oil manual rev 01

8/11/2019 Oil Manual Rev 01

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Petrofac International Ltd. Elf Petroleum IranJI-163 Dorood Project Onshore Facilities & e! PlantDoc. o. I"#$-%11-$$-%%%$$$-P"'-($1)*"e+ $1

,tart u and Oeratin /anualOil Processin Facilities

,tartu andOeratin /anual

Oil Processin Facilities

For

Dorood Onshore Facilities & e! Plant0har Island

Elf Petroleum Iran

Doc o. I" #$ %11 $$ %%$$$ P"' ($1)

Preared 2

Petrofac International Ltd.

JI-163

"e+ o. Date Preared 2 'erified 2 %ro+ed 2

01 Feb. 2004 PFI G.Faber P.L. dHaussy

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4%5LE OF O4E4,

1 I4"OD74IO............................................................................................................81.1 Project ,coe.........................................................................................................9

1.: ;eneral Descrition of the Facilit.......................................................................)1.2.1 Plant Capactes................................................................................................91.2.2 !ns"ore Ppelnes............................................................................................91.2.# !l $reat%ent..................................................................................................101.2.4 Gas $reat%ent and Co%presson...................................................................111.2.& 'ea(ater $reat%ent and In)ecton..................................................................111.2.* Produced +ater $reat%ent.............................................................................121.2., Flarng 'yste%s..............................................................................................121.2.- Fuel Gas 'yste%............................................................................................121.2.9 !t"er tltes (t"n /e( Plant.......................................................................121.2.10 uldngs......................................................................................................... 1#

1.3 5asis of Desin....................................................................................................1#1.#.1 esgn ass for orood #..............................................................................141.#.2 Flo( ates......................................................................................................14

1.# Fluid omosition...............................................................................................161.4.1 Producton Flud..............................................................................................1*1.4.2 In)ecton Gas...................................................................................................1*1.4.# 'ea(ater........................................................................................................1,1.4.4 Produced +ater..............................................................................................1-

1.( ,ite and /eteoroloical Data..............................................................................1)1.&.1 !ns"ore esgn Condtons............................................................................191.&.2 !ffs"ore esgn Condtons............................................................................191.&.# Cl%atc Condton...........................................................................................20

: P"OE,, DE,"IP4IO OF OIL P"OE,,I; ,er ,ection.................................................................................................((

2.&.1 'tabl;er colu%n5 C8 #10...............................................................................&&2.&.2 'tabl;er eboler5 6C #10.............................................................................&*

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:.6 Product crude umin?coolin.........................................................................()2.*.1 'tabl;ed !l Pu%ps5 G: #11 8..................................................................&92.*.2 Feed otto%s 6...............................................-##.1.2 Process =producton> '"utdo(n Functons =P''>...........................................-##.1.# PC'P'' 'yste% General descrpton...........................................................-##.1.4 ''' ' '?'$6.......................................................................................-.1.& FI6 3 G8' ' '?'$6. =FG'>................................................................-.1.* 6lectrcal /et(or@ anage%ent 'yste%........................................................-*#.1., C' $ranng '%ulator..................................................................................-*#.1.- Aetty PC'P''...............................................................................................-*#.1.9 an ac"ne Interface...................................................................................-,

3.: Process ontrol arrati+e...................................................................................99#.2.1 Producton +ell"eads5 Flo( lnes and anfolds............................................--#.2.2 'eparator 'ecton...........................................................................................-9#.2.# esalter..........................................................................................................92#.2.4 'tabl;er.........................................................................................................94#.2.& Product pu%pngcoolng................................................................................9.2.* !ly +ater $reat%ent 'yste%.........................................................................9*

# %L%"/,* 4"IP,* E,D %D EA7IP/E4 P"O4E4IO..........................................)8

#.1 P, %larm ,et Point............................................................................................)8#.: E,D 4ri %larm ,et Point..................................................................................1$1

#.3 Fire &;as ,stem..............................................................................................1$(

#.# "elief 'al+es.......................................................................................................1$6

#.( 5lo! do!n 'al+es..............................................................................................1$6

#.6 Emerenc ,hutdo!n 'al+es...........................................................................1$8

( ,%FE4


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;lossar of 4erms

lo( o(n alBe!P arrels of !l per ayP arrels per ay'+ asc 'ed%ents and +ater + ac@ +as"+! rac@s" (ater eBerse !s%ossCIP ouble loc@ and leedC' strbuted Control 'yste%ds do(nstrea%6G 6%ergency esel Generator 6' 6%ergency '"ut o(n

FG' Fre 3 Gas 'yste%FP Fberglass enforced PlastcF+ Fre +ater G! Gas to !l atoGP Glass renforced PlastcG$G Gas $urbne Generator HP Hg" PressureD! Dnoc@ !utL8$ Lo(est 8strono%cal $deLC Loc@ed ClosedL! Loc@ed !penLP Lo( Pressure

+P $"ousand arrels of +ater per ayCC otor Control Center %gl %llgra%s per lter I an ac"ne Interface'CF llon 'tandard Cubc Feet per ayP edu% Pressure/6 /ort" 6ast/P'H /et PostBe 'ucton Head/+ /ort" +est!C' !perator Control 'taton!PPC' Process Control 'yste%

PLC Progra%%able Logc agra%ppb Parts per llonpp% Parts per llon =eEuBalent to %glt>P'' Process '"utdo(n 'yste%P' Pressure 'afety alBeptb Pounds per $"ousand barrels! estrcton !rfce! e%ote7!perated alBerp% eBoluton per nute' '"ut o(n alBe'' 'uspended 'olds''' 'afety '"utdo(n 'yste%'+ 'ea +ater '+! 'ea(ater eBerse !s%oss

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$6G $r76t"ylene Glycol$'' $otal 'uspended 'oldsCP nt Control PanelP' nnterrupted Po(er 'upplyus pstrea% sual splay nt

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1 I4"OD74IO

$"e ob)ectBe of t"s docu%ent s to proBde orood !lfeld process and eEup%entdescrpton5 plant protecton and control5 safety gudelnes5 ntal and nor%al start upprocedures5 nor%al and e%ergency s"utdo(n procedures.

$"s %anual s prepared (t" t"e use of pro)ect Bendor docu%ents dra(ngs aBalable att"e t%e of preparaton. $"s procedures nstructons proBded n t"s %anual areconsdered as a base docu%ent and s"all be reBe(ed %odfed at ste as dee%ednecessary to reflect t"e as7bult dra(ngs docu%ents =ncludng Bendor %anuals> andoperatng e


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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 orood7#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. eference docu%ents l@e desgn sc"e%atcs are attac"ed n secton 10.

In the sstem descritions some simlified setches ha+e 2een included as an aid touicl understand the main features of the o+erall sstem. @o!e+er* it is to 2ereali>ed that these setches are simlified and that for full understandin of thesstem al!as reference shall 2e made to the latest as-2uilt P&IDs.

1.1 Project Scope$"e Pro)ect conssts of deBelop%ent of orood !lfelds5 located on D"arg Island n Isla%crepublc of Iran5 called t"e /e( Plant. $"e /e( Plant s on t"e (est sde of t"e Island and slocated at an appro


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1.2 General Description of the Facility

1.:.1 Plant aacities

Capactes of t"e /e( Plant (ll be

In)ected (ater 2,0 +PIn)ected gas 1#0 'CF #* JC a%bent te%perature5 or

120 'CF 4& JC a%bent te%perature! # ol treat%ent -05000 !PFuel Gas =HeaBy Case> 40 'CF =esgn>

21.9, 'CF =/or%al>52#.99 'CF =a

6ffluent (ater dsc"arge &4- %#" =/or%al>5 -,4 %#" =a

/ote' 'tandard condtons at 1&JC and 1 at%. t"ousand %llonCF Cubc feet per day!P arrels of ol per day+P arrels of (ater per day

1.:.: Onshore Pielines

$"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 types

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 dBdednto t"e # clusters5 as follo(s

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 10 test "eader or an1- producton "eader. 6ac" cluster s proBded (t" dedcated test and producton "eaderslocated n t"e /e( Plant. Producton control for eac" (ell s ac"eBed by a %anual c"o@eBalBe proBded at t"e (ell"ead. $"e producton "eaders fro% eac" cluster are co%bned att"e producton %anfold n t"e /e( Plant and feed to t"e frst stage separator. '%larly5 t"etest "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 10 ppelne and t(o- flo( lnes. 8 20 gas lne fro% orood 2 faclty s also routed to t"e slug catc"er at t"e

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/e( Plant and supples gas for orood # to %a@e7up t"e gas n)ecton and startupreEure%ents. 8 10 DH6C! gas ppelne s also routed to t"e treat%ent faclty and ster%nated at t"e /e( plant.

$"e (ater n)ecton %anfold s dstrbuted nto t(o "eaders routng to t"e nort" and sout" oft"e Island. !ne 1- "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* and s routedto t"e 'out" Cluster (t" t"ree * (ater n)ecton branc"es. 8 12 lne s furt"er tapped offfro% t"e 1* "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" Cluster

Cluster /o. of Producton

+ell

/o. of +aterIn)ecton +ell

/o. of GasIn)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 serBces

+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 seas"ore Ba t(o 1- GP lnes. $"e fre(ater s delBered t"roug" one 1* GP lne.

1.:.3 Oil 4reatment

!ne test separator s proBded for t"e faclty. Producton fro% any gBen (ell can be routedto t"e $est anfold. Fro% t"e $est anfold5 producton s routed nto t"e $est 'eparator='7#00>5 ("c" s desgned for t"ree7p"ase separaton. 8ssocated gas s flas"ed fro% t"ecrude ol and routed to t"e P %anfold.

Fro% t"e producton %anfold n t"e /e( Plant5 producton s routed to a sngle frst7stage

separator ='7#01>. $"e 1st 'tage 'eparator (ll operate as a t"ree7p"ase separaton ofol5 gas and (ater. Produced (ater separated n t"e 1st stage separator (ll be routed tot"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 routedto LP separator Feed Pre7"eater =6C7#1#>. In t"s e. $(o stages ofdesaltng are proBded. $"e nco%ng "ot feed s %


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'eparated ol fro% t"e frst stage esalter s %5 ("ere any Baporgenerated flas"es fro% t"e ol. apor fro% t"e reboler passes up(ards t"roug" t"e colu%n5contactng (t" descendng crude on t"e trays and strppng H2' and lg"t "ydrocarbonsfro% t"e crude. 'tabl;ed crude = ,0pp% H2'> fro% t"e reboler drops nto t"e colu%nbotto%s secton fro% ("ere t s pu%ped out by t"e Crude ol transfer Pu%ps.

1.:.# ;as 4reatment and omression

apor fro% t"e frst stage separator ='7#01> and test separator ='7#00> flo(s to t"e Pslug catc"er =' #0&>. P gas fro% orood 2 plant s also connected to t"e slug catc"er.Gas fro% t"e P %anfold feeds to a%ne unt =fuel gas> and P gas co%pressor =for gasn)ecton>.

Co%pressed gas fro% t"e P Co%presson 'yste% =$(o stage centrfugal co%pressor> srouted to t"e P boosted gas cooler. !utlet fro% t"s cooler enters P boosted gasscrubber. $"e (et gas s t"en treated n a Gas e"ydraton 'yste% for t"e purpose ofre%oBng (ater fro% t"e gas. et"od of gas de"ydraton s by absorpton (t" lean $6G.$"e syste% conssts of glycol contactor and rc" glycol regeneraton. e"ydrated gas =e(pont 0oC 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. sc"argefro% t"e second stage HP co%pressor s sent to t"e gas n)ecton (ells t"roug" t"e n)ectongas ppelne 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@estaton basn close to t"e s"ore Ba t(o 42 nc" lnes. $"s basn s t"e sea(ater lft statonand 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 atappro


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1.:.6 Produced =ater 4reatment

Produced (ater fro% t"e 1st and 2nd stage separators5 test separator5 esalter and

stabl;er colu%n s routed to t"e degassng s@%%er dru% ='7400>. 8 part of t"e H2' andC!2 are separated n t"s dru% and t"e separated ol s re%oBed usng s@%%ng deBce.LEud effluent fro% '7400 s sent to flotaton unt ='7401>5 ("ere ol specfcaton n (aters ac"eBed. e%anng H2' n t"e (ater s re%oBed n t"e (ater flas" Bessel ='7402>("c" operates under Bacuu%. $"e collected crude fro% '7400 and '7401 s recycledbac@ to t"e esalter pac@age for furt"er treat%ent.

1.:.8 Flarin ,stems

$"e /e( Plant "as t"ree flare stac@s on a co%%on derrc@ structureK Hg" Pressure =HP>5Lo( pressure =LP> and 8cd flares.

$"e HP Flare syste% conssts of one #0 C' (ar% "eader5 one 1* '' cold "eader5 one HPFlare D! ru%5 t(o Bertcal pu%ps and t"e HP flare tp. $"e condensate fro% HP flare D!ru% s pu%ped to 2nd stage separator.

$"e LP Flare syste% conssts of a 20 C' "eader and one LP Flare D! ru%. $"e acdflare syste% ncludes a 12 leadng to a 1* '' "eader and a Bertcal acd Flare D! ru%.$"e condensate fro% bot" LP and acd flare D! ru%s are routed to closed dran.

1.:.9 Fuel ;as ,stem

Fuel gas for t"e /e( Plant consu%pton5 because of ts "g" H2' content5 s s(eeteneddo(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 andsent to %edu% pressure =P> fuel gas consu%ersK .e.5 co%pressors turbnes5 (atern)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( Plant

Fres" +ater oler Feed (ater5 Lo( pressure stea%5 Po(er generaton5 /trogen5 Instru%ent ar5

esel5 and C"e%cal n)ecton syste%s

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Closed dran syste% receBes all process lEudcondensate 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 coolngand flter bac@(as" (ater5 oBerflo( fro% open dran syste%5 ran(ater fro% conta%natedpaBed areas5 etc.

1.:.1$ 5uildins

$"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 Desin 5asis for Dorood 3

$"e desgn bass for orood # s gBen belo(

1.3.1.1 Feed to New Plant

Co%poston Producton fro% ne( clusters5 as per 'ecton 1.4.1of t"s operatng %anual

esgn G! 1-&07#000 scftbbl

Flo( ate !l effluent N (ater to produce -05000 '!P+ater Cut 0 to #0M+ater Flo( ate #05000 +P =a+ater 'alt content efer to produced (ater c"aracterstcs ='ec. 1.4.4>a

$rue Bapor pressure 14.& psa &0J Ced Bapor pressure =P> -.& psa 100J FH2' content ,0 pp% (t.'+ 0.&M Bol.'alt content *0%gl =or 20 ptb>!l pressure at attery 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(

Cluster $otal !l N +ater Flo( ate=1>5 P

+ater Cut Gas Flo( ate=2>5'CF

/ort"76ast 405000 0 O #0M -0/ort"7+est 405000 0 O #0M -0

'out" 405000 0 O #0M -0

/otes1> esgn producton flo( fro% eac" (ell s 125000 P of !l N +ater2> esgn assocated gas flo( fro% eac" (ell s #0 'CF

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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 table/o%nal Gas In)ecton Flo( ate 120 'CFesgn Gas In)ecton Flo( ate 1#0 'CF at #* JC e


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1.# Flid $o%position

1.#.1 Production Fluid

$"e co%poston of producton flud for t"ree Gas to !l atos =G!> n %ole percent drybass s

Co%ponent G! Q 1-&0 G! Q 2400 G! Q #000H2' 9.490 ,.*1& ,.,*C!2 &.4#& &.1,4 &.2,C1 4#.&11 &1.149 .*,C2 *.*01 -.*02 9.0#

C# #.**2 #.-* #.,*C4 0.,91 0.,2- 0.,1nC4 1.-90 2.014 1.9*C& 1.401 0.,,2 0.,0nC& 2.,,* 1.0 0.9*nC* 2.4&& 2.2&* 2.0&nC, 2.94# 2.4*, 2.14nC- 2.12& 1.,- 1.&&nC9 1.4-* 1.249 1.0-nC10 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 are

Pseudo7Co%ponent + 'tandard densty =gc%#>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(ngte%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%pressordsc"arge5 n %ole M s s"o(n belo(

Co%ponent Lg"t Case HeaBy Case

H2' *.&1 11.*0C!2 *.,4 ,.4,

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Co%ponent Lg"t Case HeaBy CaseC1 ,1.09 *2.,-C2 9.#* -.*2C# #.** #.9#C4 0.&0 0.*4nC4 0.9& 1.##C& 0.#* 0.&-nC& 0.&* 0.94nC* 0.1, 0.29nC, 0.0, 0.09nC- 0.02 0.02nC9 0.0 0.0nC10 0.0 0.0C/18 0.0 0.0C/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


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$"e n)ected (ater s e


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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 Desin onditions

1.&.1.1 Baro%etric Pressre

aro%etrc pressure 1010 % bar

1.&.1.2 (le)ation

/e( plant locaton around && %

1.&.1.3 *e%peratreHg"est %ont"ly aBerage N &JF #* J C =9*.- J F>Lo(est %ont"ly aBerage 710JF 11 J C =&1.- J F>a


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1.&.2.# +elati)e ,%idity

aFrst 'econd $"rd Fourt"

n%u% *& MaFrst 'econd $"rd Fourt"

PreBalng +ndrecton /+7/esgn elocty &&.9 @%"

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: P"OE,, DE,"IP4IO OF OIL P"OE,,I;

,and gas. $"e content of gas s nor%ally e. $"e (ater content of ol s e of t"e total fluds.

$"e ol co%poston5 Bscosty and specfc graBty =Bscosty and specfc graBty depends ont"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 andBscosty.

4he as associated !ith the crude consists of mainl methane* ethane* roane and2utane and non-hdrocar2on ases such as nitroen* car2on dioGide and ossi2lhdroen.

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 seasly separated n t"e t"ree p"ase separators and n t"e storage tan@ (t"n reasonablesettlng t%e.

$"e co%poston and flo( condton of crude produced fro% t"e (ells s tested perodcally5by 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 andto(ards t"e end of t"e lfe of a reserBor t"e (ater content s %a


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:.:.: =ellheads

2.2.2.1 "ellhead description

8s part of ! # pro)ect5 1# ne( producton (ells (ll be routed to t"e ne( treat%entfacltes. $"ese are dBded nto # clusters5 ("c" are

/ort"east Cluster 4 (ells/ort"(est Cluster 4 (ells'out" Cluster & (ells

6ac" (ell s eEupped (t"

7 Hydraulcally operated do(n "ole safety BalBe ='urface controlled 'ub7surface

'afety BalBe5 'C''>7 Hydraulcally operated %aster BalBe ='urface 'afety BalBe5 ''>7 anually operated aster BalBe7 anually operated (ng BalBe7 anually operated (re lne BalBe ='+8 8L6>7 anually operated C"o@e BalBe.7 +ell"ead pressure gauge located upstrea% of t"e (ng BalBe

$"e 'C'' and t"e '' are "ydraulcally actuated and controlled by t"e (ell"ead controlpanel 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 consultatonof producton engneerng and geoscences depart%ents.

2.2.2.2 "ellhead $ontrol Panels

efer to endor =Petro Controls> P3I I40 #04, :00 88000 88D 0010

6ac" +HCP s po(ered by %otor drBen N "and pu%p5 proBdes fal7safe close actuaton oft"e '' 3 'C''5 co%bned (t" (ell s"utdo(n n case fre or "g" lo( flo( lne pressureand re%ote 6'. $"e safety cabnet s co%posed of t"e follo(ng te%s

Ite%s co%%on to t"e '' and 'C'' crcuts7 Flud reserBor (t" ol ndcator7 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 crcut7 8 safety relef BalBe set at *.0 barg nstalled on t"e control crcut7 8 "ydraulc accu%ulator (t" a capacty of 0.& lter pre7c"arged at #.& barg.

!n t"e '' "ydraulc crcut =HP>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

Page 2, of 149


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!n t"e 'C'' "ydraulc crcut =HP>

7 8n ntensfer to step up t"e pressure fro% 200 barg to #00 barg7 'afety relef BalBe set at 490 barg7 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''.

:.:.3 ;atherin ,stem

2.2.3.1 Description

$"e producton fro% t"e (ell"ead clusters (ll be routed to t"e orood7# faclty as per t"e

table belo(

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 bpdFlo( 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 (ellsneed 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 10 test "eader or an 1- producton"eader. 6ac" cluster s proBded (t" dedcated test and producton "eaders. $"e productoncontrol for eac" (ell s ac"eBed by a %anual c"o@e BalBe proBded at t"e (ell "ead. $"eproducton "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 areco%bned at t"e test %anfold and feeds to t"e test separator. outng of t"e (ells to aproducton "eader or to a test "eader s ac"eBed by operatng t"e %anual solaton BalBesproBded.

Corroson n"btor n)ecton proBson s aBalable at clusters. efer secton 2.9 for detals ont"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 protectonsyste% proBded for t"e gat"erng syste%. 8ll flo(lnes and cluster %anfolds are desgnedfor t"e (ell"ead s"ut7n pressure. $"e ppelnes fro% t"e Clusters to t"e /e( Plant and t"enlet %anfolds at t"e /e( Plant "aBe a 900S ratng. Protecton of t"e 900S syste% for

oBerpressure s as follo(s 6ac" flo(lne s proBded (t" a P'HH set at #- barg. +"en t"sone 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'. $"ere s

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anot"er 6' on t"e co%%on test and producton "eaders orgnatng fro% eac" cluster.$"ese 6's are operated on t"e 2 out of # Botng "g" pressure s(tc"es on t"eproducton and test %anfolds =set at ,0 barg>. efer secton 4.* for t"e tag nu%bers for t"endBdual (ell "ead flo( lnes.

6's are nstalled also on t"e testproducton lnes at t"e nlet to t"e ne( plant. 8part fro%plant 6' 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 arenstalled on t"e producton and test lnes co%ng fro% clusters =set at 12, barg>. efersecton 4.& for t"e tag nu%bers for t"e P's nstalled on ndBdual cluster testproducton"eaders co%ng to t"e plant. $"ese P's can relef t"e full cluster producton.$"e Producton and $est 'eparators "aBe a desgn pressure of 2, barg and are protectedby nlet 's actBated by P'HHs =set at 24 barg> and P's =set at 2, barg>.

In case of a Plant 6'5 t"e 6's 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 %asterBalBes. In case of falure to close of one or %ore of t"e (ell"eads5 t"e P'HHs on t"eCluster %anfolds (ll close t"e 6's at nlet and outlet of t"e cluster %anfolds. !nly ncase of t"e co%bned falure to close of t"e 6' n t"e sa%e flo(lne as ("ere t"e (ellfaled to close and t"e %anfold outlet 6' of t"e %anfold to ("c" t"at flo(lne (asconnected5 t"e P' at t"e plant nlet (ll be actBated.

2.2.3.3 $lster (SD/ panels

efer to endor =Petro Controls> P3Is

'out" Cluster I40 #04, :00 88000 88D 001#

I40 #04, :00 88000 88D 0014I40 #04, :00 88000 88D 001&I40 #04, :00 88000 88D 001*

/ort" 6ast Cluster I40 #04, :00 88000 88D 001,I40 #04, :00 88000 88D 001-I40 #04, :00 88000 88D 0019

/ort" +est Cluster I40 #04, :00 88000 88D 0020I40 #04, :00 88000 88D 0021I40 #04, :00 88000 88D 0022

$"e 6' panel s po(ered by 2 %otor drBen and one "and pu%p5 proBdes fal safe closeactuaton of t"e 6' BalBes5 co%bned (t" (ell s"utdo(n control n case of fre or "g"ppelne pressure and re%ote 6'. $"e 6' panel s co%posed of t"e follo(ng te%s

7 $(o %otor drBen N one "and pu%p (t" safety relef BalBes set at #14 barg togenerate 200 barg of "ydraulc pressure to 6' BalBes at t"e cluster %anfolds.

7 $(o pressure regulators set at &.& barg to energ;e t"e plot crcut and 6'control crcut

7 8 safety relef BalBe set at , barg nstalled on t"e plot crcut and 6' controlcrcut

7 $(o "ydraulc accu%ulators pre7c"arged at 140 barg5 nstalled on t"e "ydraulc HPsupply "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' actons

2.2.3.# $lster Drainage

efer P3I I407117:0078810078887&0-#8 dranage syste% s proBded at eac" cluster for depressur;aton dranage of (ell"eadannulus5 flo(lnes and %anfolds. 8t eac" cluster s nstalled one %ult7purpose dran "eader.a a nu%ber of portable spools t"e Barous Bent and dran ponts on t"e faclty can beconnected to t"s dran "eader. !ne %oble burner unt s proBded t"at can be connected tot"e dran "eader at any of t"e clusters to allo( for safely dsposal of t"e fluds.etaled operatng procedures for t"s syste% are proBded n !IL!P0*5 +ell 8nnulusleed Procedure and !IL'0*5 Cluster Isolaton5 ranage and +ater Flus"ng.

:.:.# ontrol & /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. 4e Function?Location

PG 1T0P:::

Pressure Gauge !l Producer +ell C"rst%as tree

PG 1T1P:::

Pressure Gauge !l Producer +ell lne to cluster

PG 1T2P:::

Pressure Gauge !l Producer +ell lne depressur;aton connecton

PG 1T#P:::

Pressure Gauge !l Producer +ell 8nnulus bleed

PG 1T4P:::


PG 1T&P:::


P'HH O

1::2P

Pressure '(tc" !l Producer +ell lne to cluster

P'LL O1::#P

Pressure '(tc" !l Producer +ell lne to cluster

'' 1::1P aster alBe !l Producer +ell'C''1::0P

'ub7 'urface 'afety alBe !l Producer +ell

$G 170::!P

$e%perature Gauge !l Producer +ell lne to cluster

6' 10-1710-*

6%ergency '"utdo(nBalBes

/ort" east cluster e%ergency s"utdo(n BalBes

6' 10917109*


/ort" (est cluster e%ergency s"utdo(n BalBes

6' 11017110,


'out" cluster e%ergency s"utdo(n BalBes

FG -#,05-#-05 -#90

Flo( Gauge /65/+ 3 'out" cluster C"e%cal In). Pu%pssc"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 InletPr.

PG8 -#,05

-#-05 -#90

Pressure Gauge /65/+ 3 'out" cluster C"e%cal In). Pu%ps

sc"arge Pr.PG -#,05-#-05 -#90

Pressure Gauge /65/+ 3 'out" cluster C"e%cal In). Pu%pssc"arge Pr.

P'HH10-&855C

Pressure Plots HH pressure s(tc" /6 cluster test "eader

P'HH 109&855C

Pressure Plots HH pressure s(tc" /+ cluster test "eader

P'HH 110&855C

Pressure Plots HH pressure s(tc" sout" cluster test "eader

P'HH10-*855C

Pressure Plots HH pressure s(tc" /6 cluster producton "eader

P'HH 109*855C Pressure Plots HH pressure s(tc" /+ cluster producton "eader

Page #1 of 149


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P'HH 110*855C

Pressure Plots Fro% !l +ell to Producton Header

P' -#,05-#-05 -#90 Pressure 'afety alBe /65/+ 3 'out" cluster C"e%cal In). Pu%psdsc"argePG 10#0 Pressure Gauge /ort" 6ast Cluster $est nlet anfoldPG 10#2 Pressure Gauge /ort" 6ast Cluster nlet anfoldPG 10#* Pressure Gauge /ort" (est Cluster $est nlet anfoldPG 10#, Pressure Gauge /ort" +est Cluster nlet anfoldPG 10#- Pressure Gauge 'out" Cluster $est nlet anfoldPG 10#9 Pressure Gauge 'out" Cluster nlet anfoldPG 1000 Pressure Gauge /ort" 6ast Cluster $est Inlet anfoldPG 1002 Pressure Gauge /ort" 6ast Cluster Inlet anfoldPG 100* Pressure Gauge /ort" +est Cluster $est Inlet anfold

PG 100, Pressure Gauge /ort" +est Cluster Inlet anfoldPG 100- Pressure Gauge 'out" Cluster $est Inlet anfoldPG 1009 Pressure Gauge 'out" Cluster $est Inlet anfoldPI 1020 Pressure Indcator /ort" 6ast Cluster $est Inlet anfoldPI 102# Pressure Indcator /ort" 6ast Cluster Inlet anfoldPI 102* Pressure Indcator /ort" +est Cluster $est Inlet anfoldPI 102, Pressure Indcator /ort" +est Cluster Inlet anfoldPI 102- Pressure Indcator 'out" Cluster $est Inlet anfoldPI 1029 Pressure Indcator 'out" Cluster Inlet anfoldP'HH 1010 ery Hg" Pressure '(tc" /ort" 6ast Cluster $est Inlet anfoldP'HH 1012 ery Hg" Pressure '(tc" /ort" 6ast Cluster Inlet anfold

P'HH 101* ery Hg" Pressure '(tc" /ort" +est Cluster $est Inlet anfoldP'HH 101, ery Hg" Pressure '(tc" /ort" +est Cluster Inlet anfoldP'HH 101- ery Hg" Pressure '(tc" 'out" Cluster $est Inlet anfoldP'HH 1019 ery Hg" Pressure '(tc" 'out" Cluster Inlet anfoldP'LL 1010 ery Lo( Pressure '(tc" /ort" 6ast Cluster $est Inlet anfoldP'LL 1012 ery Lo( Pressure '(tc" /ort" 6ast Cluster Inlet anfoldP'LL 101* ery Lo( Pressure '(tc" /ort" +est Cluster $est Inlet anfoldP'LL 101, ery Lo( Pressure '(tc" /ort" +est Cluster Inlet anfoldP'LL 101- ery Lo( Pressure '(tc" 'out" Cluster $est Inlet anfoldP'LL 1019 ery Lo( Pressure '(tc" 'out" Cluster Inlet anfold

P$ 1020 Pressure $rans%tter /ort" 6ast Cluster $est Inlet anfoldP$ 102# Pressure $rans%tter /ort" 6ast Cluster Inlet anfoldP$ 102* Pressure $rans%tter /ort" +est Cluster $est Inlet anfoldP$ 102, Pressure $rans%tter /ort" +est Cluster Inlet anfoldP$ 102- Pressure $rans%tter 'out" Cluster $est Inlet anfoldP$ 1029 Pressure $rans%tter 'out" Cluster Inlet anfold

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2.3 Separator section

efer PF I 40 11 02 88#00 0240 '"t 001

$"s syste% s desgned to process producton flud fro% ol (ells to produce -05000 bopd ofol and assocated gas and (ater. $"e secton conssts of t"e follo(ng eEup%ent.

1ststage separator =' #01>$est 'eparator =' #00>LP separator feed pre"eater =6C #1#>2ndstage separator =' #02>!l booster pu%ps =G: #10 8>

:.3.1 Princile of ,earation of =ater from Oil in ,earators

$"e functon of a separator s to proBde re%oBal of free gas fro% ol and or (ater at aspecfc pressure and te%perature. 8ll t"e separators n t"e /e( plant are desgned to %eett"e follo(ng reEure%ents

7 LEud %ust be separated fro% gas n a pr%ary separatng secton7 Gas Belocty %ust be lo(ered to allo( lEuds to drop out7 Gas %ust be scrubbed t"roug" an effcent de%ster7 +ater and ol %ust be dBerted to a turbulence7free secton of t"e Bessel7 LEuds %ust be retaned n t"e Bessel long enoug" to allo( separaton

7 $"e (ater O ol nterface %ust be %antaned7 +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 %


34/149



P Q a%eter of (ater droplet5 ft( Q LEud densty lbft#l Q !l densty lbft#

$"e Belocty of s%all (ater droplets =free coalesced (ater> n !l p"ase s goBerned by t"efollo(ng 'to@es La(.

t Q 14-- < g < p2 < =(V7 lU>

+"eret K $er%nal Belocty ftsecg K 8cceleraton due to graBty #2.2 ftsec2

p K a%eter of lEud partcle ft( K LEud densty lbft#l K !l densty lbft#

$"e aboBe eEuaton s not applcable to Bery s%all lEud droplet s;es. ery s%all (aterdroplets =stable e%ulson> n ol e%ulson (ll %oBe (t" e


35/149



Page #& of 149


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Inlet de+ice 0Pri%ary separation section

$"e nlet strea% co%es upon t"e nlet deflector5 ("c" acts as a %o%entu% brea@er =Ite%1>.Collson of % "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 searation comartment

GraBty separaton s ac"eBed. Free (ater s re%oBed ol and (ater s"all not for% a stablee%ulson. $"e desgn of t"s co%part%ent s based on 'to@es la( and retenton t%es. For agBen 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 separatoneffcency.

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+8$6 !l P"asePartcles

!ILPartcles +ater p"ase !l p"ase

Oil comartment

$"e second co%part%ent s ol7collectng co%part%ent. !l oBerflo(s t"e Bertcal (er("ose "eg"t s c"osen5 to aBod any (ater carry oBer n co%part%ent for all t"e specfedflo( rates. =$"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 fnot separated at t"e treat%ent plant5 (ll be carred nto t"e e beng dstrbutedas 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.$"s poses proble%s n t"e separaton of (ater n t"e 'eparators and 'torage [email protected]> !l n +ater typeK !l p"ase dspersed as s%all droplets n t"e contnuous (ater p"ase.$"s poses proble%s n reducng t"e ol concentraton n t"e effluent (ater.e%ulsfyng c"e%cals are added for brea@ng t"e stable e%ulsons and coalescng t"es%all droplets nto bgger droplets.

e%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%>.

Page #, of 149

+6I2


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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. $"e 1st'tage 'eparator (ll operate as a t"ree7p"ase separator of ol5gas and (ater. Produced (ater separated n t"e 1ststage Inlet 'eparators (ll be routed tot"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 routedto LP separator Feed Pre7"eater =6C #1#>. $"e nlet separator5 ' #015 s a t"ree7p"aseseparator5 desgned to process -05000 bpd of ol and #05000 bpd of (ater. It s a "or;ontalpressure Bessel5 4*00 %% I and 1#,00 %% $$ lengt"5 desgned for 2, barg and 110 oC.

$"e specfcatons of t"e separator are %entoned n t"e table belo(.

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$"e separator sdesgned tooperate n t(odfferent pressureleBels5 referred to

as HP and LP %odesof operaton. $"e

operatngpressure of t"eseparator s 20.,7

barg n HP %ode and12.4 barg n LP %ode.

$"e Bessel snsulated. $"eBessel s ftted

(t" leBel%easure%ents onet"er sde of t"e(er5 to proBdenterface and olleBel%easure%entbesdes adeEuateconnectons for

pressure%easure%ent.

In case of Bery lo((ater cut5 t %ay

be %possble toestabls" 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 * by7pass lne *7GH7#0070#97C&2#8 s"all be opened5 suc" t"at t"eseparator effectBely operates as 27p"ase separator only.

Pressure n t"e Bessel s %antaned by controllng t"e Bapor outlet flo( et"er to 'lugCatc"er =' #0&> or to HP flare. Flo( %easure%ent s proBded on t"e (aterBapor outletfro% separator.

$"e separator s eEupped (t" 4 dran connectons on et"er sde of t"e (er and a utltyconnecton to facltate Bessel dranngpurgng. PostBe solaton of t"e separator sac"eBed by t"e spectacle blndsspacers nstalled at Bessel no;;le flanges pror to%antenance nspecton.

efer to secton 2.9 for detals on c"e%cal n)ecton to t"e 1ststage separator.

'eparator s protected aganst oBerpressure by Pressure safety BalBes =P' #011 8C O# +or@ng N 1 'tandby>. urng e%ergency5 t"e separator can be depressur;ed t"roug" #01*.

Page #9 of 149

@%"%4E"I,4I, 7I4 '%L7E

1st,4%;E ,EP%"%4O"

G8' esgn flo( rate @g" 49-9*

!IL 8ctual desgn flo( rate @g" -22*9

+8$6 8ctual desgn flo( rate @g"0 O 2,., M+C

!peratng pressure HP ode barg 20.,

!peratng pressure LP ode barg 12.41

a


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efer secton 2.#.1 of t"s %anual for t"e detals of nternals n t"e separator.Control and %ontorng sc"edule for t"s secton s as belo(


#01* !n!ff alBe =all $ype> ' #01 1st 'tage 'eparator lo(do(n

6 #01* 'olenod alBe ' #01 1st 'tage 'eparator lo(do(n

WH #01* !pen L%t s(tc" ' #01 1st 'tage 'eparator lo(do(n

WIH #01* Indcator ' #01 1st 'tage 'eparator lo(do(n

WIL #01* Indcator ' #01 1st 'tage 'eparator lo(do(n

WL #01* Close L%t '(tc" ' #01 1st 'tage 'eparator lo(do(n

F6 #010 'enor !rfce plate ' #00 1st 'tage 'eparator Gas !utlet

F6 #011 'enor !rfce plate ' #00 1st 'tage 'eparator +ater !utlet

FI #011 PCell $rans%tter ' #00 1st 'tage 'eparator +ater !utletFI #010 ecorder ' #00 1st 'tage 'eparator Gas !utlet

FI #010 $otal;er ' #00 1st 'tage 'eparator Gas !utlet

FI #011 $otal;er ' #00 1st 'tage 'eparator +ater !utlet

F$ #010 PCell $rans%tter ' #00 1st 'tage 'eparator Gas !utlet

F$ #011 PCell $rans%tter ' #00 1st 'tage 'eparator +ater !utlet

H' #012 'elector '(tc" uty'tandby

L8H #01& Hg" 8lar% ' #01 1st 'tage 'eparator LeBel

L8L #01& Lo( alar% ' #01 1st 'tage 'eparator LeBel

L8H #012 Hg" 8lar% ' #01 1st 'tage 'eparator 7 Interface LeBel

L8L #012 Lo( alar% ' #01 1st 'tage 'eparator 7 Interface LeBel

LG #010 LeBel Gauge =$ransparent> ' #01 1st 'tage 'eparator 7 Interface LeBel

LIC #012 Controller ' #01 1st 'tage 'eparator 7 Interface LeBel

L$ #011 splacer $rans%tter ' #01 1st 'tage 'eparator 7 Interface LeBel

L$ #012 splacer $rans%tter ' #01 1st 'tage 'eparator 7 Interface LeBel

L #012 Control BalBe =Globe $ype> ' #00 1st 'tage 'eparator +ater !utlet

LG1 #01# LeBel Gauge =$ransparent> ' #01 1st 'tage 'eparator leBel

LG2 #01# LeBel Gauge =$ransparent> ' #01 1st 'tage 'eparator leBel

LIC #01& Controller ' #01 1st 'tage 'eparator LeBel

L$ #014 ap"rag% 'eal LeBel

$rans%tter =P>

' #01 1st 'tage 'eparator leBel

L$ #01& ap"rag% 'eal LeBel$rans%tter =P>

' #01 1st 'tage 'eparator LeBel

L #01& Control BalBe =Globe $ype> ' #00 1st 'tage 'eparator !ly 6ffluent !utlet

P8H1 #012 Hg" 8lar% ' #01 1st 'tage 'eparator pressure

P8H2 #012 Hg" 8lar% ' #01 1st 'tage 'eparator pressure

P8L1 #012 Lo( alar% ' #01 1st 'tage 'eparator pressure

PG #010 Pressure Gauge ' #00 1st 'tage 'eparator !ly 6ffluent !utlet

PIC1 #012 Controller ' #01 1st 'tage 'eparator pressure

PIC2 #012 Controller ' #01 1st 'tage 'eparator pressure

P'HH #011 ery Hg" 'afety ' #01 1st 'tage 'eparator pressureP'LL #011 ery Lo( 'afety ' #01 1st 'tage 'eparator pressure

Page 40 of 149


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P'8 #011 Pressure 'afety BalBe ' #01 1st 'tage 'eparator blo(do(n

P' #011 Pressure 'afety BalBe ' #01 1st 'tage 'eparator lo(do(n

P'C #011 Pressure 'afety BalBe ' #01 1st 'tage 'eparator lo(do(nP' #011 Pressure 'afety BalBe ' #01 1st 'tage 'eparator lo(do(n

P'6 #011 Pressure 'afety BalBe ' #01 1st 'tage 'eparator lo(do(n

P'F #011 Pressure 'afety BalBe ' #01 1st 'tage 'eparator lo(do(n

P$ #011 Pressure $rans%tter ' #01 1st 'tage 'eparator pressure

P$ #012 Pressure $rans%tter ' #01 1st 'tage 'eparator pressure

P1 #012 Control BalBe =Globe $ype> ' #00 1st 'tage 'eparator $o +ar% HP Flare

P28 #012 Control BalBe =Globe $ype> ' #00 1st 'tage 'eparator Gas !utlet $o ' #0&

P2 #012 Control BalBe ' #00 1st 'tage 'eparator Gas !utlet $o ' #0&

! #011 estrcton orfce ' #01 1st 'tage 'eparator lo(do(n

! #01- estrcton orfce ' #01 1st 'tage 'eparator lo(do(n' #010 !n!ff alBe =all $ype> ' #01 1st 'tage 'eparator !ly 6ffluent Inlet

' #011 !n!ff alBe =all $ype> ' #01 1st 'tage 'eparator !ly 6ffluent Inlet

' #012 !n!ff alBe =all $ype> ' #01 1st 'tage 'eparator +ater !utlet

' #01# !n!ff alBe =all $ype> ' #01 1st 'tage 'eparator !ly 6ffluent !utlet

' #014 !n!ff alBe =all $ype> ' #01 1st 'tage 'eparator Gas !utlet = $o ' #0&>

' #01& !n!ff alBe =all $ype> ' #01 1st 'tage 'eparator !ff 'pec !l IL

'WH #010 !pen l%t s(tc" ' #01 1st 'tage 'eparator !ly 6ffluent Inlet

'WH #011 !pen l%t s(tc" ' #01 1st 'tage 'eparator !ly 6ffluent Inlet

'WH #012 !pen l%t s(tc" ' #01 1st 'tage 'eparator +ater !utlet

'WH #01# !pen l%t s(tc" ' #01 1st 'tage 'eparator !ly 6ffluent !utlet'WH #014 !pen l%t s(tc" ' #01 1st 'tage 'eparator Gas !utlet = $o ' #0&>

'WH #01& !pen l%t s(tc" ' #01 1st 'tage 'eparator !ff 'pec !l IL

'WIH #010 Indcator ' #01 1st 'tage 'eparator !ly 6ffluent Inlet

'WIH #011 Indcator ' #01 1st 'tage 'eparator !ly 6ffluent Inlet

'WIH #012 Indcator ' #01 1st 'tage 'eparator +ater !utlet

'WIH #01# Indcator ' #01 1st 'tage 'eparator !ly 6ffluent !utlet

'WIH #014 Indcator ' #01 1st 'tage 'eparator Gas !utlet = $o ' #0&>

'WIH #01& Indcator ' #01 1st 'tage 'eparator !ff 'pec !l IL

'WIL #010 Indcator ' #01 1st 'tage 'eparator !ly 6ffluent Inlet

'WIL #011 Indcator ' #01 1st 'tage 'eparator !ly 6ffluent Inlet'WIL #012 Indcator ' #01 1st 'tage 'eparator +ater !utlet

'WIL #01# Indcator ' #01 1st 'tage 'eparator !ly 6ffluent !utlet

'WIL #014 Indcator ' #01 1st 'tage 'eparator Gas !utlet = $o ' #0&>

'WIL #01& Indcator ' #01 1st 'tage 'eparator !ff 'pec !l IL

'WL #010 Close L%t '(tc" ' #01 1st 'tage 'eparator !ly 6ffluent Inlet

'WL #011 Close L%t '(tc" ' #01 1st 'tage 'eparator !ly 6ffluent Inlet

'WL #012 Close L%t '(tc" ' #01 1st 'tage 'eparator +ater !utlet

'WL #01# Close L%t '(tc" ' #01 1st 'tage 'eparator !ly 6ffluent !utlet

'WL #014 Close L%t '(tc" ' #01 1st 'tage 'eparator Gas !utlet = $o ' #0&>

'WL #01& Close L%t '(tc" ' #01 1st 'tage 'eparator !ff 'pec !l IL

Page 41 of 149


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$8L #011 Lo( alar% ' #00 1st 'tage 'eparator Gas !utlet $e%p

$G #010 $e%perature Gauge ' #01 1st 'tage 'eparator Gas !utlet

$I #011 Indcator ' #00 1st 'tage 'eparator Gas !utlet $e%p$$ #011 $e%perature $rans%tter ' #00 1st 'tage 'eparator Gas !utlet $e%p

:.3.3 4est ,earator

efer to P3I I 40 11 02 ' #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 anfold. Fro% t"e $est anfold5 producton s routed nto t"e$est 'eparator =' #00>5 ("c" s desgned for t"ree7p"ase separaton. 8ssocated gas sflas"ed fro% t"e ol and routed to t"e P %anfold =' #0&>.

$"e test separator s desgned to "andle 125000 bopd of ol (t" 0 O &0 M (ater cut and #0'CF of assocated gas. $"e constructon and operaton of t"e Bessel s s%lar to t"efrst stage separator.

$"e specfcaton of t"e separator s %entoned n t"e table belo(.

@%"%4E"I,4I, 7I4 '%L7E

G8'

esgn flo( rate @g" ##2*40

olecular (eg"t 2&.01

Gas densty @g %X 12.2&

Co%presson factor 0.9*02

scosty cP 0.01#

!IL 8ctual desgn flo( rate @g" &4-4*0

+8$6 8ctual desgn flo( rate @g" 21*1,2

!peratng pressure HP ode barg 20

!peratng pressure LP ode barg 12.41

a


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@%"%4E"I,4I, 7I4 '%L7E

HC retenton t%e /!L to /IL5 %n &

esgn Pressure5 barg 2,esgn $e%perature5 oC oC 110 =7> 1&

ateral of constructon C' =/8C6>

InsulatonPersonnelProtecton

Internals y Bendor

efer 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' #000 8 O 1+or@ng N 1 'tandby>. urng e%ergency5 t"e separator can be depressur;ed t"roug" #00#.



#00# !n!ff alBe =all $ype> ' #00 $est 'eparator lo(do(n

WH #00# !pen L%t s(tc" ' #00 $est 'eparator lo(do(n

WIH #00# Indcator ' #00 $est 'eparator lo(do(n

WIL #00# Indcator ' #00 $est 'eparator lo(do(n

WL #00# Close L%t '(tc" ' #00 $est 'eparator lo(do(n

F8L #001 Lo( alar% ' #00 $est 'eparator +ater !utletFI #002 ecorder ' #00 $est 'eparator Gas !utlet

FI #000 $otal;er ' #00 $est 'eparator !ly 6ffluent !utlet

FI #001 $otal;er ' #00 $est 'eparator +ater !utlet

FI #002 $otal;er ' #00 $est 'eparator Gas !utlet

F$ #000 ass Flo( eter =Corols$ype>

' #00 $est 'eparator !ly 6ffluent !utlet

F$ #001 PCell $rans%tter ' #00 $est 'eparator +ater !utlet

F$ #002 PCell $rans%tter ' #00 $est 'eparator Gas !utlet

H' #00# 'elector '(tc" uty'tandby

L8H #00& Hg" 8lar% ' #00 $est 'eparator leBel

L8L #00& Lo( alar% ' #00 $est 'eparator leBelL8H #002 Hg" 8lar% ' #00 $est 'eparator7 Interface LeBel

L8L #002 Lo( alar% ' #00 $est 'eparator7 Interface LeBel

LG #000 LeBel Gauge =$ransparent> ' #00 $est 'eparator7 Interface LeBel

LIC #002 Controller ' #00 $est 'eparator7 Interface LeBel

L'LL #001 ery Lo( 'afety ' #00 $est 'eparator7 Interface LeBel

L$ #001 splacer $rans%tter ' #00 $est 'eparator7 Interface LeBel

L$ #002 splacer $rans%tter ' #00 $est 'eparator7 Interface LeBel

LG #00# LeBel Gauge =$ransparent> ' #00 $est 'eparator LeBel

LIC #00& Controller ' #00 $est 'eparator leBel

L'HH #004 ery Hg" 'afety ' #00 $est 'eparator LeBelL'LL #004 ery Lo( 'afety ' #00 $est 'eparator LeBel

Page 4# of 149


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L$ #004 ap"rag% 'eal LeBel$rans%tter =P>

' #00 $est 'eparator LeBel

L$ #00& ap"rag% 'eal LeBel

$rans%tter =P>

' #00 $est 'eparator leBel

L #002 Control BalBe =Globe $ype> ' #00 $est 'eparator +ater !utlet

L #00& Control BalBe =Globe $ype> ' #00 !ly 6ffluent !utlet $o ' #02

P8H1 #00# Hg" 8lar% ' #00 $est 'eparator Pressure

P8H2 #00# Hg" 8lar% ' #00 $est 'eparator !utlet $o +ar% HP Flare

P8L1 #00# Lo( alar% ' #00 $est 'eparator Pressure

P8L2 #00# Lo( alar% ' #00 $est 'eparator !utlet $o +ar% HP Flare

PG #000 Pressure Gauge ' #00 !ly 6ffluent Inlet

PG #001 Pressure Gauge ' #00 $est 'eparator lo(do(n

PIC1 #00# Controller ' #00 $est 'eparator Pressure

PIC2 #00# Controller ' #00 $est 'eparator !utlet $o +ar% HP Flare

P$ #002 Pressure $rans%tter ' #00 $est 'eparator Pressure

P$ #00# Pressure $rans%tter ' #00 $est 'eparator Pressure

P1 #00# Control BalBe =Globe $ype> ' #00 $est 'eparator !utlet $o +ar% HP Flare

P28 #00# Control BalBe =Globe $ype> ' #00 $est 'eparator !ly 6ffluent !L

P2 #00# Control BalBe =Globe $ype> ' #00 $est 'eparator !ly 6ffluent !L

! #002 estrcton orfce ' #00 $est 'eparator !ly 6ffluent Inlet

! #00* estrcton orfce ' #00 $est 'eparator !ly 6ffluent lo(do(n

' #000 !n!ff alBe =all $ype> ' #00 !ly 6ffluent Inlet

' #001 !n!ff alBe =all $ype> ' #00 $est 'eparator !ly 6ffluent Inlet

' #004 !n!ff alBe =all $ype> ' #00 $est 'eparator +ater !utlet

' #00& !n!ff alBe =all $ype> ' #00 $est 'eparator !ly 6ffluent !utlet' #00, !n!ff alBe =all $ype> ' #00 $est 'eparator Gas !utlet

'WH #000 !pen l%t s(tc" ' #00 $est 'eparator !ly 6ffluent Inlet

'WH #001 !pen l%t s(tc" ' #00 $est 'eparator !ly 6ffluent Inlet

'WH #004 !pen l%t s(tc" ' #00 $est 'eparator +ater !utlet

'WH #00& !pen l%t s(tc" ' #00 $est 'eparator !ly 6ffluent !utlet

'WH #00, !pen l%t s(tc" ' #00 $est 'eparator Gas !utlet

'WIH #000 Indcator ' #00 $est 'eparator !ly 6ffluent Inlet

'WIH #001 Indcator ' #00 $est 'eparator !ly 6ffluent Inlet

'WIH #004 Indcator ' #00 $est 'eparator +ater !utlet

'WIH #00& Indcator ' #00 $est 'eparator !ly 6ffluent !utlet

'WIH #00, Indcator ' #00 $est 'eparator Gas !utlet'WIL #000 Indcator ' #00 $est 'eparator !ly 6ffluent Inlet

'WIL #001 Indcator ' #00 $est 'eparator !ly 6ffluent Inlet

'WIL #004 Indcator ' #00 $est 'eparator +ater !utlet

'WIL #00& Indcator ' #00 $est 'eparator !ly 6ffluent !utlet

'WIL #00, Indcator ' #00 $est 'eparator Gas !utlet

'WL #000 Close L%t '(tc" ' #00 $est 'eparator !ly 6ffluent Inlet

'WL #001 Close L%t '(tc" ' #00 $est 'eparator !ly 6ffluent Inlet

'WL #004 Close L%t '(tc" ' #00 $est 'eparator +ater !utlet

'WL #00& Close L%t '(tc" ' #00 $est 'eparator !ly 6ffluent !utlet

'WL #00, Close L%t '(tc" ' #00 $est 'eparator Gas !utlet$G #000 $e%perature Gauge ' #00 $est 'eparator Gas !utlet

Page 44 of 149


45/149




$I #001 Indcator ' #00 $est 'eparator Gas !utlet

$$ #001 $e%perature $rans%tter ' #00 $est 'eparator Gas !utlet

#01* !n!ff alBe =all $ype> ' #01 1st 'tage 'eparator lo(do(n

:.3.# LP ,earator Feed Preheater* E-313 %?5??D

efer to P3I I 40 11 02 6C #1# 888 19 '"eet 1 of 2

LP 'eparator Feed Pre"eater s proBded for "eatng t"e co%bned separated ol fro% Frststage 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 egassng n 'econd stage separator7 Hg" te%perature (ll ncrease t"e actBty of de%ulsfyng agents7 $"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 esalter effcency s %proBed at eleBated te%peratures.7 Lo(er operatngdesgn pressure of t"e esalter.7 educng t"e (a


46/149



@%"%4E"I,4I, 7I4 '%L7E

LP ,earator Feed Preheater* E-313

uantty 4 unts n parallel6

In t"s e


47/149



about #M. It s a "or;ontal pressure Bessel5 #900 %% I and 1,200 %% $$ lengt"5desgned for 10 barg 110 oC.

$"e separator operates at &.47barg =LP %ode> and *.4 barg =HP %ode> pressure and -0 oCte%perature. $"e Bessel s nsulated. $"e Bessel s ftted (t" leBel brdles on et"er sde oft"e (er5 to proBde nterface and ol leBel %easure%ent besdes adeEuate connectons forpressure %easure%ent.

@%"%4E"I,4I, 7I4 '%L7E

G8' esgn flo( rate @g" ##-&-

!IL 8ctual desgn flo( rate @g" &442-0

+8$6 8ctual desgn flo( rate @g" ,4#1*

!peratng pressure HP ode barg *.41

!peratng pressure LP ode barg &.41

a


48/149



'eparator s protected aganst oBerpressure by Pressure safety BalBes =P' #020 8C O 2+or@ng N 1 'tandby>. urng e%ergency5 t"e separator can be depressur;ed t"roug" #02#.



FI #021 Indcator ' #02 2nd 'tage 'eparator Gas !utlet

FI #020 ecorder ' #02 2nd 'tage 'eparator Gas !utlet

FI #021 $otal;er ' #02 2nd 'tage 'eparator Gas !utlet

F$ #020 PCell $rans%tter ' #02 2nd 'tage 'eparator Gas !utlet

F$ #021 PCell $rans%tter ' #02 2nd 'tage 'eparator Gas !utlet

L8H #02& Hg" 8lar% ' #02 2nd 'tage 'eparator LeBel

L8L #02& Lo( alar% ' #02 2nd 'tage 'eparator LeBel

L8H #022 Hg" 8lar% ' #02 2nd 'tage 'eparator7 Interface LeBel

L8L #022 Lo( alar% ' #02 2nd 'tage 'eparator7 Interface LeBel

LG2 #020 LeBel Gauge =$ransparent> ' #02 2nd 'tage 'eparator7 Interface LeBel

LIC #022 Controller ' #02 2nd 'tage 'eparator7 Interface LeBel

L$ #021 splacer $rans%tter ' #02 2nd 'tage 'eparator7 Interface LeBel

L$ #022 splacer $rans%tter ' #02 2nd 'tage 'eparator7 Interface LeBel

L #022 Control BalBe =Globe $ype> ' #02 2nd 'tage 'eparator +ater !utlet

LG1 #02# LeBel Gauge =$ransparent> ' #02 2nd 'tage 'eparator LeBel

LG2 #02# LeBel Gauge =$ransparent> ' #02 2nd 'tage 'eparator LeBel

LG# #02# LeBel Gauge =$ransparent> ' #02 2nd 'tage 'eparator LeBel

LIC #02& Controller ' #02 2nd 'tage 'eparator LeBel

L$ #024 ap"rag% 'eal LeBel$rans%tter =P> ' #02 2nd 'tage 'eparator LeBel

L$ #02& ap"rag% 'eal LeBel$rans%tter =P>

' #02 2nd 'tage 'eparator LeBel

P8H #022 Hg" 8lar% ' #02 2nd 'tage 'eparator Pressure

P8L #022 Lo( alar% ' #02 2nd 'tage 'eparator Pressure

PG #020 Pressure Gauge ' #02 2nd 'tage 'eparator

PG #1#0 Pressure Gauge 6C #1#8C LP 'eparator Feed Pre"eater !IL IL

PG #1#1 Pressure Gauge 6C #1#8C LP 'eparator Feed Pre"eater !IL !L

PG #1#2 Pressure Gauge 6C #1#8C LP 'eparator Feed Pre"eater !IL IL

PG #1## Pressure Gauge 6C #1#8C LP 'eparator Feed Pre"eater !IL !L

PIC #022 Controller ' #02 2nd 'tage 'eparator PressureP$ #021 Pressure $rans%tter ' #02 2nd 'tage 'eparator Pressure

P$ #022 Pressure $rans%tter ' #02 2nd 'tage 'eparator Pressure

P #022 Control BalBe =Globe $ype> ' #02 2nd 'tage 'eparator !utlet $o +ar% HP Flare

! #024 estrcton orfce ' #02 2nd 'tage 'eparator lo(do(n

' #020 !n!ff alBe =all $ype> ' #02 2nd 'tage 'eparator +ater !utlet

' #021 !n!ff alBe =all $ype> ' #02 2nd 'tage 'eparator !ly 6ffluent !utlet

'WH #020 !pen l%t s(tc" ' #02 2nd 'tage 'eparator +ater !utlet

'WH #021 !pen l%t s(tc" ' #02 2nd 'tage 'eparator !ly 6ffluent !utlet

'WIH #020 Indcator ' #02 2nd 'tage 'eparator +ater !utlet

'WIH #021 Indcator ' #02 2nd 'tage 'eparator !ly 6ffluent !utlet

'WIL #020 Indcator ' #02 2nd 'tage 'eparator +ater !utlet'WIL #021 Indcator ' #02 2nd 'tage 'eparator !ly 6ffluent !utlet

Page 4- of 149


49/149




'WL #020 Close L%t '(tc" ' #02 2nd 'tage 'eparator +ater !utlet

'WL #021 Close L%t '(tc" ' #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 ' #02 2nd 'tage 'eparator Gas !utlet

$I #021 Indcator ' #02 2nd 'tage 'eparator Gas !utlet

$IC #1#4 Controller 6C #1# LP separator feed pre"eater !l !utlet

$$ #021 $e%perature $rans%tter ' #02 2nd 'tage 'eparator Gas !utlet

$$ #1#4 $e%perature $rans%tter 6C #1# LP separator feed pre"eater !l !utlet

$ #1#4 Control BalBe =all $ype> 6C #1# LP separator feed pre"eater ypass

:.3.6 Oil 5ooster Pums* ; 31$ %?5

efer to P3I I 40 11 04 G: #10 888 19&4

!l ooster Pu%ps5 G: #10 85 are used to pu%p ol fro% second stage separator to apressure reEured for t"e esalter. !peraton pressure n t"e esalter s"all be at least 1 baraboBe t"e second stage separator pressure to aBod any gas release fro% t"e crude.fferental pressure generated by t"e pu%p also ncludes t"e pressure drops n %

$ypeHor;ontal5centrfugal

/u%ber of 'tages 1'ucton $e%perature oC -0ated 'ucton Pressure barg &.-7*.-

sc"arge +or@ng Pressure barg 12.,71#.,esgn Flo( ate %#"r *-2+or@ng Flo( ate %#"r *20n%u% Flo( ate %#"r 242fferental Head % -#.#/P'H eEured % #.0/P'H 8Balable % 4.&otor 'peed rp% 14*0ateral C' =/8C6>ated Po(er @+ 22&ec"ancal 'eal Flus"ng Plan 8PI 115 *15

Page 49 of 149


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$"e pu%ps are desgned for contnuous operaton. /or%ally one pu%p s n operaton andt"e ot"er s a stand by.

$"e pu%ps are ftted (t" double %ec"ancal seals5 ("c" use an e G: #108 !l ooster Pu%p Z8Z !utlet Flo(

PG #1108 Pressure Gauge G: #108 sc"arge

PG #110 Pressure Gauge G: #10 sc"arge

PG #11#8 Pressure Gauge G: #108 Inlet

PG #11# Pressure Gauge G: #10 Inlet

P'HH #1118 ery Hg" 'afety G: #108 !l ooster Pu%p !utlet

P'HH #111 ery Lo( 'afety G: #10 !l ooster Pu%p !utlet

P'LL #1118 ery Lo( 'afety G: #108 !l ooster Pu%p !utlet

P'LL #111 ery Lo( 'afety G: #10 !l ooster Pu%p !utlet

P'LL #11#8 ery Lo( 'afety G: #108 !l ooster Pu%p Inlet Pressure

P'LL #11# ery Lo( 'afety G: #10 !l ooster Pu%p Inlet Pressure

P$ #1118 Pressure $rans%tter G: #108 !l ooster Pu%p !utlet

P$ #111 Pressure $rans%tter G: #10 !l ooster Pu%p !utlet

P$ #11#8 Pressure $rans%tter G: #108 !l ooster Pu%p Inlet Pressure

P$ #11# Pressure $rans%tter G: #10 !l ooster Pu%p Inlet Pressure

Page &0 of 149


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2.# Desalter Section

efer PF I 40 11 04 88#40 888 0241

:.#.1 Princile of oeration

For effectBe de"ydraton5 t"e follo(ng basc steps are to be follo(edK

7 rea@ng =destabl;aton> of t"e e%ulson.7 Coalescence of t"e destabl;ed (ater droplets7 'eparaton of t"e (ater fro% t"e ol p"ase

In t"e esalter follo(ng steps are used for brea@ng t"e stable e%ulsons and coalescngt"e s%all droplets nto bgger droplets.

7 8ddton of de%ulsfer7 6lectrostatc coalescng7 .

7 '"o(s t"e sa%e drop n an energ;ed electrc feld (t" t"e c"arges beng attractedto t"e opposte electrode. $"s drop s pulled and elongated by t"e attracton of t"e c"argesto t"e opposte electrode. Ho(eBer5 t"e drop7center tself does not %oBe as t"e forces are

alternatng Eute rapdly =8C current>

Page &1 of 149


52/149



7C '"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 san 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(ngt"e droplets to coalesce =co%bne> nto one larger droplet and falls to t"e botto% because ts "eaBer t"an ol.

$"e 'peed of Coalescng n 6lectrc esalters.

$"e collson and coalescng of (ater droplets bet(een t"e electrcal grds s Beryrapd due to "g" freEuency =&0 H;> of t"e 8lternatng Current =electrc feld>.

Fg 2. 6FF6C$ !F 6L6C$IC FI6L !/ +8$6 !PL6$'

%- 7@%";ED =%4E" D"OPLE4 * ELE4"I%LL< E74"%L

5- @%";ED =%4E" D"OPLE4 I ELE4"I%L FIELD

- 4=O @%";ED =%4E" D"OPLE4, I ELE4"I FIELD

Page &2 of 149

7 N 7 N 7 N 77 N 7 N 7 N 7 N 7 N 7N 7 N 7 N 7 N 7 N 7N7 N 7 N 7 N 7 N 7N 7N 7 N 7

N 7N 7 N 7N 7

N 7 N 7 N [7

N7N

N7N

N7N

N N N 7 7 7N N N N 7 7 7 N N N 77 7 77N N N N 7 7 7N N N N 7 7 7 N NN 7N 7 7 7

N N 7 7 N N7 7

7 77 777 77 7 777

N N NN N NNN NNNN NN

NN N

N N N 7 7 7N N N N 7 7 7 N N N 77 7 77N N N N 7 7 7N N N N 7 7 7 N NN 7N 7 7 7

N N 7 7 N N7 7

7 77 777 77 7 777

N NNN NNN NNN NNN NN

NN N

N N N N 7 7 77

N NN N N

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7 7

7777

N N N 7 N

NNN

N NNN N N

77N N N 7 7 7N N N N 7 7 7 N N N 77 7 77N N N N 7 7 7N N N N 7 7 7 N NN 7N 7 7 7

N N 7 7 N N7 7

7 77 777 77 7 777

N NNN NNN NNNN NN NN

NN N

7 777

N N7 7 77


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+as" +ater =Fres" +ater> In)ecton

$"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"esalt 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 esalter (ll result nreducton of t"e salt content of t"e crude. $"e (ater %. ue to t"sdfference 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. $"sseparaton of ol and (ater =free (ater> p"ases by graBtatonal forces due to denstydfference s called as GraBty settlng.

$"e (ater droplets coalesced n t"e electrc feld of t"e esalter are separated by graBtysettlng n t"e esalter.

$"e Belocty of s%all (ater droplets =free coalesced (ater> n !l p"ase s goBerned by t"efollo(ng 'to@es La(.

t Q 14-- < g < p2 < =( 7Vl>

+"eret K $er%nal Belocty ftsecg K 8cceleraton due to graBty #2.2 ftsec 2

p K a%eter of lEud partcle ft( K LEud densty lbft#l K !l densty lbft#

$"e aboBe eEuaton s not applcable to Bery s%all lEud droplet s;es. ery s%all (aterdroplets =stable e%ulson> n ol e%ulson (ll %oBe (t" e


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:.#.: Desalters* D, 3:$ %?5

efer to P3I I 40 11 04 8 #20 888 19&& '"t. 12 of 2$"e crude fro% 2ndstage separator s pu%ped by G: #10 8 to t"e esalter =' #20 8>.$(o stages of desaltng are proBded. $"e nco%ng "ot feed s %

Produced +ater%#"r

##.0=ased on &M

(ater cut>'alt Content n Produced +ater g%lt 2*,

'alt Content n +as" 'ea(ater g%lt #*.1

Pac@age $urn o(n ato M #0

luton +as" 'ea(ater*M of total desgnflo( =a

!peratng Pressure barg9.& =frst stage>- =second stage>

!peratng $e%perature oC ,& to -0

esgn Pressure barg 21

esgn $e%perature oC 0 110

!utlet 'alnty P$ 20

!utlet ' 3 + M ol. 0.12

essel I %% #**0

essel $$ lengt" %% 2**00

Page &4 of 149


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$"e esalter operates at -7barg pressure and ,& oC te%perature. /ote t"at t"e electrostatcesalter s"ould be operated at least 1 bar aboBe t"e second stage separator pressure toaBod any gas release fro% t"e crude5 ("c" can result n spar@ng (t"n t"e Bessel.

For t"e sa%e reason \ bleed connectons are proBded on t"e no;;les /48C5 t"e"g"est ponts of t"e Bessels5 to aBod any accu%ulaton of gas. $"ese bleeds s"all beper%anently @ept open durng operaton and are connected to ds t"e control BalBe n t"edsc"arge of eac" of t"e esalters. In case of parallel operaton of t"e esalters5 t"e bleedsfro% esalter 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 besdesadeEuate connectons for pressure te%perature %easure%ent. $"e control BalBes on t"e(ater outlet fro% t"e esalters controls nterface leBel n t"e esalter.

6ac" esalter s proBded (t" a P' t"at s desgned for fre relef.

$"e esalter s eEupped (t" dran connectons and a utlty connecton to facltate Besseldranngpurgng. PostBe solaton of t"e esalter s ac"eBed by rotatng t"e spectacleblndsspades nstalled at Bessel no;;le flanges pror to %antenance nspecton.

$"e Bessel s ftted (t" try7coc@s to establs" t"e ol(ater nterface leBel durng start up.

$"e electrostatc esalter co%prses a set of electrodes postoned nsde t"e Bessel5 nlet outlet dstrbutor "eaders5 a "g" Boltage entrance syste% and a "g" Boltage po(er unt%ounted e


56/149



Interface dra(7off "eaders are proBded to allo( for re%oBal of any e%ulson t"at %ay "aBefor%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 ss"o(n belo(

Internals1. Crude nlet "eader2. Crude outlet tray#. 6ffluent "eader4. Interface dra(7off "eader&. 6lectrode grds

/o;;les

/18 Crude nlet/28 Crude outlet/#8C +ater outlet/98 Interface dra(7off

@ih 'oltae Entrance ,stem

$"e "g" Boltage entrance syste% s t"e %ost %portant part of an electrostatc de"ydrator esalter unt.

It double protects t"e "g" Boltage po(er unt fro% entrance of ol by usng a pressure

bus"ng. ot" 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"ere%oBal serBce nspecton blnds n t"e ol7flled bus"ng "ousng.

@ih 'oltae Po!er 7nit

$"e electrostatc esalter s eEupped (t" t"ree po(er unts. $"e syste% utl;es a non7oBerloadng 100M %pedance sngle p"aseK "g" Boltage po(er unt desgned to allo( t"eesalter to stay n operaton eBen under upset condtons. $"s desgn also guarantees t"atBoltage s %antaned across t"e lo(er electrode and t"e (ater leBel as (ell as bet(een t"et(o electrodes.

Page &* of 149

/28 /2

/#8 /98

/18

/# /#C /9 /1 /#

4 # 1

& 2


57/149



ry ol contanng 0.2M by Bolu%e (ater fro% t"e 6lectrostatc esalter5 s routed to t"etop of t"e 'tabl;er Colu%n.

:.#.3 =ater irculation Pums* ; 3:$ %?5

efer to P3I I 40 11 04 8 #20 888 19&& '"t. 1 of 2

In t"e esalter syste%5 fres" (as" (ater fro% bac@up (as" (ater pu%ps =G: ,22 8> sn)ected upstrea% of t"e %< BalBe of t"e second stage esalter. $"e separated (ater fro%2ndstage s recycled usng G: #20 8 and n)ected upstrea% of t"e %< BalBe of t"e frststage usng esalter pu%p. $"s sc"e%e leads to a greater econo%y of (ater usage.

$"e +ater crculaton pu%ps5 G: #20 85 are "or;ontal5 sngle stage5 centrfugal processpu%ps (t" radal splt5 centerlne %ounted and closed %peller.

@%"%4E"I,4I 7I4 '%L7E

,ta2ili>ed Oil Pums B; 311 %?5C

uantty 2 =1 N 1>

$ypeHor;ontal5centrfugal

/u%ber of 'tages 1'ucton $e%perature oC -0ated 'ucton Pressure barg 9.&sc"arge +or@ng Pressure barg 1*.4esgn Flo( ate %#"r

+or@ng Flo( ate %

#

"r #*n%u% Flo( ate %#"r 9fferental Head % ,4/P'H eEured % #/P'H 8Balable % ] &otor 'peed rp% 29&0ateral uple< ''ated Po(er @+ 22ec"ancal 'eal Flus"ng Plan 8PI 115 *1

$"e pu%ps are ftted (t" %ec"ancal seals5 (t" lea@ detecton syste%. $"e pu%ps areproBded (t" %n%u% flo( recrculaton (t" auto%atc flo( control BalBe.

ontrol and monitorin schedule for this section is as 2elo!


F8H #200 Hg" 8lar% ' #20 esalter nt ZZ +as" +ater Inlet

F8H #204 Hg" alar% G: #208 esalter Pu%p !utlet

F8L #200 Lo( alar% ' #20 esalter nt ZZ +as" +ater Inlet

FIC #200 Controller ' #20 esalter nt ZZ +as" +ater Inlet

FIC #204 Controller G: #208 esalter Pu%p !utlet

F$ #200 PCell $rans%tter ' #20 esalter nt ZZ +as" +ater Inlet

F$ #204 PCell $rans%tter G: #208 esalter Pu%p !utletF #200 Control BalBe =Globe $ype> ' #20 esalter nt ZZ +as" +ater Inlet

Page &, of 149


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F #204 Control BalBe =Globe $ype> G: #208 esalter Pu%p ypass

L8H #2028 Hg" 8lar% ' #208 esalter Z8Z Interface leBel

L8H #202 Hg" 8lar% ' #20 esalter ZZ Interface leBelL8L #2028 Lo( alar% ' #208 esalter Z8Z Interface leBel

L8L #202 Lo( alar% ' #20 esalter ZZ Interface leBel

LG #2048 LeBel Gauge =$ra

oil manual rev 01

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