes> safety lg"tng and e<t lg"tng (ll be
proBded n t"e %an plant tec"ncal buldng. In addton5 battery bac@ed up e<t lg"tng (ll
be proBded n t"e sea(ater nta@e area tec"ncal buldng5 offce bloc@ and t"e laboratory
buldngs.
$"e safety lg"tng f<tures are of 2<#* (atts fluorescent type and t"e e<t lg"ts are of 1< -
(atts fluorescent type. $"e battery bac@ed up f<tures referred aboBe s 6<d type.
8s t"ere s no e%ergency generator po(er aBalable at t"e sea (ater nta@e5 t"e sea (ater
nta@e tec"ncal buldng safety lg"tng f<ture s connected to t"e 2#0 Bolts 8C .P' po(er
source aBalable at t"e )etty area =e<tended fro% t"e %an plant>.
P"oto cell controlled street lg"tng and outdoor lg"tng (ll be proBded n t"e outdoor areas
and sea (ater nta@e area. In addton to t"e p"oto cell control5 t"e street9 outdoor lg"tng
(ll "aBe auto%atc control t"roug" a progra%%able t%er and oBerrdng %anual control.
+"en G$G po(er s aBalable t"e entre lg"tng ncludng t"e nor%al lg"tng and
e%ergency lg"tng f<tures (ll be po(ered fro% t"e G$G po(er. Ho(eBer5 t"e lg"tng
syste% s desgned n suc" a (ay t"at all t"e street lg"ts and &0M of bot" outdoor and
ndoor f<tures5 ("c" are ter%ed as e%ergency lg"tng f<tures5 (ll be po(ered
auto%atcally by t"e e%ergency generator source durng t"e loss of G$G po(er.
1urng 6'1718 ("en only t"e 6%ergency 1.G set (ll be aBalable5 t"e follo(ng lg"ts (ll
be aBalable at t"e %an plant.
6<t lg"ts
6%ergency lg"ts and t"e street lg"ts
'afety lg"ts
1urng 6'170 ("en net"er t"e G$Gs nor t"e 6.1.G set (ll be aBalable5 only t"e follo(ng
lg"ts (ll be aBalable at t"e %an plant.
6<t lg"ts
'afety lg"ts
Furt"er detals on t"e lg"tng can be found n secton 2.1#.& of t"e .tltes !peratng
4anual.
&.1#Noise
/ose l%ts and calculated nose leBels are lad do(n n t"e nose specfcaton. $"ese nose
calculaton s"o( t"at t"e nose leBels on t"e Plant durng nor%al operaton can reac" or
e<ceed -& d08 (t"n areas.
In areas ("ere nose leBels %ay result n s"ort or long ter% da%age to personnel ear
protecton sgns (ll be proBded and ear protecton (orn.
Page 1#& of 149
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6 ,4%"4 7P P"O6ED7"E,
For t"e start up of t"e producton facltes5 t s essentals t"at all of t"e utltes and off7stes
are co%%ssoned and are operatng. $"s secton descrbes t"e start up procedures for t"e
ol processng facltes.
It is em-hasi>ed that the -rocedures outlined in this section shall in no !a3
su-ersede the +endor recommended -rocedures for start u- ? normal o-eration and
shutdo!n.
4herefore the reader is reEuested to refer to the +endor documents for 2etter
understandin. of the s3stems.
$"e procedures are ncluded n Bolu%e 2 of t"s %anual.
Page 1#* of 149
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Page 1#, of 149
8ssu%e batteres 61G
and Fre +ater Pu%p
desel engne are c"arged
Prepare Fre +ater 'yste%
='tand7by5 nor%al stuaton>
@*!7!*!(S4S@422
'tart 6%ergency 1esel
Generator 'et
6nerg;e 6%ergency '(tc"
0oard
'tart Control 3 'afety 'yste%s
'tart Instru%ent 8r 'yste%
@*!7!*!(S4S@492
'tart /trogen Pac@age
@*!7!*!(S4S@49#
'tart Aetty 1esel 'yste%
@*!7!*!(S4S@49&? Section 2
'tart Fre +ater Aoc@ey Pu%p
@*!7!*!(S4S@422
'tart one $urbo Generator on
desel fuel
'tart 1esel 'yste%
@*!7!*!(S4S@49&? Section 1
'tart Flare syste%s
Purge (t" ntrogenK Plots on propane
@*!7!*!(S4S@413
'tart 'tea% Generaton on
desel fuel
@*!7!*!(S4S@498
'tart !pen 1ran 'yste%5 but
@eep !l 'u%p Pu%p on G!FFH
@*!7!*!(S4S@415
'tart Fres" +ater and 0oler
Feed +ater syste%s
@*!7!*!(S4S@495
'tart 'ea(ater Lftng5 C"lornaton and Fltraton
and Coolng +ater for 'tea% Generaton
"!4S@491
'tart Fuel Gas 'yste% =ncludng 8%ne 'yste%
and Fuel Gas Co%pressor> and store condensate
n 2
nd
'tage 'eparator5 1esalters and 'tabl;er.
G.S4S@492
'tart 2
nd
$urbo Generator on 1esel
'et Closed 1ran Pu%p to G8.$!H
@*!7!*!(S4S@413
Pressur;e and lea@ test 2
nd
'tage
'eparator5 1esaltes and 'tabl;er (t"
gas fro% 1orood72
O!74S@493
Pressur;e and lea@ test Fuel Gas
'yste% (t" gas fro% 1orood72
G.S4S@492
'et !l 'u%p Pu%p n !pen 1ran
'yste% to G8.$!H
'tart Closed 1ran 'yste%5 but @eep
Closed 1ran Pu%p on G !FFH
@*!7!*!(S4S@41&
'tart !l Producton 3 6<port
O!74S@492
PL%4 ,4%"4-7P 6O/PLE4ED
'tart Gas In)ecton =ncludng Glycol
1e"ydraton 'yste%>
G.S4S@493
'tart !ly +ater 'yste%
O!74S@493
=1ependng on t"e a%ount of (ater produced5
t"s pac@age %ay need to be started already
durng t"e condensate collecton p"ase>
'tart 1eaerator and +ater In)ecton
'yste%
"!4S@491
'(tc" oBer to fuel gas purge of Flare 'yste%s.
'(tc" 'tea% Generaton to Fuel Gas.
'(tc" t"e t(o runnng $urbo Generators to
Fuel gas.
Contd
Contd
Contd
Contd
Contd
Contd
'tart of c"e%cal n)ecton pac@ages s referred to n t"e procedures for t"e
applcable syste%s =l@e +I5 !l !ly (ater5 etc.>
Doc. o. I"#$-%11-&$$-%%%$$$-P"'-($1)*
"e+ $1
8 OPE"%4I; P"O6ED7"E,
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"e+ $1
9 ,@74DO= P"O6ED7"E,
Page 1#9 of 149
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) 4"O75LE,@OO4I;
It is em-hasi>ed that the -rocedures outlined in this section shall in no !a3
su-ersede the +endor recommended -rocedures Bas a--lica2leC for trou2le shootin.
and maintenance.
4herefore the reader is reEuested to refer to the +endor documents for 2etter
understandin. of the s3stems.
8.1 'anifolds
4rou2le shootin. 6hecDlist for /anifolds
Pro2lem O-erator "es-onse to De+iation
Hg" pressure n t"e (ell flo(
lne =P8H>
C"ec@ and ensure t"at t"e BalBe n t"e nlet %anfold
connectng lne s opened fully.
C"ec@ t"at t"e c"ec@ BalBe n (ell flo( lne connecton
s not gettng stuc@ closed.
6nsure t"at t"e '1C and t"e solaton BalBes n
separator nlet fro% t"e nlet %anfold are fully open.
Lo( pressure n t"e (ell flo(
lne =P8L>.
C"ec@ and ensure t"at t"e upstrea% BalBes n t"e (ell
flo( lne are opened fully.
C"ec@ for any lea@age n t"e (ell flo( lnes.
Hg" pressure n t"e crude nlet
4anfold =P8H 3 P8HH>
6nsure t"at t"e '1C and t"e solaton BalBes n
separator nlet fro% t"e nlet %anfold are fully open.
C"ec@ t"e operatng pressure of t"e separators and
t"en c"ec@ for any nstru%ent %alfunctonng.
Lo( pressure n t"e crude nlet
4anfold =P8L>
6nsure t"at t"e BalBes n t"e connected (ell flo( lnes
are opened fully.
Increase no of (ell connectons to t"e producton
%anfold f possble.
C"ec@ for any %alfuncton of t"e nstru%ent.
6nsure t"at t"e dran BalBe s not opened.
Page 140 of 149
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8.2 Separators
4rou2le ,hootin. 6hecDlist for ,e-arators
Hg" pressure n t"e
separators =P8H>. =P'HH n
t"e separator s"uts do(n t"e
separator nlet BalBes>
C"ec@ t"at t"e Pressure controller and control BalBes n
t"e gas outlet lne are (or@ng properly.
C"ec@ t"e nstru%ent ar supply tubng f t"e BalBe s
re%anng closed.
C"ec@ t"at t"e Control BalBes n t"e Bent lne to HP flare
"eader are functonng properly.
C"ec@ and ensure t"at t"e Gas In)ecton co%pressors
are (or@ng and 'lug catc"er pressure control s (or@ng
properly.
Lo( pressure n t"e separators
=P8L>.
6nsure t"at t"e '1C and t"e solaton BalBes n t"e nlet
to t"e separator5 fro% t"e nlet %anfold are fully open.
C"ec@ t"e functonng of t"e control BalBes =and
controller (rng> n t"e gas Bent lnes to HP flare5 ensure
t"at t"ey are not n open condton due to falure of
nstru%ent ar tubng.
Hg" LeBel n t"e ol
co%part%ent
C"ec@ ("et"er t"e do(n strea% '1C BalBes are closed
due to trp sgnals.
controller (rng> n t"e ol outlet lne and ensure t"at
t"ey are not stuc@ closed due to falure of nstru%ent ar
tubng.
8lso c"ec@ t"e oly (ater outlet lne control BalBes.
Lo( LeBel n t"e ol
co%part%ent
C"ec@ ("et"er t"e dran BalBes n t"e oly (ater
co%part%ent are opened nadBertently.
controller (rng> n t"e ol outlet lne and ensure t"at
t"ey are not stuc@ open.
C"ec@ t"e flo( rate of ol fro% t"e separator5 f t s %uc"
belo( t"e desgn flo(5 ncrease t"e nu%ber of (ell
connectons f possble.
Hg" Interface LeBel n t"e
separator.
C"ec@ ("et"er t"e do(n strea% '1C BalBes are closed
due to trp sgnals.
controller (rng> n t"e oly (ater outlet lne and ensure
t"at t"ey are not stuc@ closed due to falure of nstru%ent
ar tubng.
Lo( Interface LeBel n t"e
separator.
C"ec@ ("et"er t"e dran BalBes n t"e separator are
opened nadBertently.
controller (rng> n t"e oly (ater outlet lne and ensure
t"at t"ey are not stuc@ open.
Page 141 of 149
Doc. o. I"#$-%11-&$$-%%%$$$-P"'-($1)*
"e+ $1
In case t"e (ater cut of t"e ol s Bery lo(5 t"e separators
can be operated as 2 p"ase separators.
Page 142 of 149
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8.3 Desalter
4rou2le ,hootin. 6hecD List for Desalters
Possi2le 6auses 6orrecti+e /easure
8. +dely Fluctuatng Coltage and Current
1. Hg" +ater LeBel n Cessel C"ec@ (ater leBel by usng
$rycoc@s. Lo(er leBel bet(een
$rycoc@ # and $rycoc@ 2
2. 6lectrcal 8rc"ng of 6lectrcal If a bus"ng or nsulator "as beco%e
surface5 0us"ngs or Insulators conta%nated5 arc"ng along t"e
surface of 6lectrode Insulators %ay
occur nter%ttently for seBeral
%nutes. If per%anent da%age
occurs5 t"e Boltage (ll fall to a Bery
lo( Balue (t" t"e a%perage
ncreasng to %a<%u%. $"e
da%aged bus"ng and9or nsulator
%ust be replaced.
Lo( Coltage 9 Hg" Current

1. Hg" +ater LeBel C"ec@ (ater leBel by usng
$rycoc@s. Lo(er brne leBel n
Bessel.
2. 6<cess 4<ng CalBe Pressure !pen %<ng BalBe co%pletely.
8llo( Boltage drop to return to a
steady state. 2eset pressure drop
to opt%u% settng.
#. 6%ulson Layer at Interface C"ec@ $rycoc@s. If e%ulson s
ndcated n t"e upper t(o $rycoc@s5
lo(er (ater leBel as lo( as possble
and ncrease c"e%cal addton rate.
If e%ulson layer s not dsspated n
- O12 "rs5 du%p (ater and e%ulson
layer and re7establs" leBel.
4. Hg" Crude ConductBty '(tc" to a lo(er Boltage tap. De-
ener.i>e 4ransformer before
c"angng tap poston.
C. Cery Lo( or /o Coltage 9 Cery Hg" Current
1. Hg" +ater LeBel C"ec@ (ater leBel (t" $rycoc@s.
Lo(er leBel bet(een t"e second and
t"rd $rycoc@s.
Page 14# of 149
Doc. o. I"#$-%11-&$$-%%%$$$-P"'-($1)*
"e+ $1
Possi2le 6auses 6orrecti+e /easure
2. 1a%aged 6ntrance 0us"ng 1sconnect po(er to unt. !pen t"e
$ee7$ransfor%er 0us"ng Housng
and dsconnect t"e copper (re
bet(een t"e entrance bus"ng and
t"e transfor%er bus"ng. 2e7
energ;e t"e transfor%er. If t"e fault
s cleared5 t"e proble% s (t" et"er
t"e entrance bus"ng or an nsulator
supportng t"e grd. If t"e fault does
not clear5 t"en t"e proble% s (t"
transfor%er bus"ng or t"e
transfor%er tself.
#. 6<cess 4< CalBe Pressure !pen %<ng BalBe co%pletely.
8llo( Boltage drop to stabl;e and
t"en reset t"e pressure drop to ts
opt%u% Balue.
4. 6%ulson Layer at Interface C"ec@ $rycoc@s. If e%ulson layer s
ndcated n t"e top t(o $rycoc@s5
lo(er (ater leBel as %uc" as
possble and ncrease t"e feed rate
of t"e e%ulson
brea@er c"e%cal. If t"e layer s not
dsspated n - O 12 "ours5 du%p t"e
(ater5 e%ulson layer5 and re7
establs" t"e (ater leBel.
Wero Coltage 9 Wero Current
1. Interrupted Po(er 'upply C"ec@ unt ("en po(er s restored.
2. Capor;aton n CesselLo( LeBel '(tc" (ll s"ut off po(er to t"e
transfor%er. Increase t"e Bessel
pressure or reduce t"e crude
te%perature.

Page 144 of 149
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1$ %PPEDI6E,
19.1(fflent "ater Balance
I240 011 :00 88000 018 021*5 '"t 00,5 2eB. 00
Page 14& of 149
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19.2Syste% P<!Ds
Document um2er ,ht of 4itle "e+.
I24071117:00788710078887
1,10
001 00# Clusters 7 $ypcal !l Producer (ells 0&
I24071117:00788710078887
1,10
002 00# Clusters 7 $ypcal +ater In)ecton (ells 0&
I24071117:00788710078887
1,10
00# 00# Clusters 7 $ypcal Gas In)ecton +ells 0&
I2407111780*788710078887
1,11
001 00# Producton and $est %anfold 7 /ort" 6ast
Cluster
0&
I2407111780*788710078887
1,11
002 00# Producton and $est %anfold 7 /ort" +est
Cluster
0&
I2407111780*788710078887
1,11
00# 00# Producton and $est %anfold 7 'out" Cluster 0&
I240701170027887#0078887
1940
001 002 P 3 I1 7 $e7 In 3 Inlet 4anfold 0#
I2407011700271'7#0078887
1940
002 002 P 3 I1 7 $e7 In 3 Inlet 4anfold 0#
I2407011700271'7#0078887
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001 001 P 3 I1 7 $est 'eparator 0#
I2407011700271'7#0178887
19&1
001 001 P 3 I1 7 1st 'tage 'eparator 0#
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19&#
001 002 P 3 I1 7 LP 'eparator Feed Pre"eater 04
I2407011700271'7#0278887
19&#
002 002 P 3 I1 7 2nd stage separator 0#
I240701170047G:7#1078887
19&4
001 001 P 3 I1 7 !l booster pu%ps 0#
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19&&
001 002 P 3 I1 7 1esaltng unt 0#
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19&&
002 002 P 3 I1 7 +as" +ater Pre"eater 0#
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001 001 P 3 I1 7 'tablser Colu%n 3 2eboler 0#
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001 001 P 3 I1 7 Crude ol transfer pu%p 9 1esalter
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0#
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001 001 P 3 I1 7 'tablsed !l coolng 0#
I2407011701271'740078887
19,0
001 001 P 3 I1 7 !ly +ater $reat%ent Pac@age 0#
I2407011701271'740178887
19,1
001 001 P 3 I1 7 +ater Flas" 'yste% 0#
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001 001 P 3 I1 O +ell"ead9cluster7depressursaton 9
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001 001 P 3 I1 O +ater flus"ng sc"e%e 01
Page 14* of 149
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19.3Pac=age P<!Ds
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001 P 3 I1 7 FL!$8$I!/ ./I$ 7 1'7401 81
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001 'I/GL6 +6LL P2!1.C$I!/ P3I1 00
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001 P3I1 7 +6LLH681 6462G6/C?
'H.$1!+/ P8/6L =G8' I/A6C$I!/
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19.#Sht Down 7ogic Diagra%
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I2 40 011 :00 88000 888 &0*- '"eet 29*5 2eB. 02
I2 40 011 :00 88000 888 &0*- '"eet #9*5 2eB. 02
I2 40 011 :00 88000 888 &0*- '"eet 49*5 2eB. 02
I2 40 011 :00 88000 888 &0*- '"eet &9*5 2eB. 02
I2 40 011 :00 88000 888 &0*- '"eet *9*5 2eB. 02
Page 14- of 149
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I2 40 011 :00 88 000 888 &0&9
Page 149 of 149

Oil Manual Rev 01

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Petrofac International Ltd.

Elf Petroleum Iran

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