PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 2 of 275
Document Title
Document Number
00180-PCP-300-PD-MAN-12503-01
Type of Document
Manual
Rev
A1
Date
REVISION STATUS
Description
Originator
08-10-09
Issue for Info-training
RL
Expiry Date of Procedure
Life Cycle of review
APPROVAL
Verified
AD
Approved
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 3 of 275
TABLE OF CONTENTS
SECTION I
1.0
2.0
3.0
4.0
5.0
6.0
7.0
INTRODUCTION......................................................
ABBREVIATION................................................................................
TERMINOLOGY...............................................................................
UNIT OF MEASUREMENT...................................................................
OBJECTIVE OF OPERATION MANUAL..................................................
PREAMBLE.....................................................................................
EMERGENCY SHUTDOWN..................................................................
INTENDED USERS............................................................................
SECTION II
HEALTH, SAFETY AND ENVIRONMENT..........................
SECTION III HAZOPS & ROUNDS.................................................
SECTION V
GAS GATHERING STATION.........................................
1.0
INTRODUCTION............................................................
1.1
2.0
2.1
2.2
2.2.1
2.2.2
2.2.3
2.3
3.0
EQUIPMENT SPECIFICATION.............................................
4.0
4.1
PRODUCTION SEPARATOR.................................................................
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 4 of 275
4.1.1
Principle of Separation of Water from Oil in Separators......................
4.1.2
Production Separator Controls.........................................................
4.2
FIELD GAS COMPRESSOR..................................................................
FIELD GAS COMPRESSOR SUCTION KNOCK-OUT DRUM........................................
FIELD GAS COMPRESSOR................................................................................
FIELD GAS COMPRESSOR AFTERCOOLER...........................................................
4.2.1
Process Description........................................................................
4.2.2
Field Gas Compressor Controls.........................................................
4.3
CONDENSATE SYSTEM......................................................................
4.3.1
PROCESS DESCRIPTION....................................................................
CONDENSATE PUMPS.....................................................................................
CONDENSATE COALESCER...............................................................................
CONDENSATE SOLIDS FILTER...........................................................................
EARLY OPERATION CONDENSATE PUMPS...........................................................
4.3.2
Condensate System Control.............................................................
4.3.3
Condensate Coalescer Interface Level Control...................................
4.4
GAS DEHYDRATION SYSTEM..............................................................
4.4.1
Process Description........................................................................
GAS DEHYDRATION COLUMN...........................................................................
4.4.2
Gas Dehydration Controls................................................................
4.5
TEG REGENERATION SYSTEM............................................................
4.5.1
Principle of TEG Regeneration System..............................................
GLYCOL CIRCULATION PUMPS..........................................................................
TEG BURNER AIR FAN.....................................................................................
TEG MAKE-UP FILTER.....................................................................................
TEG DRAIN VESSEL........................................................................................
TEG STRIPPING COLUMN................................................................................
TEG DRAIN PUMP..........................................................................................
TEG STORAGE TANK......................................................................................
TEG MAKE-UP PUMP......................................................................................
COLD LEAN/RICH GLYCOL HEAT EXCHANGER....................................................
HOT LEAN/RICH GLYCOL HEAT EXCHANGER......................................................
4.5.2
Process Description........................................................................
4.5.3
TEG Regenerator Controls...............................................................
4.6
TEG INCINERATOR SYSTEM...............................................................
4.6.1
TEG Incinerator Controls.................................................................
4.7
UTILITIES.......................................................................................
4.7.1
Plant Air System.............................................................................
4.7.2
Instrument Air System.....................................................................
AIR COMPRESSOR..........................................................................................
INSTRUMENT AIR RECEIVER............................................................................
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 5 of 275
4.7.3
Nitrogen System.............................................................................
NITROGEN RECEIVER.....................................................................................
WET AIR RECEIVER........................................................................................
4.7.4
Utility Water..................................................................................
UTILITY WATER TANK.....................................................................................
BOREHOLE WATER PUMP................................................................................
UTILITY WATER PUMP....................................................................................
4.7.5
Potable Water System.....................................................................
POTABLE WATER TANKER UNLOADING PUMP.....................................................
POTABLE WATER DISTRIBUTION PUMP..............................................................
4.7.6
Diesel System................................................................................
4.8
FUEL GAS SYTEM............................................................................
FUEL GAS KNOCK-OUT DRUM..........................................................................
FUELGAS HEATER..........................................................................................
FUELGAS SUPER HEATER................................................................................
4.8.1
Fuel Gas System Control Description................................................
4.9
FLARE SYSTEM...............................................................................
FLARE KO DRUM...........................................................................................
FLARE KO DRUM HEATER................................................................................
FLARE KNOCK-OUT DRUM BOOSTER PUMP........................................................
FLARE KO DRUM PUMP...................................................................................
4.9.1
Flare System Controls.....................................................................
4.10
PRODUCED WATER SYSTEM...............................................................
4.11
DRAIN SYSTEM................................................................................
4.11.1
Open Drain System.........................................................................
4.11.2
Closed Drain system.....................................................................101
4.12
POWER GENERATOR SYSTEM...........................................................102
5.0
ELECTRICAL..............................................................106
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.2
5.3
5.4
5.5
ELECTRICAL SYSTEMS....................................................................107
Electrical System Controls.............................................................108
Electrical System Start-Up.............................................................110
System under Plant Normal Operating Condition..............................113
Electrical System GTG Failure.....................................................114
EMERGENCY DIESEL GENERATOR SET...............................................118
MAIN HV SWITCHBOARD................................................................122
POWER TRANSFORMER..................................................................122
LV POWER DISTRIBUTION...............................................................123
6.0
INSTRUMENTATION......................................................127
6.1
6.2
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 6 of 275
6.3
EMERGENCY SHUTDOWN SYSTEM (ESD) GGS...................................132
Double Isolation Valves...............................................................................138
7.0
7.1
7.2
7.3
7.4
7.5
8.0
TELECOMMUNICATION..................................................150
8.1
8.2
8.3
8.3.1
8.4
8.4.1
8.5
8.6
8.7
TELECOM SUBSYSTEMS..................................................................151
SDH TRANSMISSION SYSTEM...........................................................151
TELEPHONE SYSTEM......................................................................152
Telephones..................................................................................152
RADIO SYSTEM.............................................................................152
Radio Tower.................................................................................153
ENVIRONMENTAL MONITORING SYSTEM............................................153
LOCAL AREA NETWORK..................................................................154
TELECOM SUPERVISORY SYSTEM......................................................154
9.0
PRODUCT SPECIFICATION..............................................155
9.1
9.2
9.3
10.0
10.1
10.1.1
10.1.2
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.6
10.2.7
PRE-REQUISITE SAFETY...............................................................159
Introduction................................................................................159
Safety.........................................................................................159
PRE-REQUISITE ACTIVITIES.............................................................159
Vessels and Pipelines....................................................................159
System Leak Testing and Purging....................................................160
HVAC in Control Room...................................................................160
Diesel and Chemicals....................................................................160
Checking of Functional Loop and Control Valves...............................160
Charging of Lubricants for Rotating Equipment................................160
L.P. Fuel Gas System.....................................................................161
11
11.1
11.1
11.2
11.3
SEQUENCE OF START-UP................................................................163
START-UP OF DIESEL SYSTEM..........................................................163
START-UP OF EMERGENCY POWER GENERATOR PACKAGE....................165
START-UP OF UTILITY WATER SYSTEM..............................................167
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 7 of 275
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
START-UP OF
START-UP OF
START-UP OF
START-UP OF
START-UP OF
START-UP OF
START-UP OF
START-UP OF
START-UP OF
START-UP OF
START-UP OF
START-UP OF
12.0
12.1
12.2
12.2.1
12.3
12.4
12.5
12.5.1
12.5.2
12.6
12.6.1
12.6.2
12.7
12.7.1
12.7
12.7.1
13.0
13.1
13.2
13.3
14.0
14.1
14.2
14.2.1
14.2.2
14.2.3
14.2.4
14.2.5
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 8 of 275
14.2.6
14.2.7
14.2.8
14.2.9
14.2.10
14.2.11
14.2.12
14.2.13
14.2.14
14.2.15
14.2.16
14.2.17
14.3
14.4
14.5
15.0
16.0
TROUBLESHOOTING OPERATION.....................................252
SHUTDOWN...............................................................260
16.1
16.2
16.2.1
16.2.2
16.2.3
16.3
PLANNED SHUTDOWN....................................................................261
EMERGENCY SHUTDOWN................................................................264
ESD Level-1 Shutdown...................................................................265
ESD Level-2: Process Shutdown......................................................265
ESD LEVEL-3: Unit/Equipment Shutdown.........................................267
DRAINING PHILOSOPHY/RECOVERY FOR START-UP.............................270
SECTION I
INTRODUCTION
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
1.0
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
ABBREVIATION
Acronym
AC
AMB
API
ATM
BA
BCS
BDV
BGU
CCR
CD
CGR
CNE
CO2
CS
CSO
DB
dB
DBB
DCS
DE
DP
EDG
ESD
F&G
FV
FW
FZ
GC
GGS
GOR
GTP
H2S
HC
HH
HMI
HP
HPS
HSE
I&C
IS
KCS
Expansion
Alternating Current
Ambient
American Petroleum Institute
Atmospheric
Breathing Apparatus
Burner Control System
Blowdown Valve
Break Glass Unit
Central Control Room
Closed Drain
Condensate to Gas Ratio
Cause and Effect
Carbon dioxide
Carbon Steel
Car-Seal Open
Double Block
Decibel
Double Block & Bleed
Distributed Control System
Drive End
Differential Pressure
Emergency Diesel Generator
Emergency Shutdown
Fire & Gas
Full Vacuum
Fire water
Fire Zone
Gas Chromatograph
Gas Gathering Station
Gas to Oil Ratio
Gas Treatment Plant
Hydrogen Sulphide
Hydrocarbon
High High
Human Machine Interface
High Pressure
High Pressure Separator
Health, Safety and Environment
Instrument & Control
Intrinsically Safe
Killed Carbon Steel
Operations
Page 10 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
Acronym
KOD
LC
LCP
LCS
LCV
LEL
LL
LO
LP
LPG
LSS
LTS
MMSCFD
MP
N2
NC
NDE
NO
NPSH
O&M
O/L
ORP
P&ID
PB
PCV
PMS
POM
PPE
ppm
ppmv
ppmw
PSD
PSV
PTW
ROV
RTU
RV
RVP
SB
SBB
SGS
TCV
TDS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Expansion
Knock Out Drum
Lock Close
Local Control Panel
Local Control Station
Level Control Valve
Lower Explosive Limit
Low Low
Lock Open
Low Pressure
Liquified Petroleum Gas
Low Speed Side; Low Signal Selector
Low Temperature Separator
Million Standard Cubic Feet Per Day
Medium Pressure
Nitrogen
Normally Closed
Non-Drive End
Normally Open
Net Positive Suction Head
Operation & Maintenance
Outlet
Oxygen Reduction Potential
Piping and Instrumentation Diagram
Pushbutton
Pressure Control Valve
Power Management System
Plant Operating Manual
Personal Protective Equipment
Parts Per Million
Parts Per Million by Volume
Parts Per Million by Weight
Process Shutdown
Pressure Safety Valve
Permit to Work
Remote Operated valve
Remote Terminal Unit
Relief Valve
Reid Vapour Pressure
Single Block
Single Block & Bleed
Satellite Gathering station
Temperature Control Valve
Total Dissolved Solids
Operations
Page 11 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Acronym
TEG
TSS
TVP
UC
UCP
UPS
WHCP
WHFP
WPT
2.0
Operations
Page 12 of 275
Expansion
Tri-Ethylene Glycol
Total Suspended Solids
True Vapour Pressure
Utility Connection
Unit Control Panel
Uninterrupted Power Supply
Well head Control Panel
Well head Flowing Pressure
Working Pressure & Temperature
TERMINOLOGY
Acid Gas
Antifoam Agent
API Gravity
Aromatics
Auto Ignition
Point
Balanced
Draught
Barrel
Block Valve
Catalyst
Ceramic Balls
Coalescer
Condensate
Dehydration
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
ESD Level-1
Shutdown
ESD Level-2
Shutdown
ESD Level-3
Shutdown
Gas Turbine
Hydrate
KOD
LEL
LPG
Mercaptans
Mole %
Purging
Pyrophoric
Schoepentoeter
Sour Gas
Stabiliser
Operations
Page 13 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Stripping
Total
Suspended
Solids
Turn Down
3.0
Page 14 of 275
UNIT OF MEASUREMENT
BOPD
BPD
BWPD
CFD
kg/h
kW
M
m3/h
mg/l
MM
MMSCFD
Nm3/h
ppb
ppmv
ppmw
S
STOBPD
4.0
Operations
The objective of this manual is to guide and provide an overview of the GGS facilities,
and a detailed description of Process and Control, Start-up and Shutdown of the plants.
These manual details the safety measures, built-in protections employed, handling of
emergencies in operation and start-up of the GGS facilities. This manual is to be used
in conjunction with other vendor manuals; it summarizes various aspects of
engineering including process, mechanical, electrical and control & instrumentation.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 15 of 275
The manual describes process, utilities, offsite, the activities required for the plant
start-up and shutdown, and, controls and safety hazards in the plant in various
sections as detailed below:
o
Section 8: Telecom
Sections 9, 10 and 11: Product Specification, Pre-Requisites for Start-up and Startup procedures for Utilities.
Sections 12, 13 and 14: Plant Start-up, Normal Operating & Monitoring and Plant
Start-up after Emergency Shutdown.
The Annexure Section contains Plot plan, PFD, Heat and Material balance, Alarms &
Trip schedule, Cause & Effect diagram, Utility summary and Vendor Operation
Manual references.
Though plant safety aspects are addressed in detail, this manual is not intended in any
way to supersede safety practices approved by the Company and/or adopted as per
manufacturers standards that should be followed by all personnel involved with these
facilities.
Step-by-step instructions and procedures for plant Start-up operations are discussed
and should be used as a guideline . However it is cautioned that all scenarios and
emergencies arising during plant operation cannot be visualized and explained in an
Operating Manual.
5.0
PREAMBLE
Ebla Production Facilities consist of Well heads & Flowlines, Gas Gathering Station
(GGS), Trunk line and Gas Treatment Plant (GTP). The production capacity of the
plants is rated for 80 MMSCFD of Gas and 22.5 m3/h of Condensate. There are seven
Gas Production Wells in Ash-Shaer facilities. The Well Fluid comprises of Gas and
Condensate. The well fluids are transported to manifolds through trunk lines and then
to a high pressure Production Separator in GGS. The Production Separator is a threephase separator vessel where the gas, condensate and produced water are separated.
The field reserve profiles indicate that the well-pressure will be high during the initial
phase of production and then the well-pressure will be reduced substantially. Hence
the production operation is termed as Initial-Phase (HP-Phase) and Normal Operation
(LP-Phase) of the Project. During the HP production phase, the pressure in the well
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 16 of 275
head is adequate for transportation of fluid to GTP, located 76 km away from GGS.
However during the LP Phase, a Field Gas Compressor and High Pressure Booster
Condensate Pumps are installed in GGS to compensate the pressure loss during
transportation to GTP, processing at treatment plants in GTP and then to export the
gas to the existing high pressure gas grid in Syria. The gas from Production Separator is
dried in Glycol-operated Dehydration Unit (moisture: 1.5 lb/MMSCF); similarly the
water content in Condensate (water specification: 200 ppmv) is removed before
transporting to GTP. The condensate and dried gas are mixed and then transported to
GTP through a Trunk line.
At the Gas Treatment Plant (GTP), the gas and condensate are received in a Slug
Catcher which knocks off the condensate from the gas. The condensate is sent to a
Stabiliser which produces stabilised condensate and is sent to Condensate Storage
Tanks. The gas from the slug catcher is sent to Gas Dehydration Unit which contains
Molecular Sieves to remove the moisture down to 0.1 ppmv level. The cooled gas from
Turbo-expander exchanges its heat with incoming feed gas and is recompressed in
Expander-Compressor to 36 barg. The dried gas pressure is boosted in a Sales Gas
Compressor and exported through Sales Gas Grid. The liquid separated from the cooled
gas (Turbo-Expander) and the Low Temperature Separator flows to De-ethanizer for
removal of uncondensed C1 and C2 components; this is then compressed and recycled to
the suction of Sales Gas Compressor for export. The De-ethanizer bottoms are sent to
De-butanizer to separate Stabilised Condensate and LPG. The LPG is dosed with an
odorant (Ethyl Mercapton) in a dosing facility and sent for LPG truck filling.
Condensate flows to storage tanks from where it is exported. Both GGS and GTP are
provided with utilities such as Plant Air, Instrument Air and Nitrogen Generation Unit.
Also Gas Turbo-Generators and Emergency Diesel Generators are provided in GGS as
well as GTP. Both units are provided with Utility Water and Potable Water Systems. Fire
Water System is provided only in GTP. The plant operations are executed with DCS at
both units. The GTP has the provision to operate GGS and Well heads from its Control
Room.
6.0
EMERGENCY SHUTDOWN
The Emergency Shutdown (ESD) system forms an integral part of the overall Plant
Safety system. A separate ESD system is provided at Wellheads, GGS and GTP. The ESD
system at GGS and GTP shall operate on three hierarchical levels, namely ESD-1, 2 & 3.
ESD Level 1: This represents the highest level of emergency that may occur at the
facility. ESD Level-1 will shutdown and depressurize the Process facilities.
ESD Level 2: This is activated in the event of a significant process abnormality at the
facilities. Operation of the facility shall be stopped by closing dedicated XVs and
tripping all process equipment.
ESD Level 3: ESD Level-3 shutdown is non-emergency process abnormalities affecting
only one equipment item or unit. ESD Level-3 trips are provided primarily for
equipment protection like shutdown of a Compressor on High-High discharge
temperature and shutdown of Glycol Dehydration unit on High-High level in the Inlet
Separator.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
7.0
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 17 of 275
INTENDED USERS
It is intended that this manual be used by the Operating Personnel to give equipment
description, system control and a start-up guideline .Note: the start-up section is
intended as a guideline and not to replace the Operating Procedures .
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 18 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 19 of 275
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PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 20 of 275
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GGS Operating Manual Vol #1
Operations
Page 21 of 275
Safety-starts with you! It is the expectation that everyone must follow all Codes of
Practice, site specific procedures and work instructions, and wear the proper Personal
Protective Equipment at all times when performing their assigned task/job.
Although not fully inclusive, the following are some of the tools that will assist you in eliminating
or reducing the Risks and Hazards:
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 22 of 275
One of our basic and simple principles is to determine which behaviors lead to incidents
occurring, and then initiate improvement to our Management Systems to eliminate or
reduce the unsafe behaviours and incident potential.
The most effective and pro-active method of avoiding accidents is through a worker to
worker behaviour based safety process. This is a worker observation process designed to
help identify unsafe behaviours, unsafe acts and/or unsafe conditions before they can
cause a loss.
Task Risk Assessments will be incorporated into the work scope for the operation of the
EBLA Gas Treatment Project. The Risk Assessment process is an essential component to
ensuring the safe and efficient operation. All mitigation measures that are identified must
be implemented to reduce the risk to as low as reasonably practicable.
Environmental:
Effects to the environment were considered during the design phase for this new facility.
Some of the equipment in the plant that has been designed to protect the environment are:
flaring systems,
closed drain system,
open drain system with holding ponds and
spill kits.
Housekeeping is a key part of maintaining a safe and clean working environment. The
Ebla Gas Treatment Project has also developed a waste management strategy for items
like filter disposal.
ALWAYS REMEMBER IF IN DOUBT, ASK!
For further information or assistance contact your supervisor or HS&E
representative.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 23 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 24 of 275
The following list are the Hazops action items that must be followed to ensure the
safety of personnel and equipment damage
Hazop Action No. 372
Confined space entry shall be as per company PTW procedure. It may be required to
inspect the vessel internals or repair a vessel/drum or Closed Drain Drum boot. After
draining the vessel and purging with N2, it should be dampened by water source to avoid
any fire due to pyrophoric iron deposits. Also purge it for sufficient time such that the
vessel is free from H2S/hydrocarbon content before vessel entry. There should not be any
traces of H2S in the vessel before vessel entry. Proper PPEs should be used for vessel
entry against H2S/Hydrocarbon presence.
Hazop Action No. 30
Special precautions need to be taken on Vessels like Production Separator prior to
releasing them to Maintenance/Turnaround Inspection. Even though H2S content is less
than 100 ppm there will be considerable accumulation of pyrophoric scale over a
prolonged period of operation. The pyrophoric dust will catch fire when it is exposed to
atmosphere. Before opening the Vessel, the Separator shall be dampened from a water
source. Disposal of the pyrophoric dust/scale shall be as per Company procedure for
disposal of hazardous waste and shall not be dumped in Plant areas which will lead to fire
accidents. Pyrophoric fire prevention measures are to be put in place (including
availability of relevant portable fire extinguishers)
Hazop Action No. 67
Handling and disposal of Contaminated filter Cartridges / Coalescer elements should be
done in a safe manner. As these filters contain hazardous sulphur and nitrogen compounds
this should be collected and disposed in designated storage areas. Proper PPEs
precautions to all personnel involved in handling the contaminated equipments to waste
storage area.
Hazop Action No. 31
When releasing Condensate/Produced Water Storage tanks, Condensate pumps/Filters,
proper safety precautions are to be taken as per PTW Procedures and for vessel entry by
Personnel. Check for Oxygen/Toxic HC components. The vessels are damped from a
water source to avoid pyrophoric iron fires. Naturally Occurring Radioactive Material
(NORM) and Low Specific Activity (LSA) Scale can appear during the drilling and
process phases of Oil and Gas exploration and tend to deposit along with other scale. Low
Specific Activity scale (LSA) which are found adhering to pipe and equipment internals
produce potential radiation illness mainly due to Radium-226 produced from the decay of
naturally occurring Uranium-238. Hence Radioactive Detection and PPEs for protection
against potential radiation illness should be used. The waste removed from Condensate
storage/Produced water storage tanks/cartridge filter should be disposed off at locations
specifically marked/designated as Waste holdup/storage area. The Waste disposal area
shall be clearly fenced, marked and identified with safety tags/boards indicating
warnings/dangers due to radioactive substances.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 25 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
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GGS Operating Manual Vol #1
Operations
Page 26 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
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During winter months, when air temperature might fall to -15C (min. ambient
temperature) ascertain that Gas Dehydration Column bottom, the wet condensate
outlet line and the chimney tray portion of the column are heated by electrical
tracing.
Switch on the electric tracing system on the level instruments installed on the
Flash Drum 305-V-002, on the TEG Reboiler 305-H-001, TEG Surge Drum
305-V-005, stand-by pump and in general where electrical tracing is given.
Increased viscosity of glycol in Surge vessel may affect the pumping and
potentially damage the glycol circulation pumps at cold operating conditions. As
the glycol lines are heat traced and insulated to retain the hot condition, it becomes
necessary to restart the electrical heat tracing and then start the Glycol Pumps
especially after prolonged shutdown and cold winter conditions.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
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Operations
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PALMYRA B.V
Unit : GGS
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Operations
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Unit : GGS
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Tank (334-T-001) and contaminated water storage tank (834-T-001) at GTP. Pressurized
draining will be allowed during start-up like draining of Compressor casing drains. For
drains which need to be used under normal operation like level instruments/bridle drains,
the spectacle blind is left in open position and operators will turn it closed as and when
required for equipment isolation. Consequently intermittent drainage required during
normal operation will be returned to the process.
Hazop Action No. 961
When the Gas Dehydration Plant is shutdown for longer periods during winter, then TEG
needs to be cooled sufficiently and drained to TEG Drain vessel.
Hazop
Item #
#766
Draining Hot TEG above 60C will damage drain piping and also hazardous for
handling.
Hence circulate TEG by the Glycol circulation pumps through Glycol Cooler. Bring
down the temperature below 60C and transfer to storage.
Drain liquid from vessels to TEG Drain drum and pump to storage.
Rounds
Equipment
Location
TEG Regeneration
Time
Sequence
2x per shift
Action
Nitrogen Unit
2x per shift
2x per shift
2x per shift
GGS Unit
1x per shift
PETRO-CANADA EBLA
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Unit : GGS
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PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
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1.0
INTRODUCTION
Operations
Page 32 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
1.1
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The multiphase fluid from each of the seven Production Well heads in the Ash-Shaer
area is transported to a Production Manifold. From the Production Manifold, the
multiphase fluid is transported to Production Separator in the Gas Gathering Station
(GGS). The Production Separator is a three-phase Separator Vessel where the gas,
condensate and water are separated. In the Early Production Phase i.e., at the
beginning of the Reservoir production, the well head pressure is high enough to
transport the gases from the well head to the Gas Treatment Plant (GTP) through the
GGS and Trunk lines. At the later stage of gas production when the Well head pressure
comes down, the Field Gas Compressor is used to boost the pressure. In the early
production phase, the differential pressure required is low and hence Early-operation
Condensate Pumps will be in operation. Later, when the Well head pressure drops, the
Field Gas Compressor is operated and Early-operation Condensate Pumps will be taken
out of service and Condensate Pumps will take over. The gas from the Production
Separator is routed to Gas Dehydration Column where water is removed by using lean
Tri-Ethylene Glycol (TEG). The rich TEG generated in the Gas Dehydration Column is
regenerated in TEG Regeneration System and returned to the Gas Dehydration Column
as lean TEG. The condensate and water are separated in the Production Separator by a
weir arrangement. The condensate is pumped by Condensate Pumps to a Condensate
Solid Filter and Condensate Coalescer where the fine particles and fine water droplets
are removed from the condensate. Finally, the dehydrated gas and condensate are
mixed together and transported through a 76 km trunk line to the Gas Treatment Plant
(GTP). GTP can be monitored from GGS control room, but no control of GTP is possible
from GGS, whereas GGS data can be monitored and controlled from GTP control room.
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
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2.0
Operations
Page 34 of 275
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PALMYRA B.V
Unit : GGS
2.1
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The safety systems in Ebla Project facilities are designed to protect personnel,
environment and assets from the threats of production hazards. A minimum risk level is
achieved by adopting the following safety aspects:
o
Containing and minimising the consequence of the hazards (fire, explosion and
toxic gas releases)
As the condensate and gas are sweet, there is no hydrogen sulphide (H2S) hazard
involved, however all systems are designed for a H2S concentration of 100 ppm.
ENTRY INTO CONFINED SPACE
Hazop Action No. 372
Confined space entry shall be as per company PTW procedure. It may be required to
inspect the vessel internals or repair a vessel/drum or Closed Drain Drum boot. After
draining the vessel and purging with N2, it should be dampened by water source to
avoid any fire due to pyrophoric iron deposits. Also purge it for sufficient time such
that the vessel is free from H2S/hydrocarbon content before vessel entry. There should
not be any traces of H2S in the vessel before vessel entry. Proper PPEs should be used
for vessel entry against H2S/Hydrocarbon presence. Refer section 2.3 for details
HAZARDS OF H2S
H2S is irritating to the eyes and the respiratory tract; it causes unconsciousness or
even death at higher concentrations. At 100 ppm, it causes coughing and loss of
sense of smell; at 500 - 700 ppm exposures, it will lead to unconsciousness and
death in 30 to 60 minutes. At 1000 ppm, it causes rapid unconsciousness; breathing
is stopped, resulting in death.
PETRO-CANADA EBLA
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When breaking into a process system that contains gas and condensate, it is necessary
to take special precautions as follows:
o
Area around the specific area is taped off to prevent personnel approaching the
worksite
o Personnel carrying out this operation shall take Work Permit, be aware of the
hazards associated with nitrogen (N2), Carbon di-oxide (CO2) and H2S and wear
appropriate Personal Protective Equipment (PPE)
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
When
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
releasing
Condensate/Produced
Water
Operations
Page 37 of 275
Storage
tanks,
Condensate
Personnel involved in the operation should wear Breathing Apparatus (BA) sets
When hydrocarbon concentration drops below 10 ppm, the All Clear is given
and normal work activities can recommence
2.2
The GGS involves methanol injection and corrosion inhibitor facilities. The Gas
Dehydration handles TEG as absorbent chemical for removing the moisture and uses
antifoam compounds for avoiding foaming in the Gas Dehydration Column.
2.2.1 Physical and Chemical Properties of TEG
TEG is a clear colourless liquid and highly miscible in water with a boiling point of
285C (545F).
In case of leak, isolate the area. Keep away unnecessary and unprotected personnel
from entering inside the area. Recover liquid wherever possible and collect liquid in an
appropriate container or absorb with an inert material (e.g. vermiculite, dry sand and
earth) and place in a chemical waste container. Do not use combustible materials, such
as saw dust. Do not flush to sewer.
Emergency and First Aid
Skin Contact
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In case of contact, immediately flush the skin with plenty of water for at least
15 minutes. Remove contaminated clothing and shoes. Wash clothing before reuse.
Eye Contact
If splash occurs, immediately flush the eyes with water for at least 15 minutes, lifting
upper and lower eyelids occasionally.
2.2.2 Physical and Chemical Properties of Methanol
Methanol is a clear colourless liquid with a characteristic pungent odour; it is miscible
in water with a boiling point of 65C (149F).
TLV (Threshold limit value)
: 200 ppm
: 250 ppm
In case of leak, isolate the area. Keep unnecessary and unprotected personnel from
entering. Contain and recover liquid when possible. Collect liquid in an appropriate
container or absorb with an inert material (e.g. vermiculite, dry sand and earth) and
place in a chemical waste container. Do not use combustible materials, such as saw
dust. Do not flush to sewer.
Effects of Over-Exposure
Inhalation may cause headache, nausea, vomiting, dizziness, lower blood pressure
and depression of central nervous depression
: 1 ppm
Do not allow spilled material to enter sewers or streams. Flush with water to dilute as
much as possible and pump into polyethylene containers for disposal. Avoid heat and
contamination with acid materials. Do not use combustible materials such as saw dust
PETRO-CANADA EBLA
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Unit : GGS
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to absorb hypochlorite. Aquatic toxicity not established, but bleach, if not diluted may
seriously affect aquatic life.
Emergency and First Aid
Eye Contact
If splash occurs on eyes, flush with plenty of water for atleast 15 minutes. Get prompt
medical attention immediately.
Skin Contact
In case of contact, immediately flush the skin with plenty of soap and water. If
swallowed drink large quantity of milk or gelatine solution. If these are not available
drink large quantity of water. Do not give vinegar or other acids. Do not induce
vomiting. Get prompt medical attention.
2.3
PPE REQUIREMENTS
Skin Protection
Wear protective impervious gloves such as rubber, neoprene or vinyl with rubber safety
shoes and body-covering clean clothing.
Eye Protection
Use chemical safety goggles plus full face shield to protect against splashing (For
Sodium Hypochlorite). Maintain eye-wash fountain and quick-drench facilities in work
area.
Fire Extinguishing Media
Keep on hand water spray, dry chemical, alcohol foam, or carbon dioxide
extinguishers. Water or foam may cause frothing.
Special Information
In the event of fire, wear full protective clothing and Self-Contained Breathing
Apparatus (SCBA) with full face-piece, operated in pressure-demand mode or other
positive pressure mode.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
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GGS Operating Manual Vol #1
3.0
EQUIPMENT SPECIFICATION
Operations
Page 40 of 275
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Operations
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Minimum
82.0
2.5
45.0
20.0
55.0
800
4100 ID x 5000H
Shell/Bottom: Carbon Steel
Internals: SS 316L
Unit
C
mbarg
C
mbarg
m3
kg/m3
mm
3.3
329-T-001
Tank
Methanol
Maximum
15.0
180.0
15.0
329-P-001A/S
Centrifugal
Methanol
Rated
15.0/45.0
0.012/0.59
1.20
20.0
800
0.7
3.7
Casing: CS; Impeller: CS
Unit
C
bara
bara
m/h
kg/m
Cp
kW
332-P-001 A/S
Centrifugal
Water
Rated
Min 4.0/Max 45.0
0.152
3.7
50
997
0.9
9.6
Casing: SS 316 L;
Unit
C
barg
barg
m/h
kg/m
Cp
kW
PETRO-CANADA EBLA
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00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Material of Construction
332-P-001 A/S
Impeller: SS 316 L
332-P-002 A/S
Vertical Centrifugal Pump
Water with oil
Rated
Min 4.0/Max 45.0
0.152
2.3
5.0
1000
0.9
3.7
Casing: SS 316 L;
Impeller: SS 316 L
Unit
C
barg
barg
m/h
kg/m
Cp
kW
Page 42 of 275
3.5
Operations
333-V-001
Drum -Horizontal
Hydrocarbon Gas & Condensate
Maximum
Minimum
15.0
82.0
5.0
FV
4.0
45.0
0.1
5.0
Condensate - 600/Water - 1000
Shell: CS;
Boot Cladding: SS316L
2500 ID X 9000 TT
Unit
C
barg
C
barg
kg/h
Kg/m3
mm
333-H-001
Electrical
Condensate
Maximum
15.0
3.5
4.0
Minimum
82.0
4.0
0.1
600
SS 316L
Unit
C
barg
C
barg
kg/m3
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
3.7
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3.8
Operations
333-P-001A/B
Vertical Centrifugal
Hydrocarbon Drains
Rated
45
3.66
1.94
5
700
0.47
4.12
Casing: SS316L;
Impeller: SS316L
Unit
C
bara
bara
m/h
kg/m
Cp
kW
334-P-001 A/S
Centrifugal
Produced Water
Rated
45
1.27
5.2
25.5
1200
1.1
11.96
Casing: CS;
Impeller: 12% Cr CS
Unit
C
bara
bara
m/h
kg/m
Cp
kW
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
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Operations
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PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
4.1
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Page 45 of 275
PRODUCTION SEPARATOR
The Production Separator is a horizontal three-phase separator vessel where the gas,
condensate and water are separated. Equipment Specification
Equipment Tag No.
Type
Process Medium
Description
Design Temperature
Design Pressure
Operating Temperature
Operating Pressure
Liquid Quantity
(Condensate/Water)
Density at Working
Pressure & Temp. (WPT)
(Condensate/Water)
Vapour Quantity
Molecular Weight
Density at WPT
Material of Construction
Dimensions
ID
Length (T/T)
302-V-001
Three Phase Separator Vessel Horizontal
Hydrocarbon Condensate, Gas & Water
Maximum
Minimum
Unit
82.0
15.0
C
95.2
barg (kPa)
41.0
7.7
C
86.64
25.39
barg (kPa)
14503/38386
kg/h
554.03/956.48
kg/m3
97980
19.28
20.66
Shell: Killed Carbon Steel (KCS)
Internals: Duplex Stainless Steel
Cladding: Incoloy 825
2700
12800
kg/h
kg/kg mole
kg/m3
mm
mm
Water and oil must be removed from the vessel at their respective outlets
PETRO-CANADA EBLA
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Unit : GGS
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(continuous phase). Due to this difference in densities, water droplets will travel
downwards under gravitational forces. The higher the size of water droplets, the faster
will be the speed of downward movement. Similarly condensate droplets in water
phase will travel upwards due to buoyancy forces. This separation of oil and water
(free water) phases by gravitational forces due to density difference is called as
Gravity Settling. Bulk of the water in the condensate is easily separated as it enters
the separators. A typical schematic sketch of Three Phase Separator is illustrated in
Fig. 1 as given below.
Schematic of Three-Phase Separator
The condensate and the water phase are separated in a Weir Plate and the separated
condensate flows over the Weir Plate and collects in the Condensate Compartment. A
600 mm internal Baffle Plate is provided at 3000 mm from the inlet nozzle end of the
vessel and at a height of 1000 mm from the bottom of the Separator. This Baffle Plate
is required to alleviate separation when slug arrives. The separated gas exits through
the top outlet nozzle provided with a Mist Eliminator arrangement capable of
separating liquid particles larger than 10 micron size.
The Production Separator is maintained at a pressure of 87 barg during the HP phase
and 36 barg during the LP phase. ESD valve 302-XV-1104 at Production Separator will
depressurize to the Flare Header when ESD Level-1 shutdown is activated. The Safety
Valves 302-PSV-100A/302-PSV-100B, is set at 95.2 barg and will open to the Flare
Header. The Condensate level is controlled by Level Controller and 302-LIC-1119
controls the Interface level.
PETRO-CANADA EBLA
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Operations
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PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
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Operations
Page 48 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
4.1.2.2
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Operations
Page 49 of 275
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Operations
Page 50 of 275
During the initial HP phase, the Well head gas pressure is adequate to meet the GTP
operating pressure. However, during later phase of operation (LP mode) of wells, the
Well head pressure will be low and hence it requires a Field Gas Compressor to boost
the pressure. During the HP phase, the entire Compressor circuit is kept in bypass
condition. The gas flow joins the inlet of the Gas Dehydration Column (305-C-001).
FIELD GAS COMPRESSOR SUCTION KNOCK-OUT DRUM
Equipment Tag No.
Type
Process Medium
Description
Design Temperature
Design Pressure
Operating Temperature
Operating Pressure
Liquid Quantity
Density at WPT
Vapour Quantity
Molecular Weight
Density at WPT
Material of Construction
Dimensions
ID
Length (T/T)
304-V-001A/B
Vessel Vertical
Hydrocarbon Gas
Maximum
Minimum
110.0
15.0
95.2
41
7.4
86.04
24.8
24.1
717.04
107623
19.28
20.3
Shell: KCS, Clad with SS 316L;
Internals: SS 316L
2700
4400
Unit
C
barg (kPa)
C
barg (kPa)
kg/s
kg/m3
kg/h
kg/m3
mm
mm
304-K-001A/B
Centrifugal
Wet Hydrocarbon Gas
Rated
35.5
24.9
166.3
87.5
97839
19.28
9080
Casing: Duplex Stainless Steel
Impeller: Duplex Stainless Steel
Unit
C
bara
C
bara
kg/h
kW
PETRO-CANADA EBLA
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Unit : GGS
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304-E-001A/B
Air Cooler & Forced Draft
Tube: Wet Hydrocarbon Vapour
Maximum
Rated
192
Inlet: 166.2
Outlet: 50.1
95.2
Inlet: 87.5
Outlet: 86.8
97839
8254.7 + 10% margin
45 Max.; 15 Min.
4
Tube: SS 316 L + Aluminium fins
Air
Unit
C
C
bara
bara
kg/h
kW
C
No.
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measured by 304-FI-1220, 304-TI-1222 and 304-PI-1221 which is also used for the
anti-surge control of the compressor. Similarly the discharge pressure and temperature
of the Compressor is indicated by 304-PI-1232 and 304-TI-1231 respectively. The
compressed gas from the compressor discharge at a pressure of 87.5 barg and
temperature of 166C flows to the Field Gas Compressor Aftercooler-A (304-E-001A)
where the temperature is cooled to 50C by Fin Fan Coolers. The compressed gas
temperature is controlled by using 304-TIC-1215 which will control the Variable Speed
Drive of the Fin Fan Motors. From the outlet of the Fin Fan Coolers, the gas is recycled
to the suction of KO Drum 304-V-001A by the Antisurge Controller to minimise the
surge. The compressed gas flows to the Gas Dehydration column through an ESD valve
304-XV-1219.
4.2.1.1
The Field Gas Compressor has two main auxiliary units the Lube Oil system and the
Seal Gas system.
Auxiliary Lube Oil System
The Lube Oil system comprises the following: Lube Oil Reservoir (304-T-1500), Lube Oil
Heater (304-H-001A), Auxiliary Lube Oil Pump (304-P-002A), Main Lube Oil Gear Pump,
Lube Oil Cooler (304-E-002A) and Lube Oil Filters 304-F-001A1/A2.
During normal operation, the lube oil is supplied by the gear-driven main pump. The
Auxiliary Lube Oil Pump is used during start-up, shutdown and also as a standby pump
to main oil pump when the oil pressure is not adequate. The Lube Oil Reservoir level
and temperature are indicated by Level Indicator 304-LI-1505 and Temperature
Indicator 304-TI-1514 respectively. The Reservoir temperature is maintained by an
PETRO-CANADA EBLA
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Unit : GGS
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Page 53 of 275
electric Heater which maintains the lube oil in the reservoir at a constant
temperature. The temperature indicator 304-TI-1514 and level indicator 304-LI-1505
are provided with High and Low level alarms. The lube oil from the discharge of the
Auxiliary/Main Lube oil pump is cooled in Lube Oil Coolers (304-E-002A) which are Air
Fin Coolers. The lube oil header pressure is maintained at 2.5 barg by a Pressure
Control Valve 304-PCV-1510 by regulating the lube oil back to the Lube Oil Reservoir.
The lube oil is then filtered by Lube Oil Filters (304-F-001A1/A2) and distributed to the
Motor and the Compressor (DE & NDE).
The lube oil is supplied to the following items:
o
Motor Bearings
Gearbox
The return lube oil flows to the lube oil reservoir through restriction orifices.
PETRO-CANADA EBLA
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The primary seal gas from the discharge of the Compressor is filtered at the Seal Gas
Filters 304-F-002A1/304-F-002A2. During Normal operation of the Compressor, Seal Gas
is supplied from the Compressor Discharge. However, during the Start-up condition and
Black-Start condition, bottled nitrogen will be used for the dry gas seal. In case of
pressurized shutdown, the Settle-out Pressure is 46.4 barg. During this period, the seal
gas supply can be supplied from the HP Fuel Gas tapped from the downstream (D/S) of
Fuel Gas Heater (321-H-001A/B) to ensure dry heated gas supply to Dry Gas Seals. The
suction pressure of the compressor is controlled by a self-regulating Pressure Control
Valve 304-PCV-1294 whose set pressure is above the settle out pressure. This PCV will
be used to maintain pressure in the system during pressurized shutdown of the
Compressor and not during normal operation.
PETRO-CANADA EBLA
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Similarly, the Secondary Seal Gas is nitrogen gas, filtered in Buffer Gas Filters
304-F-003A1/A2. The Nitrogen (from Utilities) from the Buffer Gas Filters is split into
two lines - one supplying as secondary seal gas through 304-PV-1465 and the other
supplying seal gas through 304-PV-1449 for bearing separation seal. The leaking gas
from the primary and secondary seal is vented to the Flare Header under Backpressure Controller 304-PCV-1464. The seal vent between the secondary seal and
bearing separation seal is vented to the atmosphere at a safe location.
4.2.2 Field Gas Compressor Controls
All control and safeguarding functions of the Field Gas Compressor and its auxiliaries
will be controlled by Unit Control Panel (UCP) based control system, which consists
mainly of PLC, Vibration and Displacement monitoring system and Human Machine
Interface (HMI). All functions like the compressor start-up and shutdown sequence,
anti-surge control, performance control, control and safeguarding of lube oil system,
seal gas system, separation gas system, compressor bearings, motor bearings/purge
unit/stator windings/cooling system, and, vibration and displacement monitoring
system will be executed in the UCP.
The compressor control system has interface with the plant DCS and ESD systems for
monitoring, alarming and safe operation. It will also perform operations like Start-up
sequence initiation, emergency stop, and manual operation of lube oil pumps and
coolers from DCS.
The various controls of Field Gas Compressor below relate to Compressor Train-A.
Train-B is similar to Train-A, and hence not described separately. During Early Plant
(HP) operation, all motor blocks and controllers related to Suction KO Drums,
Compressors and After-coolers shall be disabled.
Feed Gas Compressor Anti-Surge Control
The anti-surge controller resides in the UCP. The process variable inputs to the antisurge controller and their related alarms will be conveyed to DCS over the serial link.
The anti-surge control algorithm determines the compressor operating point relative to
the surge limit/anti-surge control line, based on the following process variable inputs:
o
Static pressure at the inlet and outlet of compressor: 304-PT-1221 and 304-PT-1232
When the compressor approaches the anti-surge control line, the anti-surge controller
will open the Anti-Surge Valve 304-FV-1212, located on the compressor recycle line, to
prevent surge. When the compressor is running and well above the surge control line,
the anti-surge valve is closed.
The various modes of the anti-surge controller are listed below:
o
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The anti-surge controller can be manually operated to open or close the anti-surge
valve from the UCP HMI (Human-Machine Interface). However, if the compressor
operating point approaches the anti-surge control line, the controller is switched
back to Auto mode automatically.
DCS set point is written to the Controller (DCS shall track the controller set
point when in local). The controller shall send the set point, as an analog value,
back to the DCS for display of set point on the DCS Controller faceplate.
In MANUAL, the output of the valve can be manipulated from the DCS. The DCS
requested valve position, which is an analog signal, is written to the controller.
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 57 of 275
The controller shall send the valve position, as an analog value, back to the DCS
for display of valve position on the DCS faceplate.
The VSDS tends to decrease the speed of the compressor in case the suction pressure is
decreasing below the set point.
The various modes of the Compressor Suction Pressure Controller are listed below:
o
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 58 of 275
However the ESD3 (recycle trip) causes unit shutdown in recycle mode, whereas all
other shutdown conditions cause unit shutdown without blowdown.
Refer Siemens Cause & Effect diagram (HE612428200)
Compressor Sequencing
Compressor start-up and shutdown sequence is built in the PLC (UCP). The Start-up
sequence can be started in Manual mode in step-by-step sequence or the sequence can
be stopped from the DCS. The status of various stages of the sequence shall be
displayed in the DCS graphics.
During normal operation when the compressor is running, all the controllers are in
Auto. Before initiating the start-up sequence, all trips have to be cleared and all the
start-up interlocks have to be fulfilled. When all systems are healthy, the compressor
will be pressurized. The casing and seal cavity shall be drained before every start-up,
which is a manual activity and upon completion, will be conveyed from DCS to the PLC
as a pulse command.
The compressor is started with an open anti-surge valve. Once the motor is running at
minimum speed, the compressor can be loaded; the anti-surge and performance
controllers will be switched from SEQUENCE to AUTO. When the compressor is stopped,
the anti-surge controller is switched to SEQUENCE, the anti-surge valve is force-opened
and the compressor is brought to a standstill in the pressurized state. The motor will
stop within a predefined time.
ESD trip with or without blowdown shall be as per the conditions given in suppliers
C&E diagram, document no. JI-190-C02411-EMR-D16-002. Also refer C&E diagram
250-EPR-CNE-05001.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 59 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 60 of 275
simultaneously given to all the three louvers, such that the three louvers of the same
bay always have the same tilt angle.
If temperature at outlet of Air Cooler goes below the set point, first VSD driven fan
reduces speed. When it reaches to minimum speed, fixed speed fan is switched off and
VSD fan increases up to the requirement. Louver is operated based on intake air
temperature controller. The set point of air temperature controller is above hydrate
formation temperature and louver control will come only when air temperature drops
below the set point value.
Early Plant (HP) Operation
During this mode, the suction KO Drums, the Field Gas Compressors and their
Aftercoolers will be bypassed. Hence, all controllers, as listed below, related to the
suction KO Drums, the Field Gas Compressors and the Aftercoolers shall be forced to
Manual and outputs driven to 0% during HP mode operations.
304-TICA-1268
304-TICA-1275
304-TICA-1215
304-LIC-1210
304-TICA-1368
304-TICA-1375
304-TICA-1315
304-LIC-1310
Field
Field
Field
Field
Field
Field
Field
Field
Gas
Gas
Gas
Gas
Gas
Gas
Gas
Gas
In addition to the above, the compressor faceplate for DCS operations like compressor
start sequence, compressor motor start, lube oil standby pump start and lube oil
coolers start shall be disabled during HP mode.
4.3
CONDENSATE SYSTEM
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 61 of 275
line and the differential pressure across the filter 302-F-001A is measured by
302-PDI-1146; 302-PDI-1144 measures the differential pressure for 302-F-001B filter. As
the differential pressure of the filters increases, alarm will sound and the filter will be
isolated and changed to the standby filter. There are two Safety Relief Valves
302-PSV-105 and 302-PSV-106 set at a pressure of 142 barg which opens to the
Flare Header.
The Condensate from the Condensate Filters flows to the Condensate Coalescer
302-F-002A/B where water from the Condensate is removed. The Coalescer is designed
for inlet water content of 1% by volume and the outlet water content should be less
than 200 ppm. The Interface levels of Coalescer 302-F-002A/B are measured by Level
Transmitters 302-LT-1156A&B respectively. One Coalescer will be on line and the
differential pressure across the Coalescer element 302-F-002B is measured by
302-PDI-1168 and 302-PDI-1169 measures the differential pressure for 302-F-002A. At
high differential pressure alarm of the Coalescer, the Coalescer will be isolated and
changed to the standby Coalescer. There are two Safety Relief Valves 302-PSV-107 and
302-PSV-108 set at a pressure of 142 barg and the blowdown is connected to the Flare
Header.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 62 of 275
CONDENSATE PUMPS
Equipment Tag No.
Type
Fluid
Description
Temperature
Suction Pressure
Discharge Pressure
Flow
Density of Liquid at WPT
Viscosity of Liquid at WPT
Motor Power
Material of Construction
Seal Type
302-P-001A/B
Centrifugal
Hydrocarbon Condensate
Rated
36.0
26.2
95.0
24.5
661
0.33
202
Casing: Duplex Stainless Steel
Impeller: Duplex Stainless Steel
Mechanical
Unit
C
bara
bara
m/h
kg/m
Cp
kW
CONDENSATE COALESCER
Equipment Tag No.
Type
Process Medium
Description
Design Temperature
Design Pressure
Operating Temperature
Operating Pressure
Liquid Quantity
Density at WPT
Material of Construction
302-F-002A/B
Coalescer Vessel
Condensate
Maximum
28.0
142.0
8.0
87.3
36.7
0.650
Shell: Carbon Steel
Cladding: Duplex SS
Minimum
82.0
41.1
Unit
C
barg
C
barg
M3/h
Kg/m3
Minimum
82.0
41.1
Unit
C
barg
C
barg
m3/h
kg/m3
302-F-001A/B
Filter Catridge
Condensate
Maximum
28.0
142.0
8.0
87.9
36.7
0.650
Shell: Carbon Steel
Internals: Duplex SS
Cladding: Duplex SS
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 63 of 275
302-P-002A/B
Rotary Progressive Cavity Type
Hydrocarbon Condensate
Rated
41
87.4
98.2
36.6
Unit
C
bara
bara
m/h
664.5/554
kg/m
0.18/0.307
Cp
40.56
Casing: Duplex Stainless Steel
Impeller: Duplex Stainless Steel
Mechanical
kW
During LP mode, the Condensate pumps are protected against low flow by the
Minimum-Flow Control Valve 302-FV-1130 operated by Controller 302-FIC-1130, which
shall be forced to Manual and output driven to 0% under the following conditions:
o
4.3.2.2
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 64 of 275
recycle line. The Early Operation Condensate Pumps are Positive displacement Pumps
and works on back pressure. Trunk line operating pressure varies from 68.2 Bara
(during turndown operation) to 86.2 bara (during normal Plant Operation). During HP
mode of operation, Production Separator pressure is 87.0 bara. Hence during the HP
mode of operation, there are chances of operating 302-P-002A/B at very low
differential pressure. 302-PIC-1132 will maintain certain differential pressure for
302-P-002A/B by throttling 302-FV-1182 using output from 302-PIC-1132.
302-LIC-1119A shall be forced to Manual mode and output driven to zero under the
following conditions:
o
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 65 of 275
one for bottom level control of condensate in the inlet scrubber 305-LT-3013 and the
other for ESD control 305-LT-3015. For the effects of 305-LAHH-3015 and
305-LALL-3015, refer Cause & Effect Diagram 250-EPR-CNE-05001.
The inlet gas separation device allows a large gas flow turndown while assuring even
gas distribution. The gas separation device (vane type) uses curved plates to disperse
all inlet gas evenly beneath a wire mesh Mist Eliminator and to separate gas and liquid
efficiently. The purpose of the mist eliminator is to coalesce the condensate droplets
from the gas stream. The gas then flows through the gas risers of the glycol chimney
tray, which allows a uniform distribution of the gas before it enters in the gas/glycol
contacting section. The structured packing in the Gas Dehydration Column is to ensure
uniform distribution and contact between the liquid and the vapour. There are two
level transmitters 305-LT-3017 which control the rich TEG level and 305-LT-3016 for trip
purpose. There are High-High and Low-Low level alarms 305-LAHH-3016 and
LALL-3016, the effects of which are detailed in Cause & Effect Diagram
250-EPR-CNE-05001.
The lean glycol from the discharge of Glycol Circulation Pumps (305-P-003A/B) enters
at 55C in order to have a contact temperature of 10C above the wet gas inlet
temperature. The lean glycol enters at the top of the column and is equally distributed
over the whole section of the column by the Glycol Distributor installed above the
packed bed. The dehydration by absorption takes place as the gas flows upwards
through the packing, contacting the wetted surface of the packing. A high efficiency
Demister removes entrained glycol droplets from the dehydrated gas stream before it
leaves the top of the contactor. The dehydrated gas from the top of 305-C-001 enters
Dry Gas/Lean TEG Heat Exchanger (305-E-004) where the lean TEG is cooled to
maintain the difference of 5 to 10C between the lean TEG and wet gas (entering the
dehydration column).
The rich TEG comes down the structured packing after absorption of moisture and is
sent to TEG Regeneration system. There are two Safety Relief Valves 305-PSV-119A and
305-PSV-119B which are set at a pressure of 95.2 barg provided on the top of 305-C-001
which will release to Flare header during over-pressurization of Dehydration Column.
The differential pressure across the packed column is monitored by Differential
Pressure Transmitter 305-PDI-3007 and sounds a high differential pressure alarm when
the pressure reaches the alarm set point. The higher differential pressure across the
contactor indicates foaming in the Contactor. There are high-pressure and low-pressure
alarm set points indicated by 305-PAL-3009 and 305-PAH-3009. The flow of dehydrated
gas from the outlet of 305-E-004 is measured by 305-FI-3006. At the downstream of ESD
Valve 305-XV-3004, the dry condensate from Coalescer and the dehydrated gas are
mixed and transferred to GTP through the trunk line. There are methanol injection
points ME-711 and ME-713 on the top vapour lines. There is a Moisture Analyzer 304-AI3022 which measures the moisture content of the dehydrated gas. The analyser is
provided with High alarm and High-High alarm set at 1.3 lb/MMSCF and 1.5 lb/MMSCF
respectively.
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 66 of 275
Material of Construction
Dimensions: OD
Length (T/T)
305-C-001
Packed Column
Hydrocarbon Gas & TEG
Maximum
Minimum
Unit
82
15
C
95.2
barg
12.5
55
C
67.2
85.2
barg
6201
kg/h
1100
kg/m3
97980
kg/h
19.28
20.66
kg/m3
4600
mm
Top Shell: A516 Gr7 ON
Bottom Shell: A516 Gr7ON + 3mm SS-316L
Cladding:
Internals: A516 Gr 70
Cladding: 3 mm SS-316L
Bottom: 1714;Top: 1494
Mm
12600
mm
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 67 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 68 of 275
4.4.2.2
The rich TEG after the absorption of water is routed to TEG Regenerator system by
level control. The Rich TEG level is controlled by a Level Controller 305-LIC-3017 which
controls 305-LV-3017 to TEG Regenerator system.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
4.4.2.3
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 69 of 275
All the liquids (condensate hydrocarbons or liquid water) recovered in the bottom of
the Inlet Scrubber are drawn down under level control and returned to the Production
Separator/Flare during LP/HP Mode. 305-LIC-3013 controls the bottom level of the
Inlet Scrubber. It is a Gap Controller which has On/Off action on Control Valve
305-LV-3013 through which the knocked out condensate liquid is returned back to the
inlet of Production Separator during LP mode operation. During HP mode operation, all
liquid recovered in the bottom of dehydration column is routed to flare.
4.5
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 70 of 275
PETRO-CANADA EBLA
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GGS Operating Manual Vol #1
Operations
Page 71 of 275
The rich glycol is then heated to about 60C or 70C in the Cold Lean/Rich Glycol Heat
Exchanger before entering the Glycol Flash Vessel (operating pressure is 4 barg). In this
3-phase separator, dissolved and entrained gases flash off and are removed from the
glycol. Liquid hydrocarbon condensate, if present, is also separated from the glycol. If
not separated off, these hydrocarbon components would flash in the Regenerator and
lead to an increased still-column vapour load, a higher reboiler duty requirement,
greater glycol losses and a loss of recoverable product. These components could also
lead to coking of the reboiler heating elements, fouling, foaming and a higher BTEX
level in the water condensed from the overhead condenser.
While this arrangement is typical, in some units the Glycol Flash Vessel is located
immediately downstream of the contactor, operating at a lower temperature. From the
flash vessel the rich glycol flows through a full flow particle filter and an activated
carbon filter often in slipstream service, to remove solids and dissolved hydrocarbons
and degradation products, respectively. The rich glycol is further heated in the LP
rich/lean glycol heat exchanger and then flows to the regenerator still column where
it enters between two contacting sections. Heat is provided at the bottom of the
regenerator in order to evaporate water from the glycol.
The reboiler may be directly fired or indirectly heated by electricity, hot oil or steam.
Typical operating temperatures for TEG are up to 204C. Water and volatile species
present are evaporated from the rich glycol, and reflux is provided to reduce glycol
losses. Because of the wide difference in volatility, only a small reflux is needed to
effect water/glycol separation. The regenerated hot lean glycol leaves the Reboiler,
flows through the stripping column and collects through the TEG surge drum.
GLYCOL CIRCULATION PUMPS
Equipment Tag No.
Type
Fluid
Description
Temperature
Suction Pressure
Discharge Pressure
Flow
Density of Liquid at WPT
Viscosity of Liquid at WPT
Power Absorbed at Shaft
Material of Construction
305-P-003A/B
Reciprocating
Lean TEG 99.9%
Rated
101.6
0.11
96.8
6.0
1046
3.73
15.8
Casing: AISI 316L; Impeller: AISI 316 L
Unit
C
barg
barg
m/h
kg/m
Cp
kW
305-K-001A/B
Centrifugal Blower
Air
Rated
25
Unit
C
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 72 of 275
305-K-001A/B
ATM
barg
96.8
m barg
1500
Nm/h
4.0
kW
Casing: AISI 316 L; Impeller: AISI 316 L
305-F-001
Catridge
Lean TEG
Maximum
82.0
10.0
45.0
Minimum
15.0
4.0
3.3
5.0
1104
Shell: KCS; Internals: SS316L
203.2 ID x 1500 TT length
Unit
C
barg
C
barg
m3/h
kg/m3
mm
305-V-001
Horizontal vessel
TEG
Maximum
Minimum
15.0
82.0
3.5
15.0
45.0
0.005
1.5
Shell & Heads: CS
2000
7700
Unit
C
barg (kPa)
C
barg (kPa)
mm
mm
305-C-001
Packed Column
Hydrocarbon Gas & TEG
Maximum
Minimum
280.0
15.0
3.5
FV
204.0
0.12
Unit
C
barg (kPa)
C
barg (kPa)
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
OD
Length (T/T)
Operations
Page 73 of 275
305-C-001
0.8
160.2
Pall Rings 5/8 -1900 mm
Shell & Heads: ASTM A516 Gr60
Internals: Pall Rings 5/8 SS316L
406.4
1900
kg/h
kg/h
mm
mm
mm
305-P-001
Vertical Sump Pump
Lean/Rich Glycol
Rated
45
0.22
2.08
5
1100
57.26
5.5
Casing: SS 316 L; Impeller: SS 316 L
Unit
C
bara
bara
m/h
kg/m
Cp
kW
305-T-001
Tank
TEG
Maximum
15.0
180.0
0.0
Unit
C
mbarg
C
20.0
mbarg
28.0
m3
1100
kg/m3
4000 ID x 3000H
mm
Shell/Bottom: Carbon Steel; Internals: SS 316L
305-P-002
Centrifugal Pump
Lean TEG
Minimum
82.0
2.5
45.0
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Description
Temperature
Suction Pressure
Discharge Pressure
Flow
Density of Liquid at WPT
Viscosity of Liquid at WPT
Motor Power
Material of Construction
Operations
Page 74 of 275
Rated
45
0.5
5.56
5.0
1100
40
5.5
Casing: KCS; Impeller: KCS
Unit
C
bara
bara
m/h
kg/m
Cp
kW
305-E-001
Plate Type Heat Exchanger
Plate: Lean Glycol; Shell: Rich TEG
Maximum
Minimum
240.0
15.0
Inlet: 120.0
Outlet: 73.0
10.3
1.0
180.0
15.0
10.3
1.0
Inlet: 12.0
Outlet:62.0
6201.0
6360.0
204.0
Plate: SA240 316; Shell: SA333 Gr6
Unit
C
C
barg
C
barg
C
kg/h
kg/h
kW
305-E-002
Plate Type Heat Exchanger
Plate: Lean Glycol; Shell: Rich TEG
Maximum
Minimum
240.0
15.0
Inlet :194.0
Outlet :103.0
10.3
1.0
180.0
15.0
10.3
1.0
Inlet: 62.0
Outlet: 150.0
6201.0
6462.0
410.0
Plate: SA240 316; Shell: SA333 Gr6
Unit
C
C
barg
C
barg
C
kg/h
kg/h
kW
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 75 of 275
PETRO-CANADA EBLA
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GGS Operating Manual Vol #1
Operations
Page 76 of 275
collected in the TEG Surge Drum (305-V-005). The regenerated glycol coming from the
Surge Drum (305-V-005) is cooled down from 193.6C to 109.6C in the hot Lean/Rich
Glycol Heat Exchanger (305-E-002) and then passes through the Cold Lean/Rich Glycol
Exchanger (305-E-001) where the outlet temperature reaches 103C. The pressure is
increased to 88.5 bara by means of Glycol Circulation Pumps (305-P-003A/B).
The glycol-water vapours move up the TEG Reflux Condenser (305-E-003), on the tube
side, cooled by the rich TEG from 305-C-001 on the shell side. In the TEG Reflux
Condenser, the glycol vapours are condensed and predominantly water vapour along
with little uncondensed TEG escapes. The vapours from the outlet of TEG Reflux
Condenser go to Vent Gas KO drum (305-V-003) from where the condensed liquid is
sent to Closed Drain System. The uncondensed vapour from the top of 305-V-003 goes
to a Vent Gas Blower (305-K-001A/B & 305-K-001C/D) which operates in series. The
vent gas flows to the TEG Incinerator where the vapours are burnt with air. Provision is
given to route the off-gas to Flare when the Incinerator is not available.
The hot TEG is distilled by the removal of water from the rich TEG. The hot TEG
vapours from the TEG Reboiler (305-H-001) provide the heat input for the distillation
of rich TEG into lean TEG and water. The lean Glycol is pumped by Glycol Circulation
Pump (305-P-003A/B) and passes through the Dry Gas/Lean TEG Exchanger (305-E-004)
before entering the Dehydration Column (305-C-001) through a flow distributor. The
required make-up TEG is pumped from the TEG Storage Tank (305-T-001) by TEG
Make-up Pump (305-P-002) and it flows through a TEG Make-up Filter (305-F-001).
The TEG Storage Tank (305-T-001) is a conical fixed roof storage tank maintained at a
pressure of 80 mbarg with a nominal capacity of 28 m3. The tank pressure is
maintained by a self-regulating Pressure Control Valve 305-PCV-3049 by controlling
blanket nitrogen to tank. If the tank gets over-pressurized, then it is opened to
atmosphere through a vent by a self-regulating Pressure Control Valve 305-PCV-3048.
The drain from the various vessels of Gas Dehydration system and TEG Regeneration
system is drained into TEG Drain Vessel (305-V-001). From 305-V-001 it is pumped back
to the Regenerator system using TEG Drain pump. A Pressure Vacuum Valve
305-PVV-161 is fitted to the tank which will open at a pressure of 140 mbar and at a
vacuum of 1 mbarg. 305-PVV-161 acts as a safety device to prevent the tank during
the failure of 305-PCV-3048 or 305-PCV-3049.
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 77 of 275
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 78 of 275
TEG Incinerator unit is designed to burn off-gases from TEG Regeneration System and
Produced Water Tank. The TEG Incinerator consists of a vertical combustion chamber
directly connected to the stack through a flue gas duct, where the flue gas is
quenched with dilution air at ambient temperature. The diluted gas is exhausted to
the self-supported stack raiser connected with the top of the base chamber. The
Combustion Chamber is equipped with a special Burner and an electrically ignitable
pilot. The waste gas is directly injected together with support fuel gas and combustion
air in to the combustion chamber for burning.
The TEG Incinerator is designed to burn gases with the following parameters:
TEG Off-Gas
Flow rate
: 464 kg/h
Temperature
: 30 150C
Pressure
: 0.4 barg
Flow rate
: 242 kg/h
Temperature
: 8 45C
Pressure
: 0.03 barg
The TEG Incinerator Main Burner has a design capacity of 7 MW/h which is 10% higher
than necessary to operate the combustion chamber at 850C (1562F) under maximum
waste gas flow rates.
The fuel gas consumption for the Main Burner will be as follows:
Minimum
Normal
Maximum
kg/h
8.0
57.3
60.5
Nm3/h
10
72
76
The TEG Incinerator is designed to burn waste gases from the following sources:
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
o
Operations
Page 79 of 275
TEG off-gas is introduced through the Burner Gun and Produced Water Tank Off-Gas is
introduced directly in the Combustion Chamber. During the chamber pre-heating
phase, the main burner is operated with support fuel gas and combustion air only.
Preheating operation will be done until combustion chamber temperature reaches
750C. The operating temperature for the combustion chamber is 850C, maintained
by regulating the Fuel Gas flow rate.
The TEG Incinerator is:
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 80 of 275
UTILITIES
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 81 of 275
4.7.2.1
Process Description
Each compressor package includes one after cooler (325-E-001A/B) for maintaining the
discharge temperature to meet system requirements. A wet Air Receiver (325-V-001)
will be provided downstream of the compressors.
PETRO-CANADA EBLA
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Unit : GGS
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GGS Operating Manual Vol #1
Operations
Page 82 of 275
Wet air from the receiver is routed to Instrument Air Dryer package (325-X-002A/B)
which consists of alumina bed absorption/regeneration unit for production of air at a
dew point of -35C at 7.5 barg. The dryer beds are regenerated using dry instrument
air. Each dryer package is provided with Prefilter, Dryer vessel & Afterfilter. Coalescing
Air Pre-filters filter any water, dust and foreign matter from Plant Air before it is sent
to the Air Dryer Beds. Downstream of the dryer beds, Afterfilters are installed to
remove any desiccant fines carried over from the dryers before the air reaches the
Instrument Air Receivers. The dried instrument air is then lead to distribution header
through Instrument Air Receiver (325-V-002).
Instrument Air (IA) Receiver (325-V-002) downstream of the drier package will be sized
to provide at least 20-minutes backup supply to IA users (excluding N2 package supply)
while the pressure in the receiver falls from 8.5 barg to 4.5 barg for a flow of 495
Nm3/h.
Pressure Transmitter 325-PT-4737 is provided on the line going to Instrument Air
Distribution Header initiates Plant ESD when instrument pressure falls below 4.41 barg
(4.5 kg/cm2g).
AIR COMPRESSOR
Equipment Tag No.
Type
Fluid
Description
Suction Temperature
Suction Pressure
Discharge Temperature
Discharge Pressure
Flow
Molecular Weight
Power Absorbed at Shaft
Material of Construction
325-K-001A/B
Screw
Ambient Air
Rated
Unit
45
C
0.943
bara
54
C
11.0
bara
1480.2
Nm3/h
28.99
1485
kW
Casing: Cast Iron DIN 1691-64-GG20
Impeller: CS DIN 17200 CK35 PTFE Coated
325-V-002
Vessel
Instrument Air
Maximum
Minimum
15.0
82.0
12.0
15.0
50.0
4.5
9.5
28.82
CS
1000 OD x 3000 Length T/T
Unit
C
barg
C
barg
mm
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
4.7.2.2
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 83 of 275
Pressure Transmitter 325-PT-4732 will initiate two-level interlock based on the air
pressure. When the air pressure drops below 6 barg, it will close On/Off Valve
325-XV-4665 located on the line going to Plant Air distribution header. The second level
of interlock which is set at 5 barg to close On/Off Valve 325-XV-4725 located on the
Instrument Air supply line to Nitrogen package.
The Pressure Transmitter 325-PT-4732 will control loading and unloading of the Air
compressors. Instrument Air distribution header pressure will also be provided with
pressure Low-Low alarm represented by 325-PALL-4737. Refer Cause & Effect Diagram
250-EPR-CNE-05001.
Wet air receiver level is also provided with level High-High trip by 325-LAHH-4653 and
high level alarm is indicated by 325-LAH-4650. Refer Cause & Effect Diagram
250-EPR-CNE-05001 ESD Level-3, Unit-325) for more details.
The following signals will be available from air compressors for indication in the DCS:
Running status
Shutdown alarm
Common alarm
Note: Refer vendor operating & maintenance manual for further details.
4.7.3 Nitrogen System
4.7.3.1
Process Description
Nitrogen requirement in GGS plant is essentially for blanketing of tanks and secondary
gas for compressor seals. The nitrogen Generation package employs Membrane
technology for generation of nitrogen from air. The nitrogen Generation Package
(324-X-001) consists of one train with a capacity of 68 Nm3/h capacity of 98 vol%
purity.
The Nitrogen package unit consists of three sections namely:
Product gas
The nitrogen unit can be started or stopped locally or remotely. The feed air is taken
from Instrument Air Receiver 325-V-002.
Inlet Parameters
Parameters
Pressure (Min./Max.)
Temperature (Min./Max.)
Dew point
Feed Air Capacity
Unit
barg
C
C
Nm3/h
Value
7.0/10.0
15/50
35C @ 7.5 barg
230
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 84 of 275
Unit
barg
C
Nm3/h
Value
5.5/7.0
15/+50
68
The Instrument air stream from Instrument Air Receiver (325-V-002) is directed to
Nitrogen Generator (324-X-001) through Micron- and Activated Carbon -Filters. The Dry
Feed Instrument Air (15 50 C & 7.0 8.2 barg) is led through a set of one-micron
filter (324-F-001A) and one AC Filter (324-F-002A) to qualify feed air quality. One
standby set of Micron Filter (324-F-001B) & AC Filters (324-F-002B) are provided to
allow change-over for maintenance of filters. The feed air is then heated in Heater
(324-H-001) to 50C (max).
The filtered and dried feed instrument air is then fed to nitrogen Generation Package
(324-X-001). The oxygen-rich waste gas is discharged to atmosphere at a safe location.
The generated nitrogen stream is continuously analysed for oxygen content by Oxygen
Analyzer (324-AIT-4619) provided on downstream of membrane modules. A total
number of five membrane modules constitute the package wherein three operate and
two are spared to take care of maintenance requirement of any two modules at a
time. The package is designed to supply 68 Nm/h of nitrogen with 98% product purity
under normal operation at 5.5 barg (min) and 7 barg (normal) pressure and 4550C
temperature. If nitrogen is found to be off-specification, it is automatically vented to
atmosphere at safe location. Additional requirement for flare purging (if any) is
provided by back-up bottle supply system.
The produced nitrogen is then routed to nitrogen Storage Receiver (324-V-001). The
receiver is sized to provide 10-minutes hold-up for normal operation design flow of 68
Nm3/h. The nitrogen distribution system takes the supply through this storage receiver
to cater to GGS plant nitrogen demand. Back-up supply of nitrogen will be provided by
nitrogen bottles. It will supplement the nitrogen receiver whenever required.
PETRO-CANADA EBLA
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Unit : GGS
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GGS Operating Manual Vol #1
Operations
Page 85 of 275
NITROGEN RECEIVER
Equipment Tag No.
Type
Process Medium
Description
Design Temperature
Design Pressure
Operating Temperature
Operating Pressure
Molecular Weight
Material of Construction
Dimensions
324-V-001
Vessel
Nitrogen
Maximum
15.0
12.0
15.0
5.5
Minimum
82.0
50.0
8.2
Unit
C
barg
C
barg
28.0
SS-316
1900 OD x 4700 Length T/T
mm
324-V-001
Vessel
Wet Air
Maximum
15.0
12.0
15.0
8.0
Unit
C
barg
C
barg
Minimum
82.0
50.0
9.5
28.82
CS
1000 OD x 3000 Length T/T
mm
The package purity will be set at 98% purity for nitrogen. If the package purity for
nitrogen has reached to 97% or below, On/Off Valve 324-XV-4616 will be closed from
local control panel and Off-spec Vent Valve 324-XV-4620 will be opened; off- spec gas
from the package will be vented until nitrogen purity has reached 98%. If it continues
at nitrogen purity of 97% or below for more than 15-minutes, then the package will
undergo shutdown.
A common alarm will be provided for ICSS indication in case of any fault in the
package. Similarly Oxygen Analyzer 324-AIT-4619 provided in the package continuously
monitors oxygen percentage and High High and High alarms will be generated in ICSS
system when oxygen content goes high. It is possible to stop nitrogen package from
ICSS and shutdown of the package will be initiated when nitrogen goes below 97% for
more than 15 minutes.
Emergency shutdown of the heater is initiated when the skin temperature of the
heater goes High (324-TAHH-4602).
The following signals will be available for indication to ICSS:
Common alarm
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Heater running
Operations
Page 86 of 275
Raw water used in GGS area is required for drinking water purposes and for utility
water in hose stations. The source of raw water for GGS area is Bore-well. Raw water
is pumped from the wells using the Bore-well Water Pump 326-P-001A/S of 23 m 3/h
capacity and fed to the Utility Water Tank 326-T-002. The Utility Water tank is
designed for 171 m3 capacity corresponding to 7-day hold up of utility water. The
Utility water requirement for hose stations and potable water is 20 m 3/day.
The bore-hole water pump is controlled based on the Utility Water Tank level by the
ON-OFF Level Controller 326-LIC-4760. The water is then pumped by 326-P-003A/B
which is configured in Duty/Standby mode, to the plant utility water distribution
header at a controlled pressure. The pressure of the header is controlled by the
Pressure Controller 826-PIC-4763 which acts on the Control Valve 326-PV-4763 in the
return line.
UTILITY WATER TANK
Equipment Tag No.
Type
Process Medium
Description
Design Temperature
Design Pressure
Operating Temperature
Operating Pressure
Operating Capacity
Density at WPT
Dimension
Material of Construction
326-T-002
Tank
Water
Maximum
15.0
3.5
4.0
Minimum
82.0
2.5
45.0
Unit
C
mbarg
C
1.5
mbarg
171.0
m3
997.0
kg/m3
6000 ID x 7200H
mm
Shell/Bottom: Carbon Steel; Internals: SS 316L
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Unit : GGS
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GGS Operating Manual Vol #1
Operations
Page 87 of 275
326-P-001
Submergible Centrifugal
Raw water
Rated
45
0.9
14.1
23.1
995
0.764
47.74
Casing: CS ; Impeller: CS
Unit
C
bara
bara
m/h
kg/m
Cp
kW
326-P-003A/B
Centrifugal
Utility Water
Rated
45
0.67
7.6
11.6
995
0.765
8.24
Casing: CS; Impeller: CS
Unit
C
bara
bara
m/h
kg/m
Cp
kW
The pressure of the utility water recirculated to Utility Water Tank 326-T-002 from
utility water distribution header will be controlled by Controller 326-PIC-4763 acting
on Control Valve 326-PV-4763. Utility Water Tank 326-T-002 level will be controlled by
326-LICA-4760 from DCS by means of On/Off Controller which will control START/STOP
of the Bore-hole Pump 326-P-001A/S. Utility water tank level is also provided with
High- High and Low- Low alarms which are indicated by 326-LAHH-4761 and 326-LALL4761. Refer Cause & Effect diagram 250-EPR-CNE-05001.
Note: Refer vendor operating & maintenance manual for further details
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Unit : GGS
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GGS Operating Manual Vol #1
Operations
Page 88 of 275
Potable Water is delivered by road tankers and unloaded into the Potable Water Tank
326-T-003 using a potable water tanker Unloading Pump 326-P-004. Potable water will
be stored in 326-T-003 of capacity 12 m3 considering 3-day hold-up for potable water
consumption. Potable water from the tank is then pumped by Potable Water
Distribution Pumps 326-P-005A/B in to the Plant Distribution Header after getting
treated in Potable Water Sterilisation package 326-X-005.
The sterilisation package is a Chlorination Injection Facility in which the chlorine
dosing (NaOCl) into potable water and is controlled based on Free Residual chlorine
(FRC) in the potable water return line measured by the ORP(Oxygen Reduction
Potential) Analyzer 326-AT-4605. The Potable Water Pump 326-P-005A/B, configured in
Duty/Standby mode, should be started prior to the start of sterilisation package. The
unit can be operated locally from the field LCP or from DCS, based on the
Local/Remote selection in the LCP. As the unit is started, the pre-chlorination sampling
is taken and if the chlorine level is lower than the value set by the ORP Analyzer 326AT-4605, Chlorine Dosing Pump 826-DPM-006 will start. Once chlorine level reaches the
set value, dosing pump will stop. Manual Stop is possible from field as well as from
DCS. The typical potable water and its parameters are given in the following table:
Operating Pressure
Operating Temperature
Design Pressure
Design Temperature
Conductivity
Total hardness
Chloride Ions
Fe
Turbidity
(min/norm/max)
(min/norm/max)
(min/max)
2.5/5.3/5.8
(ambient)(1)
6.5
-15/82
250
Desirable 150-500
200
0.3
5
barg
C
barg
C
S/cm
mg/l CaCo3
mg/l
mg/l
Units
In Auto mode, when either of the potable water pump 326-P-005A or B starts (i.e.
RUN feedback is received), sterilisation unit START command is issued (326-HS-4802)
to start the chlorination dosing pumps. The unit will automatically stop when both the
potable water pumps are not running. Refer Appendix-A for motor control and interlock
details. Potable Water Sterilisation system is a standalone packaged unit. All control
and safeguarding functions will be implemented in the suppliers local control panel.
Common Fault alarm, common trip etc. shall be generated by the package and
made available to DCS. Refer suppliers documents for complete details.
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 89 of 275
326-P-004
Centrifugal Pump
Potable Water
Rated
45
0.26
1.5
10
993
0.765
1.28
Casing: SS 316L; Impeller: SS 316L
Unit
C
bara
bara
m/h
kg/m
Cp
kW
4.7.5.2
326-P-005A/B
Centrifugal
Potable Water
Rated
45
0.37
5.36
6.25
993
0.765
1.73
Casing: SS316L; Impeller: SS316L
Unit
C
bara
bara
m/h
kg/m
Cp
kW
The pressure of the potable water recirculated to potable water tank from potable
water distribution header will be controlled by 326-PIC-4789 (set point ATM) and
Control Valve 326-PV-4789.
The potable water is chlorinated so as to have a Free Residual Chlorine (FRC) value of
0.2-0.5 ppm at the final outlet. The Chlorination unit will start only when Potable
Pump 326-P-005A or 326-P-005B is running.
The following signals will be taken from sterilization package to DCS system:
o
Running indication
In addition to the above, START and STOP shall be possible from DCS system.
Potable water tank is also provided with level High-High (326-LAHH-4771) and Low Low
alarms (326-LALL-4771). Refer Cause & Effect Diagram 250-EPR-CNE-05001.
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 90 of 275
Note: Refer vendor operating & maintenance manual for further details
4.7.6 Diesel System
Diesel will be used in GGS as an alternative fuel for GTGs and in the Emergency Diesel
Generator. It is also used in the vehicle filling stations. Diesel is used as an alternative
fuel for GTG in case fuel gas is not available. The diesel fuel used for the GTG should
meet the following specifications and supply conditions.
Diesel Quality
PARAMETER
Operating Pressure (Min/Norm/Max)
Operating Temperature(Min/Norm/Max)
Grade
Quality
UNIT
barg
C
Free Water
Particulates
Density at 15C
Viscosity at 15C
Lower Heating Value
Pour point
kg/m3
cP
kJ/kg
C
VALUE
4.5/5.0/5.5
Ambient
Automotive Grade
<100 ppmv
99.9% of Particles
>5 micron removed
860
35.2
42800
10
Diesel Consumption
Diesel will be used as an alternative fuel for 2x100% GTGs and as fuel in 1x100%
diesel-driven generators for emergency power generation. Consumption figures
tabulated below are based on vendor values.
Diesel will be routed to filling stations where the same will be dispensed to
individual diesel consuming vehicles through standard pump and dispenser systems.
Consumption is 3 m3/h (50 lpm).
MW
2.5
1.2
Diesel kg/h
1205 (*1)
319.4 (*2)
Clean diesel is brought into the plant by tankers and unloaded into an atmospheric
diesel storage tank (322-T-001) located in the GGS area using Diesel Tanker Offloading
Pump (322-P-002). Pump capacity is 10 m3/h and tanker unloading will be done only
during daytime (6 hours).
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Unit : GGS
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GGS Operating Manual Vol #1
Operations
Page 91 of 275
When Diesel Storage Tank 322-T-001 level is High High (322-LAHH-3402), it will initiate
emergency shutdown by stopping diesel tanker Unloading Pump 322-P-002. When
diesel Storage Tank 322-T-001 level is Low Low (322-LALL-3402), it will stop Diesel
Transfer Pump 322-P-001A.
If Diesel Transfer Pump suction pressure is Low Low (322-PALL-3422), it will initiate
shutdown by stopping Diesel Transfer Pump 322-P-001A, GTG and Emergency Diesel
Generator. For more details, refer Cause & Effect Diagram 250 - EPR-CNE-05001.
4.8
Fuel gas is supplied at two pressure levels in the GGS. The HP fuel gas at 25 barg
(HP fuel gas pressure set for Gas turbine requirement) will be used to run Gas turbine
drives. This HP fuel gas is filtered to have 99.9% removal of particles of 100-micron
size.
The LP fuel gas at 5 barg will be used for:
o
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 92 of 275
MW
kJ/kg
kJ/kWh
kg/h
9.367
41176 (35 MJ/Nm3)
11094
2460*
kg/h
3480
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 93 of 275
Typical HP fuel gas properties and composition are given in Table given below:
Parameters
Operating Pressure
Operating
Temperature
Design Pressure
Design Temperature
Molecular weight
LHV
Solid Particulates
COMPOSITION
H2S
H2O
TE GLYCOL
Nitrogen
CO2
Methane
Ethane
Propane
i-Butane
n-Butane
i-Pentane
LP Lean Gas
LP Rich Gas
Sum
Wint
Sum
Wint
barg
26
26
26
29.6
29.92
28.4
Unit
barg
C
kJ/kg
HP
26
Lean
Sum
26
Rich
Wint
26
28.69
30.25
28.82
30
30
30
30
30
30
82
82
82
8
82
82
19.27
18.94
19.45
18.89
19.1
18.92
44737 44736
48250
48360 47948 48360
99.9% of particles <100 microns removed
Mol %
0
0
0
1.42
3.26
87.47
3.97
1.92
0.38
0.69
0.3
0
0
0
1.43
3.26
87.98
3.96
1.87
0.36
0.62
0.22
0
0
0
0.77
0.36
86.51
6.5
3.09
0.56
1.04
0.35
0
0
0
0.78
0.36
87.52
6.5
2.94
0.5
0.86
0.23
0
0
0
1.43
3.24
87.8
3.92
1.86
0.36
0.63
0.25
0
0
0
0.79
0.35
87.71
6.32
2.79
0.47
0.82
0.25
a) Stripping Gas
LP Fuel gas is used as stripping gas for TEG regeneration.
Quantity required is 85 kg/h as per vendor data. It is used in the TEG Surge Drum; it
strips the water vapour from the stripping column to produce lean TEG concentration
of 99.9 % purity.
Flares: LP Fuel gas will be used to purge flare vent headers and to fuel the pilot
burners on the flares and used as fuel in the TEG Reboiler. Flare vent purging is
typically done with fuel gas introduced at the furthest point away from the flare, in
quantities to assure a velocity that will yield a visible flare from the control room.
Velocity is adjusted in the field once the flare is operational by visual inspection of the
flare at night. Based on a fuel gas velocity of 0.01 m/s the requirement of fuel gas for
flare purging is estimated as follows:
LP Fuel Gas Requirement for Purge Flare
Details
Fuel Gas to Header at 0.1 m/s for
purging at 0.5 barg, 30C (24 dia)
Fuel Gas for Pilots (3 burners & 2 kg/h for each)
Ignition Gas
Total Fuel Gas per Flare
Unit
Continuous
Intermittent
kg/h
121.0
kg/h
6.5
127.5
4.6
kg/h
PETRO-CANADA EBLA
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Unit : GGS
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GGS Operating Manual Vol #1
Operations
Page 94 of 275
b) Blanketing
LP Fuel gas will be used for blanketing (in-breathing) Produced Water Tank, TEG Drain
Vessel, Methanol and Chemical Injection Storage Tanks. In-breathing is needed because
of liquid movement (pumping out) and thermal changes (cooling). Blanketing
requirement has been calculated based on API 2000.
Typical Fuel gas composition is given in the Table given below:
Parameters
Units
Operating Pressure
Operating
Temperature
Design Pressure
Design Temperature
Molecular weight
LHV
Solid Particulates
COMPOSITION
H2S
H2O
TE GLYCOL
Nitrogen
CO2
Methane
Ethane
Propane
i-Butane
n-Butane
i-Pentane
barg
C
barg
C
kJ/kg
LP Lean Gas
LP Rich Gas
Sum
Wint
Sum
Wint
5.0
16.0
5.0
16.0
5.0
16.0
5.0
16.0
HP
Lean
Sum
5.0
16.0
Rich
Wint
5.0
16.0
9.0
9.0
9.0
9.0
9.0
9.0
82.0
82.0
82.0
82.0
82.0
82.0
19.3
18.9
19.5
18.9
19.1
18.9
44737
44736 48250 48360
47948
48360
99.9% of particles <100 microns removed
Mol %
0.00
0.0
0.0
1.4
3.3
87.57
3.97
1.92
0.38
0.69
0.30
0.00
0.0
0.0
1.4
3.3
87.98
3.96
1.87
0.36
0.62
0.22
0.00
0.0
0.0
0.8
0.4
86.51
6.50
3.09
0.56
1.04
0.35
0.00
0.0
0.0
0.8
0.46
87.52
6.50
2.94
0.50
0.86
0.23
0.00
0.0
0.0
1.4
3.3
87.47
3.97
1.92
0.38
0.69
0.30
0.00
0.0
0.0
1.4
3.3
87.98
03.96
1.87
0.36
0.62
0.22
321-V-001
Knock-out Drum Vertical
Hydrocarbon Gas & Condensate
Maximum
Minimum
82.0
29.0
35.0
30.0
28.0
26.0
22.0
250.0
Unit
C
barg
C
barg
kg/h
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 95 of 275
321-V-001
750.0
4300.0
19.17
22.52
Shell: CS; Internals: SS316L
1500 ID X 4500 TT
kg/m3
kg/h
kg/m3
mm
FUELGAS HEATER
Equipment Tag No.
Type
Process Medium
Description
Design Temperature
Design Pressure
Operating Temperature
Operating Pressure
Design Duty
Density at WPT
Material of Construction
321-H-001A/B
Electrical
Fuel gas
Maximum
15.0
95.2
9.2
Minimum
82.0
55.0
Unit
C
barg
C
barg
kW
kg/m3
Minimum
82.0
48.4
Unit
C
barg
C
barg
kW
kg/m3
85.86
85.0
69.3
SS 316L
321-H-002A/B
Electrical
Fuel gas
Maximum
15.0
35.0
28.4
85.86
55.0
68.7
SS 316L
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 96 of 275
The Pressure Controller 321-PIC-3308 (set point5 barg) will actuate Control Valve
321-PV-3308 which will control the pressure of fuel gas from KO Drum to cater LP Gas
to small users.
Two Fuel Gas Heaters 321-H-001A/B (1 working + 1 standby) are provided, each
controlled by its own thyristor control panel to heat the fuel gas such that LP fuel gas
consumers in FG distribution network should have gas at a temperature of at least 15C
at their end. When the working heater is faulty, it will switch on to standby heater by
opening 321-XV-3403 On/Off valve and switching on Standby Heater and later faulty
heater is tripped. But the closing of the On/Off Valve 321-XV-3402 on faulty heater will
be after a time delay of xx seconds. Fuel Gas Heaters (321-H-001A and 321-H-001B) are
also provided with temperature High High trips 321-TAHH-3363 and 321-TAHH-3373.
Feed to Fuel Gas KO Drum gas outlet temperature is provided with High High and Low
Low temperatures trips (321-TAHH-3314 & 321-TALL-3314). Refer Cause & Effect
Diagram 250-EPR-CNE-05001 for more details.
The let-down gas is routed to a KOD where condensate is removed. At high level in the
KOD, 321-LIC-3311 will actuate Control Valve 321-LV-3311 which allows condensate to
flow to Flare Header. Level Controller works on Gap Control philosophy which opens
the Level Control Valve at a High level (1100 mm) and closes at Low level (600 mm).
The valve continues to be in closed condition until it reaches a higher level and then
opens. Fuel Gas KO Drum level is also provided with High-High level (321-LAHH-3312)
and Low-Low level (321-LAHH-3312) alarms. Refer Cause & Effect Diagram
250-EPR-CNE-05001 for more details.
The Fuel Gas for GTG will be routed through one of the super-heaters 321-H-002A/B,
each controlled by its own thyristor control panels. The heat input to the heaters will
be controlled by Differential Temperature Controllers 321-TDIC-3323 (Super-heater-A)
and 321-TDIC-3400 (Super-heater-B) which will measure the difference between the
temperature of super-heater outlet and KO Drum outlet. Fuel gas super-heater outlet
temperature is also provided with High-High temperatures trips (321-TAHH-3324 &
321-TAHH-3401). Fuel gas super-heater temperature is also provided with High High
temperature trips (321-TAHH-3383 & 321-TAHH-3393). For more details refer Cause &
Effect Chart 250-EPR-CNE-05001.
Feed to Fuel Gas KO Drum pressure is provided with pressure High-High and Low-Low
trips which are indicated by 321-PAHH-3307 and 321-PALL-3307. Refer Cause & Effect
Diagram 250-EPR-CNE-05001 for more details.
4.9
FLARE SYSTEM
The High Pressure Flare System serves the purpose of safely gathering and disposing of
any hydrocarbon released from operational Flare Valves, Relief Devices or Blowdown
Valves from equipment. Header from GGS is routed to KOD as a single HP Flare Header.
The relief discharges from various equipment in GGS is collected through a 24 Flare
Header which flows through the Flare Knock-Out drum (331-V-001). The KO Drum is
provided with Heater (331-H-001) to keep temperatures above 0C. The liquid from KO
Drum is pumped back to the Production Separator. Because of the pressure during HP
mode of operation, Booster Pumps (331-P-001A/B) and 331-P-002A/B are used in series
to transfer liquid from Flare KO Drum to Production Separator. During LP mode of
operation, 331-P-001A/B only are used.
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The Flare KO Drum is sized for a design droplet diameter of 300-microns. It is provided
with an elbow/diverter plate-type inlet device. Pumps are actuated by Level Control in
Flare KO Drum. LP fuel gas is to be used for purging, ignition gas and for the pilots.
Connections for start-up fuel gas are also provided. Flare header load and size shall be
determined based on relief and blowdown study.
FLARE KO DRUM
Equipment Tag No.
Type
Process Medium
Description
Design Temperature
Design Pressure
Operating Temperature
Operating Pressure
Volume
Material of Construction
Dimensions
331-V-001
Vessel
Hydrocarbon gas/Condensate/Water
Maximum
Minimum
62.0
175.0
3.5
Amb
129.9
0.15
0.7
96.6
Shell: SS316L;
Internals: SS316L
3000 ID x 12600 Length T/T
Unit
o
C
barg
o
C
barg
m
mm
331-H-001
Electrical
Condensate + Water
Maximum
Minimum
62.0
175.0
3.5
4
4
0.15
0.7
35.0
SS 316L
Unit
C
barg
C
barg
kW
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331-P-001 A/B
Centrifugal Pump
Saturated Hydrocarbon
Rated
45
3.71
34.53
10
765
0.85
54.02
Casing: CS; Impeller: CS
Unit
C
barg
barg
m/h
kg/m
Cp
kW
331-P-002A/B
Rotary
Hydrocarbon Liquid
Rated
Unit
45.0
barg
82.0
C
30.0
C
34.6
barg
50.0
C
91.6
barg
0.62
10.0
m3/h
45.0
kW
Casing: Cr SS (12%); Impeller: Cr SS (12%)
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o 331-LIC-5110 output sets the output of 331-P-001A/B Duty Booster Pump Motorcontrol-block to 1 i.e. Start command for the Duty Booster Pump of 331-P-001A is
sent to PMS over the serial link.
o
In case still the level 331-LI-5100 doesnt reset below the High control set point
within xx minutes (configurable) after the Duty Booster Pump-A has started, the
Standby Booster Pump-B will automatically start and the Duty Booster Pump-A shall
be stopped, i.e. 33-LIC-5100 output sets the output of 331-P-001A/B Standby
booster pumps motor-control-block to 1 (Start command for the Standby Booster
Pump is sent to PMS). Upon receipt of Standby pump running feedback, 33-LIC-5100
output sets the output of 331-P-001A/B Duty Booster Pump-A motor-control-block
to 0 (Stop command for the Duty booster pump-A is sent to PMS).
331-P-001A/B shall continue to run till 331-LI-5100 falls below the Low control set
point. Stop command for booster pump 331-P-001A/B is sent to PMS over the serial
link. 331-P-001A/B shall stop and remain stopped till 331-LI-5100 increases above
the High control set point and the cycle will continue.
DCS Interlocks
Close 331-XV-5129 at the discharge of Flare KOD pump 331-P-002A/B when both pumps
331-P-001A and B are Stopped and open 331-XV-5129 when 331-P-001A or B starts
running.
331-P-001A/B and 331-P-002A/B start is inhibited if the Flare KO Drum temperature
331-TI-5110 is below the Low control set point.
The High and Low control set points are different from the High and LOW alarm set
points and shall be adjustable.
Flare KO Drum Pumps 331-P-002A/B
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The Produced Water Treatment is designed to remove oil from the produced water
separated in the Production Separator and Condensate systems. Produced water from
the Production separator under Level Controller 302-LIC-1114 flows to the Produced
Water Degassing Drum through the Control Valve 302-LV-1114. Similarly liquid from
Condensate Coalescer under Level Controller 302-LIC-1156 flows through 302-LV-1156
to the Produced Water Degassing Drum.
Pressure inside Produced Water Degassing Drum is maintained by the Pressure
Controller 334-PIC-5449 by opening and closing 334-PV-5449 at High and Low set point
of 334-PIC-5449. Degassing Drum is fitted with two Pressure Safety Valves
334-PSV-0165A/B set at 5 barg. Degassed Produced Water from 334-V-001 flows to
Produced Water Tank under the control of Level Controller 334-LIC-5441.
Produced water storage tank (334-T-001) is sized for a capacity of 740 m 3
corresponding to a working volume equivalent to 4-days of water disposal volume. The
skimmed oil from the Produced Water Tank is routed to the closed drains.
The tank is blanketed with LP fuel gas to avoid oxygen ingress and the vent line is
connected to the TEG Incinerator system. Blanketing pressure is maintained by two
self- regulating Pressure Control Valves 334-PCV-5408 and 334-PCV-5409.
A Pressure-Vacuum Valve 334-PVV-170B set at a pressure of 140 mbarg and a vacuum of
2.2 mbarg prevents the tank from the effect of pressure. An Emergency Vent
334-EV-5433 is also fitted to the top manway.
Produced water is pumped to road tankers via LP Produced Water Disposal Pumps
(334-P-001A/B). Tie-in connections will be provided downstream of Produced Water
Disposal Pumps (334-P-001A/B) as a future provision for Methanol Injection System.
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Unit : GGS
4.11
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DRAIN SYSTEM
The drainage system is designed to allow disposal of liquid inventory and surface water
run-off in a safe and environmentally acceptable manner.
4.11.1 Open Drain System
The Open drain system will collect aqueous drains that may be expected to contain
hydrocarbon liquids, greases, waxes, etc. Sources include pump drip trays, sample
points, sample coolers and equipment containing process water. It will comprise of
piped collection system. The drain liquids will be routed to a paved area drain
collection hub from where it will flow by gravity to open drain sump.
Parameter
Total Hydrocarbon Content (Inlet/Outlet)
Acidity
Temperature Increase
BOD
COD
TSS
Phenols
Sulphides
Heavy Metals (Total)
Unit
mg/l
pH
C
mg/l
mg/l
mg/l
mg/l
mg/l
mg/l
Chlorides
mg/l
Guideline Value
200/30 expected
6.0 9.0
3
25
125
35
0.5
1
5
Average 600;
Maximum 1200
Water run-off from paved areas (precipitation, vessel wash water, fire water) will be
routed to Drain Hub in each area. Liquids from Drain Hub will flow by gravity to open
drain sump. No separate accidental oily water sump is envisaged in GGS.
Open Drain Sump 332-V-001 will have 3 compartments. Water will flow into the second
compartment through an underflow. Oil skimmer in the first compartment with inbuilt
pump will route the skimmed oil to 3rd compartment. The oily water is transferred to
Produced water tanks (334-T-001) through 332-P-002A/S pump where oil is separated
by gravity from water. Vertical submersible pumps 332-P-001A/S will pump the treated
Water to Holding Pond. It is required to have oil content not more then 30 ppm (w/w)
in separated water.
The Open Drain Pump is sized for 400 m3 sump on the basis of 8 hours of two utility
water hoses operation. The Sump pump shall be designed to empty the sump in 8 hours
at the most. A storm water drainage system will be provided to collect rain water
run-off from the roads and buildings, a network of open ditches and channels will
convey this water to the holding pond. Water from this holding pond will be used as
required for irrigation purposes within the camp and administration building areas;
excess water will be discharged to the surface/disposed off as required.
Hazop Action No. 384
The capacity of the Holding Pond is designed for the worst rainfall conditions. Partially
open manual valves in the Water Disposal Pumps will cause overflow of water from the
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Holding pond to be spilled over to the surrounding environment. Normally the Holding
pond receives non-contaminated water from the Open Drain Sump and Storm water. If
entrained oil is present in the Holding Pond, it can be recycled to the open drain sump
for reprocessing. Under these conditions of entrained oil in the Holding pond, over
flow of water from holding pond will create environmental problems. A portable
skimmer can be employed to remove traces of oil in the Holding Pond so that at any
time the water is free of oil in the Holding pond. A portable skimmer available at GTP
also could be used. If heavy rainfall occurs for a considerable period, a separate
Operator can be stationed round the clock to monitor the Levels and quality of water
for the Open Drain System.
Hazop Action No. 391
The contaminated water from the Open Drain Sump is pumped by Open Drain
Contaminated Sump Pump (332-P-002A/S) to Produced Water Storage Tanks through a
check valve and 3 dip pipeline with a siphon breaker. If Check valve is passing and
water level is below dip leg level, then there will be gas migration from Produced
Water tank to Contaminated Open Drain Sump. Hence the Operating personnel should
ensure water level above dipleg and then only open the valve to the Contaminated
Sump Drain Pump which will prevent gas migration and thereby avoiding potential Fire
and Explosion hazard.
4.11.2 Closed Drain system
The Closed drain system receives drains from equipment/vessels and low point drains
from pipelines. Prior to shutdown of a process unit, the liquid level of vessels is
reduced as low as possible through the normal process outlet in order to minimise the
final liquid inventory in the vessels. Once the process unit has been shut down and
equipment have been isolated, and depressurized, the liquid inventory remaining in
the unit can be drained to the closed drain system. Process vessels operating at very
high temperature should be allowed to cool down before discharging the residual liquid
to the closed drains.
The GGS plant Closed Drain Drum (333-V-001) is sized to have a working volume equal
to the volume contained by the Production Separator up to the top of the weir plate.
The liquid from closed drain drum will be removed by submerged Closed Drain Drum
Pumps (333-P-001A/B), (2x 100%) and routed to the Flare KO Drum. A provision is given
to empty the closed drain drum through truck. The pump is designed to empty the
closed drain drum hold-up in 8 hours. The pumps are controlled by an On/Off
Controller 333-LICA-5304 which starts and stops the pumps at the High and Low set
points of the controller. Low Low temperature of 333-TALL-5320 will trip the pumps
333-P-001A/B.
The Closed Drain Drum has an electric heating coil (333-H-001) which is provided to
heat any collected liquids to maintain the liquid temperature above 4C and prevent
ice formation. The heater is switched ON and OFF at the high and low set point of
Temperature Controller 333-TICA-5306. The heater will trip on High High element
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The Power Generator for GTP runs only on Fuel gas system. The schematic sketch of
the Gas Turbine is given below:
Fig. 7 Schematic sketch of a Gas Turbine
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heater control to ensure there is sufficient oil at the required temperature for turbine
operation.
Gas Fuel
Gas fuel is supplied to the engine burners via an off-skid block and vent system, an onskid double block and vent system, and metering valves. The control system positions
and monitors the block and vent valves dependant upon the operating requirements.
During a start the integrity of the on-skid block and vent valves is proved by pressure
rise and fall tests. In cold climates the control system can be configured to flow gas to
vent (for a short period) to ensure it is above a minimum temperature that is safe to
run the engine. The fuel metering valves are positioned by an independent integrated
gas fuel valve controller depending on current fuel demand from the turbine governor,
and local gas fuel pressure and temperature. There is also provision for the operator to
initiate a Controlled change from gas fuel running to liquid fuel running.
Liquid Fuel and Purge
Control is provided for an off-skid fuel forwarding pump (customer supply), an off-skid
block valve, an on-skid boost pump, metering valves, and block valves. Prior to the
block valves there are prime valves which are operated to ensure that the liquid fuel
system is full. A prime is initiated during a liquid fuel start, prior to a change to liquid
fuel and periodically while running on gas fuel. During the liquid fuel prime a small
amount of liquid fuel is pumped into the turbine drains tank. The controller sequences
the pumps and valves and positions the metering valve to obtain light-up, stable
running, fuel changeover and turbine shutdown.
The liquid burner system is purged using process air or air from the turbine compressor.
The valves that control the purge and air selection are operated automatically by the
control system on a shutdown or after a changeover from liquid fuel in order to
minimise carbon build up on the burners.
There is also provision for the operator to initiate a controlled change from running
liquid fuel to running gas fuel. The liquid fuel system is often used as a standby fuel in
case of a problem with gas fuel supply. As such the controller is capable of
automatically changing to liquid fuel if such condition arises. An automatic change
from gas fuel to liquid fuel will be initiated should a rapid reduction in gas pressure be
detected or the differential pressure across the gas throttle fall below 1.9 bar.
Elements
Governor
The turbine governor controls gas turbine speed by varying fuel demand to the fuel
system metering valves. The fuel demand is calculated using turbine shaft speed, gas
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path temperatures, gas path pressures, and turbine load. The turbine gas path
temperatures (Gas exhaust temperatures are used to optimise the turbine performance
and keep it within operating limits. Deviation from the limits is protected by initiating
a turbine shutdown. The turbine gas path pressures (gas generator inlet, compressor
delivery, and interduct) are measured to ensure that the gas turbine is running within
its operating envelope. Any deviation from the operating envelope will initiate turbine
shutdowns.
The turbine shaft speeds (gas generator and power turbine) are measured to ensure
that the turbine is not approaching or in an over speed condition. The turbine bearing
temperatures are measured to protect the bearings from over-temperature. The radial
movement of the turbine shafts is monitored to detect high levels of vibration.
Ventilation System
The turbine enclosure is fitted with a ventilation system to provide cooling for the gas
turbine and enclosure mounted equipment and a gas free environment in which to
operate the turbine.
The control system will operate the ventilation fan to maintain a purged enclosure
while the unit is operating and afterwards during the cooling period. While the fan is
running the enclosure air flow is monitored to ensure it is sufficient to supply adequate
cooling and maintain a fully purged enclosure.
Elements
Dual vent fans operating as duty/standby where the operator has the ability to
select the duty fan.
An inlet filter scavenge fan which runs when the enclosure ventilation system is
running.
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The level of gas present at the turbine enclosure ventilation exit is measured and if
the level detected is too high then a turbine shutdown is initiated and the gas fuel
system is isolated and vented. The enclosure ventilation fan will continue to run to
extract the gas. The level of gas present at the turbine enclosure
ventilation/combustion inlet is measured and if the level detected is too high then a
turbine shutdown is initiated and the gas fuel system is isolated and vented. The
enclosure ventilation fan will be isolated to prevent gas being drawn into the
enclosure.
Turbine Compressor Washing System
The turbine has connections for a compressor washing system. Washing can be initiated
with the turbine stopped (cold wash) or with the turbine running (hot wash). The
operator connects the wash module to the turbine and initiates a wash sequence which
comprises of a wash cycle followed by a rinse cycle.
Seal Air System
The turbine uses process air and P2 air from the compressor (when the shaft is rotating
at speed where sufficient pressure is being developed) to provide a seal which
prevents oil carry over from the bearings. The controller operates a valve to supply the
process air to the seals during turbine run up and shutdown. The pressure of the
sealing air is measured to ensure it is within turbine operational limits.
Fluid Drains System
The off package drains tanks (Supplied by Siemens for hydrocarbons, water wash, oil,
etc) are monitored by high level warning and shutdown transmitters respectively.
Control is provided for an automatic drain valve to ensure that any remaining fluids are
drained from the turbine into the drains system prior to running.
Starter System
Control is provided for a hydraulic starter system. The control system drives the starter
system to spin the gas turbine during start up and shutdown, and accelerate it during
the start sequence. The windings of the electric motor are monitored to prevent
damage by overheating.
Air Flow Control
The air flow through the engine is controlled by modulating the variable guide vanes
and blow off valve, and operating the interstage bleed valves. The interstage bleed
valves are used to prevent a compressor surge during the run up. The variable guide
vanes are used during a turbine start to control the air flow into the compressor to
prevent engine surge. They can also be used for emissions control while running. The
blow off valves are operated to prevent the engine from over speeding during a load
reduction. Control of these devices will keep the engine within its operating envelope
and prevent events such as surge and over speed.
Driven Unit Generator
The generator windings, bearings and cooling air are all monitored to protect
components against over temperature. Control of dual cooling fans and monitoring of a
filters differential pressure is provided.
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5.0
ELECTRICAL
Operations
Page 107 of 275
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5.1
00180-PCP-300-PDMan-12503-01
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Operations
Page 108 of 275
ELECTRICAL SYSTEMS
The Gas Gathering Station of EBLA Surface Facilities has in-house stand-alone Captive
Power Generation enough to meet the Facilitys power load requirement of HV and LV
loads. The HV Loads are being supplied at 11 kV and LV loads are supplied at 400 V.
Main power for each plant is supplied from two 11 kV, 12 MVA (Alternator rating at
35C) gas turbine-driven generators. However, at the Gas Gathering Station, the power
generation with Turbine on gas as fuel is limited to 8955 kW at 35C and to 8045 kW at
45C. The power generation with turbine on liquid fuel is limited to 7934 kW at 35C &
to 7216 kW at 45C.
Under normal circumstances i.e. up to an ambient temperature of 26C, one GTG is
expected to cater to all the loads in the plant. However, when the ambient
temperature in the plant increases beyond 26C, the GTG output ratings get reduced.
At that time the generation will have to be supplemented either with power from an
Emergency Diesel Generator (EDG) or another GTG to meet the maximum plant loads.
During starting of the second Field Gas Compressor also, the second GTG will be
required.
Under normal operating condition, the HV switchboard will operate as a single bus.
The VSDS loads of Field Gas Compressors (1-operating and 1-standby) at the Gas
Gathering Station are the only load on the 11 kV bus. At the Gas Gathering Station,
11 kV is stepped down to 400 V through two 2.5 MVA and two 1.6 MVA transformers.
In addition to GTGs, there is also a 1500 kVA Emergency Diesel Generator which is
brought into service on loss of power supply from the GTGs. The EDG has been rated to
provide power to shutdown and maintenance loads of the plant, as well as the Start-up
Auxiliary load of one GTG. At times when the Plant is running at maximum plant load,
the EDG has to be run in parallel with one GTG when maximum power generated by
one GTG gets reduced at higher ambient temperatures.
During power failure from GTG, the EDG will supply power to all the Well head,
Telecom and Instrument UPSs in CCR building, Substation UPS and to the HVAC of CCR
and Substation buildings.
During initial phase of plant operation i.e. when the Field Gas Compressor is not
running, it will be powered from one GTG.
The GTGs are designed to operate continuously in a satisfactory manner without any
deterioration of its life even at low loads (i.e. load down to as low as 1.0 MW on Fuel
gas).
The various voltage levels for the power distribution to motors in Well heads and GGS
is as follows:
Motors above 1500 kW
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The LV loads at GGS are distributed over three 400 V switchboards, namely, Process
MCC, Utility MCC and Emergency MCC. Both Process and Utility MCCs (400V, 3 Phase,
4 wire switchboards) are fed from their respective transformers with 100% redundancy.
The Emergency Switchboard is fed from the Utility MCC during normal operation.
Emergency Diesel Generator feeds Emergency Switchboard during power failure
from GTG.
Well head loads are fed from the Emergency MCC installed at GGS Substation building.
The voltage is stepped up to 3.3 kV through Well head Step-up Transformers (one for
each of the seven Well heads) at the GGS facility and power is transmitted through
underground cables up to each Well head location where the voltages is stepped down
to 420 V through respective Well head step-down transformers (again, one for each of
the seven Well heads). Well head loads are fed from one local Power Distribution Board
which is fed by respective Well head step-down transformer. Each PDB in addition is
connected to a portable Emergency Diesel Generator capable of feeding the Well head
load during an emergency.
In case of failure of the normal power supply from the GTG, the Auto-Start of the EDG
set will be initiated by the LV emergency switchboard so that the emergency loads are
powered for safe shutdown of the plant and also to ensure that the vital systems are
running for quick restarting of plant.
Instrument systems are operated on 230 V, 1 Phase, 50 Hz supply derived from 400 V,
3 Phase, 4 wire distribution boards of two equal-rated, physically & electrically
separate UPS systems, each with its own battery. Telecom supply is 230 V, 1 phase,
2 wire derived from 230 V, 1 phase, 2 wire distribution boards of two equal-rated,
physically & electrically separate AC 50 Hz UPS systems, each with its own battery.
Instrument and telecom loads at each Well head are fed from two 230 V, 1 phase
battery backup power packs located at each Well head.
The period of battery back-up for UPS will be 6 hours. Batteries will be charged to 90%
duty within 10 hours. Systems will be capable for repeat duty in 24 hours.
Each GTG and EDG is provided with a dedicated 110 V/24 V DC battery and batterycharger to take care of the power requirements of the control system and the
emergency lube oil pumps.
5.1.1 Electrical System Controls
The Plant operation is envisaged as Automatic with the minimum number of Process
Operators. Accordingly, the electrical system is designed for automatic operation as far
as possible. Separate server and RTU-PLC based Power Management System (PMS) is
being provided at the GGS facility of the EBLA project for system monitoring and
switching control via Integrated Protection and Control devices (IPCDs) or intelligent
devices. PMS at GTP has supervisory control over PMS at GGS, through a redundant
Fibre Optic Link. PMS is time-synchronized with the Plant Telecom System using
NTP protocol.
The PMS provided at the substation of GGS will communicate with the individual
electrical equipment associated with the substation via serial link. Communication
protocol is Modbus Serial except for Siemens-make VSDS of Field Gas Compressors
where Profibus to Modbus converter will be used. In addition, the PMS is linked to the
upstream plant ICSS via serial communication link. The ICSS is provided for Plant
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process control and monitoring. PMS will act as gateway between ICSS and Electrical
Power Equipment.
The control and monitoring function carried out by the PMS with respect to the
individual equipment is as detailed in the following sections. The PMS will also provide
Sequence of Event (SOE) reports including running time, number of starts, and,
number and type of trips. It will also carry out recording of all events, date- and timestamped for all circuits connected, with printout facilities including
running/stopped/alarm/
trip. Time-stamp for events will be given by Data Acquisition RTU and the same will be
communicated to SCADA for SOE logging/printing.
Load Sharing
Load sharing is performed from PMS and its signals are initiated from selected active
and reactive set points. Based on Load Monitoring results and unit operation
constraints, e.g., unit High and Low MW loading limits, maximum response rate,
system regulation margin and spinning reserve requirements, de-rating based on
ambient temperature, fuel as gas or liquid; the set points will be available for sharing
Active and Reactive power. The set points are defined such that proportionate sharing
of power happens. Depending on the load balance requirements, alarm will be
generated if the load is beyond the predefined limits. The PMS system provides request
for running of new Generator, if necessary.
Interconnection of PMS with switchboards, ICSS, UCP and location of HMI for GGS is in
line with PMS Block Diagram 300-EEL-SLD-029.
The details of electrical equipment connected with the PMS are as follows:
PMS-GGS (PMS for Gas Gathering Station: 323-PMS-1-1)
o
Two nos., Unit Control Panel (UCP) + Generator Control Panel (GCP)
Intelligent Generator Protection Relay, AVR, Exciter Controls etc. and a
common Synchronizing Panel.
11 kV Main Switchboard
Well head loads and UPS are monitored and controlled by ICSS via an optical fibre link
through a Well head RTU and are not under the purview of the PMS-GGS.
The MV and LV process motors Start/Stop control is carried out by the ICSS via
the PMS.
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For heaters without Start/Stop, control is carried out by the ICSS via the PMS
whereas for heaters with separate control panels, the ICSS controls the heaters
directly.
The ICSS will also receive the Run, Stop, Trip & Available status of all the MV and LV
motors and metering input of all the Switchboard incomers and MV motors from the PMS.
Emergency shutdown of the electrical equipment is initiated by the ESD system
through hard-wired signals to the individual equipment feeder.
The electrical LV Switchboard control philosophy for normal and emergency conditions
comprises the following options:
Normal Switchboard
a.
b.
Emergency Switchboard
a.
Local Control for the Incomer breakers under Test and Service Position.
b.
The Selection of local or remote control is done manually for Incomer & Bus coupler
and outgoing ACB feeder from the switchboard. It is possible to trip every circuit
breaker from local to the panel, irrespective of position of Local-Remote (L/R) switch.
Monitoring is not affected by the position of the Local/Remote control switch.
Lock-out relays can only be reset locally, and not from the remote position. The status
of the individual feeder on switchgear can be observed at local switchgear panel and
at the PMS.
5.1.2 Electrical System Start-Up
Condition-A Plant Electrical System Start-Up Sequence
During initial start-up of the plant, the following sequence of operations shall be
followed. Seven steps are described below:
Step 1: The objective is to start the EDG for plant start-up.
o
Start manually, the Emergency Diesel Generator set from the Local
Power Panel or EDG control panel of the EDG set.
(a) Black Start: The EDG set can be started if the starting batteries are in fully
charged condition. The starting batteries of the EDG set are rated for 3-starts
with an interval of 10-sec before lockout. Alternatively, the EDG can be started
using compressed air system with sufficient storage to provide air for 3-starts
with an interval of 10-sec.
(b) Energize the Emergency MCC by closing the DG Incomer Breaker on to the DeadBus. The closing of the breaker is automatic if DC-UPS power is available and is
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carried out manually from the LV switchboard if the DC-UPS supply is not
available.
Step 2:
The objective is to energize all emergency and critical process loads
connected to the GGS Substation for Plant start-up.
Following critical loads on the Emergency Switchboard are to be switched ON
manually or from MCCS.
o
Additionally any or all of the following loads can be switched ON, as required from
the switch itself.
o
Based on the process requirement, the following process loads fed from emergency
MCC can be started from ICSS through the PMS, as the case maybe.
Outgoing feeder to other critical process loads (if any) connected to the
Emergency Switchboard
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permissive interlock for closing circuit of incomer breaker after ensuring that 11 kV
switchboard is healthy and all incoming and outgoing feeder breakers are open. (In manual
mode 11 kV Incomer and Bus Tie Breakers can be closed in Test position from
switchboard). Operator to ensure that the 11 kV switchboard is a continuous bus with all
bus-coupler breakers closed before closing the incomer breaker during plant start-up
condition.
Identify and start one of the GTGs (either GTG-A, or GTG-B). The feeders of the
GTG-Auxiliaries shall be in ready to start condition, so that they can start when the
signals are received from the GTG-UCP. The list of GTG Auxiliaries is as follows:
o
Starter Motor
All these feeders are housed in the respective Gas Turbine Generator MCC Switchboard
fed from the Emergency MCC.
The first GTG is brought into circuit by dead-bus closing of its 11 kV incomer breaker.
The incomer circuit breaker Close command from CSP is routed through PMS to
ensure that 11 kV switch board is healthy and only one Neutral Earthing Resistor (NER)
is in circuit for earthing of neutral of 11 kV system.
On closing of the first GTG incomer breaker on to the HV switchboard, the 11 kV
system gets energized and the 11 kV bus Voltage, kW and current feedback along with
breaker status is available to the PMS and selectively to ICSS.
Step 4: Objective is to energize the Distribution
On receipt of the above information, the Operator from PMS initiates the closing of the
11 kV distribution transformer breakers at the HV switchboard and charges the
distribution transformers.
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Close breakers 52-U1 & 52-U2, 52-P1 & 52-P2 (323-MMS-1-1) and
energize the Utility and Process MCC Switchboard with the respective
Bus-coupler breakers kept open.
Close tie breaker -52E1 in the Utility MCC to supply LV power from the
Utility MCC Switchboard to the Emergency Switchboard.
This is followed by un-loading of the EDG and tripping the EDG incomer
Breaker-52E2 from the EDG- GCP panel.
At this stage, all the main HV & LV switchboards (Utility, Process & Emergency) are
energized and in normal operation. The HV & LV loads of Process and Utility can be
started.
Step 7:
Objective is to start the other GTG (if required) and HV loads with
pre-conditions of the minimum power requirements.
With the normal and emergency LV loads in operation, the first GTG is fully loaded.
Based on the process operating requirement, the operator has to decide on the
starting of the other GTG. The standby HV motor loads are to be started considering
the running reserve capacity of the GTGs.
Identify and start the second GTG (either GTG-A or GTG-B)). The feeders for the
GTG-Auxiliaries are kept in ready to start condition, so that they can start when the
signals are received from the GTG-UCP.
Once the voltage and frequency builds, start-up of second GTG is complete, operator
to initiate the Auto-synchronizing of the Incomer breaker from the PMS. On achieving
synchronism, the command to close the Incomer breaker-52E2 is issued by the GTG
common synchronizing panel automatically.
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Under plant normal operating condition, one or two GTGs are running
and feeding power to the 11 kV HV Switchboard. Load sharing between
GTGs is to be achieved through PMS.
All the bus-coupler breakers of the HV Switchboard are closed and the
HV Switchboard will operate as a continuous bus.
The outgoing LV Utility, Process and Emergency power and motor feeders
are in circuit based on the process operating conditions.
The 110 V DC UPS is energized and will feed the breaker control supply
of the HV, & LV Switchboard.
The 24V DC System of the each of the GTGs are energized and feeding
the critical loads of the GTGs.
GTG MCCs have two incomers, one connected to Utility MCC and the
other to Emergency MCC. When power is fed to plant from GTG, the
incomer connected to Utility MCC will be kept on and the other will
switched off.
Under plant normal operating condition, when the GTG supplying the
entire load of the plant trips on fault, the entire plant will be shut
down.
Only the AC and DC UPS supply is available catering to the plant critical
instruments, telecom and control supply for HV/LV breaker operations.
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operation
switchboard
carried
is
to
out
ensure
by
the
power
PMS
to
the
emergency
automatically
without
intervention of the operator, based on initiation from the EGCP. The PMS
will also carry out the tripping of the tie feeder from Utility MCC
manually to prevent back-feed of power from the Emergency DG to
Utility Switchboard. With this, critical emergency loads at Emergency
boards is catered by the EDG set via the power feeders that will remain
closed even on loss of Main GTG power. Motor feeders shall however be
started manually since on loss of power, these feeders would have
tripped on account of supply under-voltage.
o
Once the operator has established and cleared the fault that caused the
GTG tripping, the running GTGs is brought back into circuit. In the event
of a major fault on the tripped generator, then the operator has to
establish the process power requirement by bringing in the Standby
Generator into circuit.
On tripping of one of the operating GTGs, the PMS will sense a sustained
under- voltage/under-frequency condition, if the operating load on the
system at the instant of GTG tripping is greater than the capacity of the
one operating generator.
To prevent the remaining operating Generator from tripping on undervoltage or under-frequency condition, on loss of power from the tripped
GTG, load shedding shall be resorted to in real time through hard-wired
commands (for HV loads) or serial link (for LV loads) and shall be
performed by PMS. PMS shall be pre-programmed with load-shedding
priority tables.
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Situation 3: Tripping of a large Motor: Field Gas Compressor Motor (GGS) due to
Electrical Fault
o
Under plant normal operating condition with one or two GTGs feeding
the plant loads, when one of the large motors, say, the Field Gas
compressor motor trips, a sudden load throw-off condition is sensed by
the 11 kV System.
On loss of one of the large motors, the ICSS shall take up control of the
process by closing of the necessary loads based on the Plant Process
Operating philosophy.
If the fault is major requiring a major process shutdown, then one of the
two GTGs may be tripped, causing the plant to operate only on one GTG
feeding the plant minimum load.
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one GTG. The tripped loads can be brought back into circuit by the
operator after starting of the 2 nd GTG. In case any 11 kV or 400 V large
loads are being started by ICSS, it should check whether the load shall
overload the generator/s or not through the PMS. The PMS will keep the
ICSS updated by sending the total available power at any instant as an
analog signal through the serial link.
Situation 5: Tripping of Power Transformer feeding the Bus-section-A/B of
Utility/Process Switchboard
o
In case of failure of Auto-transfer, the affected bus section load will lose
power. In the event of power loss to the bus section feeding the
emergency switchboard and in the event of Auto transfer fail, the
emergency switchboard associated with that section will also lose power.
The EDG is started only on sustained under-voltage on Utility switchboard
which implies a loss of main GTG power.
For the generator control and protection, each of the two GTGs is provided with its
own generator control panel (GCP) which houses the Simatic-400 PLC. The GCP shall
house the generator protection, control and metering equipment and includes the
following functionalities:
o
Generator Excitation
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Metering
Interlocks with Unit Control Panel (UCP) will have its own Simatic-400
PLC (for turbine sequencing, control, governing and protection) and
ICSS, both of which are located in the Control Room
The GCP controls and monitors the generator synchronization/excitation process and
ensures the generator does not exceed its design limits under any operating condition,
for example, the GCP protects against over-current/voltage, reverse power, etc. When
limits are exceeded, the turbine will be signalled to shutdown. Some key system
readings (such as generator power and reactive power) are passed to the Turbine
Control Panel to allow the GCP to control turbine speed during synchronization.
Generator breaker position is monitored by the Turbine Control Panel which in turn
gives permissive to the GCP during the synchronization process. The Turbine Control
Panel monitors the vibration and temperature of generator bearings and the generator
winding. High readings will result in turbine shutdown.
o
GCP will also perform the following functions: Excitation control (for
Automatic voltage regulation/power factor control/reactive power
control). The system provided has the ability to automatically
synchronise the unit to the bus through operator action initiated from
the GCP panel. The control system will also provide protection against
high temperature of generator stator windings.
protection,
protection,
51-IDMT
87-differential
over-current
protection,
relay,
58-diode
59-overvoltage
supervision,
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The generator is connected to the NER through a local operated isolating device.
The generator income breaker closing logic will ensure that the generator is
permitted to close only if the incomer earth switch is open.
5.2
AC & DC UPS
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The emergency load is powered from EDG 400 V, 50 Hz, 1500 kVA, 1200 kW Emergency
Diesel Generator set. The EDG set is designed to start automatically on loss of main
power. The EDG set package is complete with Auto-mains failure control panel,
excitation system, AVR and other accessories.
The neutral of the DG set is solidly earthed.
Emergency DG Set Operation & Control
DG Control EDG Control Panel (EGCP) in substation
DG Protection EDG Control Panel (EGCP) in substation
DG Status Monitoring EGCP/PMS/ICSS
During normal operation, the Main GTGs are feeding power to the system, the incomer
breaker from 400 V Utility Switchboard to the emergency switchboard is in CLOSED
condition and the incomer breaker from EDG set is in OPEN condition. However,
during tripping of both GTGs, emergency power for plant loads including GTG
shutdown load will be fed from EDG.
The EDG set will normally be brought into service on loss of the main power supply
from the GTGs. The loss of power from the main GTGs, and the sustained simultaneous
under-voltage condition on Emergency Switchboard, will initiate an Auto-start
command for DG through EGCP.
The EDG is provided with a EGCP located in the substation which contains the
protective relays and meters. The AVR is housed in the Local Power Panel which is
housed within the EDG acoustic enclosure.
In addition to the above, the EDG set is also provided with synchronizing facility to
enable parallel operation with the main power system for regular testing of the set,
and reinstatement of normal power to the essential services system. Under plant
normal operating condition, periodic partial load test on the EDG set is carried out by
the operator to ensure the healthiness of the EDG set. The emergency switchboard is
designed to withstand the short circuit current that could occur during such operation.
The EDG control panel (EGCP) will house the protective relays, which will provide
following protection functions for EDG:
Voltage-controlled, time-dependent over-current relay (51V), over-voltage/undervoltage relay (59/27), inverse definite minimum time lag (IDMTL) over-current
relay (51), negative phase sequence relay (46), under-/over-frequency relay (81),
earth fault relay (51G), reverse power relay (32), loss of field excitation relay (40),
restricted earth fault relay (64) and rotor earth fault relay.
The EDG status monitoring is carried locally at the EGCP in substation and from remote
PMS/LV Emergency Switchboard via Serial/Hard-wired link.
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The Power Management System (PMS) also has the ability to generate a synchronizing
command to the EGCP for starting and synchronizing the EDG with the Emergency Bus.
During parallel operation, EDG will run at fixed power mode based on the load setting
programmed in EGCP which shall be as follows:
Control and Operating Philosophy for EDG (323-X-002)
a) Initial Status: Mains power (GTG) ON, Mains Incomer breaker of Emergency MCC
ON, EDG OFF, EDG in Auto Control mode.
Sequence of Operation
After build-up of EDG voltage on Emergency MCC, EGCP will provide hard-wired
signal to PMS for closure of EDG Incomer breaker.
PMS will give hard-wired Close command for closure of EDG Incomer Breaker of
Emergency MCC.
b) Initial Status: EDG ON, Mains power OFF, EDG in Auto Control mode.
Sequence of Operation
After resumption of normal power, PMS shall give back synchronization command
(hard-wired) to EGCP
EGCP will control synchronization process & mains breaker closure signal
(hard-wired) will be send to PMS
PMS in turn will give hard-wire command to close mains breaker of Emergency MCC.
After synchronization of EDG with mains, EDG will run in constant power mode as
per set point in EGCP. EDG power/frequency parameters are received by PMS which
will be given to EGCP
Hard-wired Stop signal from PMS will be given to EGCP for stopping the EDG.
EGCP will then slowly reduce load on EDG & give EDG incomer breaker a Open
command (hard-wired) to PMS
PMS will give EDG Open command to open EDG incomer breaker at Emergency
MCC
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In case GTG is overloaded & it is required to run EDG in parallel with mains, PMS
will give hard-wired command to EGCP for starting of EDG
EGCP will give hard-wired signal to PMS for closing of EDG incomer breaker
PMS will give hard-wired closure command for closure of EDG Incomer breaker
After synchronization of EDG with mains, EDG will run in constant power mode as
per set point in EGCP which are received by PMS via, Serial link
EGCP will give EDG breaker closing signal to PMS after synchronization conditions
are achieved
PMS will give hard-wired breaker closing command to EDG Incomer breaker
Manual Operation
5.3
MAIN HV SWITCHBOARD
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The large VSDS-driven motors (MV) of the plant are fed from this switchboard. The
starting of the large MV motors (Field Gas Compressor Motor rated at 7 MW for GGS)
connected to this board is assisted with Variable Speed Drive Systems. The LV loads of
the plant are fed through 11/0.42 kV power transformer and LV switchboards.
The GTG incomer breakers and all outgoing breakers (except bus coupler breakers) of
the HV switchboard are all of identical rating (1250 A) and accordingly there is
flexibility of using a spare breaker in case of development of electrical or mechanical
fault by any of the operation by operating breakers.
Interlocks
Every feeder in the HV switchboard is provided with earth switch at the cable side
of the module. The operation of the earth switch is manual, but interlocked
mechanically with the feeder breaker such that the earth switch can be closed only
if the associated breaker is open.
Each of the bus section of the HV switchboard is also provided with an earth switch
which is interlocked electrically & mechanically with the bus coupler breaker so
that the earth switch can be closed only if the associated bus coupler breaker and
other breakers in the bus section that can act as a power source to the bus are
open.
5.4
POWER TRANSFORMER
:
:
:
:
:
:
:
:
332-TML-1-1A/1B
2500 kVA
11 kV/0.420 kV
Dyn11, ONAN, 3 phase, 50 Hz
7.45% with no negative tolerance
9.2 (approximate)
5% in steps of 2.5%
5 X Rated Current
Tag No
Rating
Voltage Ratio
Type
Impedance
Transformer X/R ratio
No Load Tap Changers
In-rush Current
:
:
:
:
:
:
:
:
323-TML-1-3A/3B
1600 kVA
11 kV/0.420 kV
Dyn11, ONAN, 3 Phase, 50Hz
6.33%
6.17 (Approximate)
5% in steps of 2.5%
5 X Rated Current
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100% redundancy has been considered for arriving at the rating of the Power
Transformers. The transformers are operating continuously and each is loaded 50%
during normal operation.
The Well head loads are catered by the following step-up transformers which are
located in GGS.
Tag No.
Rating
Voltage Ratio
Type
Impedance
Off Circuit Tap Changers
:
:
:
:
:
The loads at Well head are catered through PDB by the following step-down
transformers located at the Well heads.
Tag No.
Rating
Voltage Ratio
Type
Impedance
Off Circuit Tap Changers
:
:
:
:
:
5.5
LV POWER DISTRIBUTION
LV Switchboard Design
The Ebla LV three phase distribution system voltage has been selected as 400 V. The LV
loads to be fed from each substation has been classified as Utility Loads, Process Loads
and Emergency Loads and accordingly each of the Plants has been provided with a
Utility Switchboard, Process Switchboard and an Emergency Switchboard.
The incomer details and the rating of these switchboards at GGS are as follows:
o
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and a bus coupler and various outgoing motor feeders, heater feeders
and bulk power feeders. The rating of the switchboard is 2500 A, 400 V,
3 Phase + Neutral, 4 Wire, 50 Hz, 50 kA for 1 sec.
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Slow bus transfer scheme/Auto change over scheme along with momentary
paralleling scheme between incomers and bus coupler breaker of utility & process
MCC has been provided for transfer of power from one incomer to other during
failure of power to any one of the supplies.
Distribution Boards for Lighting, HVAC, Heat Tracing & Cathodic Protection
Separate conventional type distribution boards will cater to the power requirement for
lighting and small power system, HVAC system, Heat Tracing System and Cathodic
Protection System. The above distribution boards shall be controlled from the
switchboard only.
400 V/230 V AC UPS System
Two numbers of 50 Hz, equally rated, physically & electrically separate UPS systems
each with its own battery is provided in the substation to cater to each of the
following loads (which includes DCS and PMS power supplies):
(a) Individual Instrument load supplies 400V, 3 Phase UPS
(b) Telecommunication load supplies 230V, 1 Phase UPS
The UPS units will operate independently for supplying power to the load. The neutral
of each of the UPS system is solidly earthed. The rating of the Instrument Supplies AC
UPS is 60 kVA (GGS) each with UPS battery backup duration of 6 hours. The rating of
the Telecom AC UPS is 4 kVA with UPS battery backup duration of 8 hours.
Incoming supply to the UPS is provided from the Emergency MCC and the bypass supply
provided from normal switchboard. Static Switches in the UPS ensure uninterrupted
and synchronized switchover from UPS supply to bypass in the event of mains failure or
inverter/rectifier failure of UPS.
The 230 V AC UPS supply for telecom loads is distributed to the loads through
conventional 230 V, 50 Hz, 1 phase distribution boards with MCCB incomer feeders and
MCB outgoing feeders.
The 230 V AC UPS supply for Instrumentation loads is derived from 400 V, 50 Hz,
3 phase distribution boards with MCCB as incomer feeders and MCCB outgoing feeders.
The 400 V and 230 V AC UPS distribution boards are located at the substation. Provision
of receiving redundant UPS supply is made in all critical loads.
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6.0
INSTRUMENTATION
Operations
Page 129 of 275
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DCS
ESD
F&G
RTU (Remote Terminal Unit), Remote I/O and SCADA for Well heads
ESD Matrix
Historian
Communication between Well heads and GGS, and communication between GGS and
GTP are through the single mode fibre optic cables. To increase the reliability of
communication, redundant fibre optic cables are used.
6.2
The HIS in the Gas Gathering Control room (GGCR) at GGS provides operator access for
all parts GGS. DCS, ESD, and F & G system for the GGS located in Instrument
Equipment Room (IER) connected by the Vnet/IP and Ethernet LAN. Engineering
workstations for the DCS and SCS is provided for development and configuration.
The GGS control building is divided in to three areas depending on the location of ICSS
equipment.
1. Gas Gathering Control Room (GGCR)
2. Engineering & Maintenance Room
3. Instrument Equipment Room (IER)
Gas Gathering control room is the principle location for the plant personnel to perform
Plant operations. For GGS, Gas Gathering control room (GGCR) is normally for process
information presentation, process operation, Control and monitoring and Maintenance
by operation personnel responsible for plant operation. The control Room house the
operator consoles with operator stations and emergency control facilities. Human
interface stations, ESD console, FGS Panel, and are mounted in GGCR.
Engineering & Maintenance Room houses the following stations and printers:
o
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SIOS station
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Laser printer.
Instrument Equipment Room (IER) houses the DCS, ESD and FGS system and marshalling
cabinets. IER also contains the ICSS sub systems necessary to interface with the
package controls and local field devices.
The Human Interface Station (HIS) is mainly used for operation and monitoring. It
displays process variables, control parameters and alarms necessary for the operator
to have quick knowledge of the operation status of the process. It also incorporates
open interfaces so that supervisory computers and workstations can access trend data,
messages and other process data.
The Engineering station has all the feature of an HIS and also can provide engineering
functions such as system generation, Maintenance and test solutions.
Plant resource Manager (PRM) is provided to enhance the efficiency of the
management and maintenance of field devices that are registered and assigned to
plant hierarchy. Also, it automatically creates documents on devices so that they can
be managed electronically.
The SIOS sits on the Vnet/IP Network. In operation integration, a SIOS (System
Integration OPC Station) is used to connect FCN controllers to a CS3000.
DCS has redundancies in the following levels:
o
Processor
Power supply
Ultra high resolution 21 duel LCD monitors are used as Operator Work Stations. GGS
has two dual screen operator workstations. One single screen ultra high resolution
21 LCD monitor is used as engineering workstation in GGS.
One fascia of Fire & Gas Matrix and one fascia for ESD Matrix are present in the GGS
control room.
One number of Alarm and Event Printer, one number A3-size colour printer for
Engineering Work Station, One number of A3 size colour printer as Historian printer and
one A3 size colour printer for general report printing are also provided.
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Package units are connected to the DCS through Modbus serial link communication bus.
This link is redundant for some of the important packages like power generation
package and field gas compression package.
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DCS I/O and control function is developed around Foundation Fieldbus (FF) technology.
Foundation Fieldbus transmitters were connected to the DCS through FF barriers which
are located in field. Power supply to FF transmitters is redundant. Conventional 4 to 20
mA analog inputs and outputs are hard-wired to the DCS via conventional I/O cards.
Similarly digital I/Os are directly hard-wired to the DCS. DCS has separate cabinets for
segregation and termination of Fieldbus and conventional instruments.
Motor Control Centre (MCC) is connected to DCS via two-way redundant Modbus serial
link cable. This cable carries control commands from DCS to the MCC switchgear panels
and status of electrical equipment and electrical data to MCC. Hard-wired are also
used between these two panels. From main trunk line maximum 10 spurs can be
connected.
Separate marshalling cabinets are provided for FF and conventional I/Os of DCS.
The data from GGS is communicated to GTP through redundant fibre optic cables.
ICSS system will be interfaced to GPS clock for the synchronization.
For communication with package units, the following packages are provided with
redundant Modbus serial link communication cables:
o
HVAC systems
At well-sites, a RTU with Hot standby CPU and simplex IOs is included in the Well head
control panel (WHCP) which will provide monitoring and control of WHCP functions and
choke. Well RTU is lined via fibre optic cable to a SCADA unit in GGS.
DCS interfaces with electrical switchgear and PMS via remote PLCs. PLCs will send
information such as breaker status, load shed alarms and load information to DCS via
serial link.
Package units are connected to the DCS through Modbus serial link communication bus.
This link is redundant for some of the important packages like power generation
package and Stabiliser compressor package.
DCS I/O and control function is developed around Foundation Fieldbus technology.
Foundation Fieldbus transmitters are connected to the DCS through FF barriers which
are located in field. Power supply to FF transmitters is redundant power supply.
Conventional 4 to 20 mA analog inputs and outputs are hard-wired to the DCS via
conventional I/O cards. Similarly digital I/Os are directly hard-wired to the DCS. DCS
has separate cabinets for segregation and termination of Fieldbus and conventional
instruments.
Separate marshalling cabinets are provided for FF and conventional I/Os of DCS.
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Stabiliser Compressors
Expander
De Ethanizer compressors
HVAC systems
MIS interface with fire wall protection is provided to enable remote monitoring, long
term trending and report generation functionality.
High reliability fault tolerant Ethernet communication network (ICSS LAN) is provided
on the facility to enable the integration of various sub systems.
For Start up of DCS refer the following Document:
Vendor
Project Doc. No.
Vendor Doc. No.
cument Title
6.3
It is part of ICSS system. A single common ESD system in GGS covers all the units of
GGS. ESD system is designed with the criteria of personnel safety, minimum pollutant
release to the environment, minimizing spurious plant shutdowns and protection of
plant equipment. ESD system has been designed incorporating the SIL (Safety Integrity
Level) analysis. SIL analysis includes personnel safety integrity analysis, AIS (Asset
Integrity Level) analysis such as loss due to damage and loss of production analysis,
and, EIL (Environmental Integrity Level) analysis such as release of pollutants in the
environment. The ESD system objectives are: Controlled shutdown of machinery and
other equipment; separation of pipe work and equipment by means of isolating valves;
and, blowdown of gaseous hydrocarbons to the flare system as required.
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ESD Level 2 Total Process shutdown with depressurization enabled, but operator
has to initiate depressurization.
ESD system is essential to the overall safety of the facility and so can act independent
of other systems. ESD system will sense any abnormal operation or equipment
condition and react to this condition by safely shutting down and or isolating the
facility or sections of the facility to reduce the effects of abnormal condition. On
severe condition, the system will depressurize the entire facility process systems or
sections of these systems either automatically or manually.
ESD system cabinet is located in the equipment rooms in the GGS control building. To
have the highest reliability, the ESD system is designed with redundancies at Processor
level, I/O level and power supply level. Redundant communication cables are provided
to communicate with DCS. Communication to DCS is through the high speed Ethernet
cables.
Process over-ride switches and Maintenance over-ride switches are provided in DCS as
soft switches. All analog transmitters connected to the ESD system are conventional
type (not FF type) and are directly hard-wired to the system. Since ESD system needs
the highest reliability, direct hard-wire connected 2-wire transmitters are used.
Similarly all the digital inputs and digital outputs connected to the system are hardwired. ESD system receives signals from Package unit UCPs, directly from package units
and main process units.
Output from ESD system to the F&G system and inputs from F&G systems to EDS system
are hard-wired between the panels.
An ESD matrix panel is located in between the operator work stations. This panel
contains the indications about the ESD initiators, switches for ESD reset, and unit-wise
ESD initiating switch.
ESD Operated On/Off Shutdown and Blow down Valves
These are solenoid operated On/Off valves that are controlled by the ESD and shall be
operated in accordance with the ESD Cause & Effect logic. ESD outputs are normally
energized.
The ESD repeats the valve demand signal to the DCS to enable the valve traveling &
discrepancy alarming functions to operate in the DCS & to synchronize logic.
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The Function of this loop is to control the ON/OFF valve from DCS through ESD. The
Serial DO signal of the ON/OFF valve is connected to ESD through soft signal.
Example: Consider the Production Separator (302-V-001) Blow down valve 302-XV-1104
mounted on the Separator to Flare header line (Line no. 10-302-PG-1007-36A-N).
The Serial output signals (SDO) 302-XHSL-1104 & 302-XHSH-1104 are configured in the
DCS as Manual switches to initiate BDV Close & Open Commands respectively.
The Operator manipulates the ON/OFF valve status change command from the SIO
block faceplate displayed on DCS HMI using a computer point device such as mouse
The Operator or the automatic control logic written in the ESD can change the ON/OFF
valve status. This configuration of the Shut down valve control means that manual
control from the DCS cannot override ESD demands from the ESD system.
The Full automatic plant depressurizing only occurs as a result of ESD1. ESD Level 2
enables the blowdown valves which provide the operator with an option for Blowdown.
The List of Blowdown Valves:
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Item
Description
302XV-1104
SEP TO FLR BDV
302XV-1150
CNDST CLSR BDV
304XV-1264
FLGS CMP-A BDV
304XV-1364
FLGS CMP-B BDV
305XV-3000
GS DEHYD COL BDV
321XV-3300
FUEL GAS KOD BDV
DCS Operated On/Off Valves
Operations
Page 138 of 275
P & ID
302-EPR-PID-03101-001
302-EPR-PID-03104-001
304-EPR-PID-03112-001
304-EPR-PID-03115-001
305-EPR-PID-03121-001
321-EPR-PID-03211-002
These are solenoid operated on/off valves controlled by the DCS and have no control
from ESD. These shall be operated in accordance with the DCS logic when in AUTO and
as per operator command when in MANUAL.
Fig. 10 DCS Initiated Air Operated ON/OFF Valve with
Status Single Acting/ Spring Return
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The Function of this loop is to control the On/Off valve through the DCS. The DO signal
of the ON/OFF valve is directly wired to DCS.
The operator or the automatic control logic can change the ON/OFF valve status.
Example: Consider the Field Gas Compressor Package (304-X-001A) Blow down valve
304-XV-1264 mounted on the Discharge line to Flare header line (Line No.
3-304-PG-1019-16A-P).
The Serial output signals (SDO) 302-XHSL-1264 & 302-XHSH-1264 are configured in the
DCS as Manual switches to initiate BDV Close & Open Commands respectively.
The Operator manipulates the ON/OFF valve status change command from the SIO
block faceplate displayed on DCS HMI using a computer point device such as mouse.
The Operator or the automatic control logic written can change the ON/OFF valve
status.
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The valve opens when the ESD trip is cleared, logic is reset & the DCS interlock is not
active.
List of ESD & DCS Operated On/Off Valves
Item
304XV-1264
304XV-1364
302XV-1157
304XV-1200
304XV-1201
304XV-1300
304XV-1301
701XV-3160
304XV-1286
Description
FLGS CMP-A BDV
FLGS CMP-B BDV
PRD SEP I/L BALL
FLGS KODA I/L VLV
FLGS KODA I/L VLV
FLGS KODB I/L VLV
FLGS KODB I/L VLV
FG HTR I/L VLV
GAS HYDRN I/L VLV
P&ID
304-EPR-PID-03112-001
302-EPR-PID-03115-001
304-EPR-PID-03101-001
304-EPR-PID-03111-001
304-EPR-PID-03111-001
304-EPR-PID-03114-001
304-EPR-PID-03114-001
701-EPR-PID-03401-001
304-EPR-PID-03111-001
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The main valve is inhibited from opening until the differential pressure (DP) across the
valve is higher than the set point. Opening the bypass valve will bring down the DP
across the valve. The main valve will open automatically once the DP falls below the
set point.
Double Isolation Valves List
Main Valve
Tag No.
302-XV-1100
304-XV-1267
304-XV-1200
304-XV-1300
Bypass Valve
Tag No.
302-XV- 1157
304-XV- 1286
304-XV- 1201
304-XV- 1301
PDT
Tag No.
302-PDT-1107
304-PDT-1266
304-PDT-1206
304-PDT-1306
P&ID
302-EPR-PID-03101-001
304-EPR-PID-03111-001
304-EPR-PID-03111-001
304-EPR-PID-03114-001
Testing of On/Off Valve locally at the Valve via the ESD System
This test shall be carried out on ESD valves that have a local test station. The local test
station comprises a test/manual bleed point, key-operated local solenoid over-ride
valve, trip & reset pushbuttons. The key-operated local solenoid over-ride valve allows
operation of the ESD & DCS solenoid valves without tripping the actuated valve. This is
achieved by sealing in the air pressure within the actuator. The over-ride can only be
applied with the key and with over-ride valve held in the test position.
o
The trip over-ride valve is depressed & held in the over-ride position.
The field trip pushbutton is depressed and input signal sent to the ESD to trip the
valve.
The ESD de-energizes its output and switches the respective solenoid to vent.
The ICSS system shall annunciate valve in local test on the HMI screen/alarm
banner.
The ICSS shall inhibit valve limit switch feedback discrepancy logic since the
actuated valve will not trip.
The operator conducting the test shall verify that the solenoid vents the air
pressure.
The field reset pushbutton is depressed and input signal sent to the ESD to reset
the valve.
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The ESD re-energizes its output and switches the respective solenoid to supply
air.
The trip over-ride valve is released and key removed (if not already done).
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Operations
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Fire & Gas system is part of the ICSS. The plant F&G detectors are directly hard-wired
to the F&G cabinet located inside the equipment room of the control building. Building
F&G detectors are connected to the Building Fire Alarm panel (BFA). These BFA panels
communicate with the main F&G panel via Modbus serial link. Inputs from package
units are also hard-wired to the F&G panel. Outputs from F&G system such as
Confirmed Fire and Confirmed Gas Leak are hard-wired to ESD system. F&G output to
ESD system will initiate ESD-1 or ESD-2 of a unit depending on criticality. For details
refer the F&G Cause & Effect diagrams of GGS & Well heads/GTP.
Operator interface to the F&G system is through the operator console in DCS. It will
display the status and any alarm signal from the F&G devices.
A Fire & Gas Matrix panel located in the GTP control room acts as an
alternate/emergency operator interface for the F&G element. The Matrix panel
provides indication of the following for each fire zone:
o
F&G matrix panel also has facilities to start fire water pump {GTP} and to select
duty/standby pump. Pushbuttons are available to manually initiate fire alarm,
pushbuttons to acknowledge, silence F&G alarms, lamp test and F&G system reset.
Input inhibit on F&G system can be done from F&G matrix panel at control room by the
control room operator using permissive zone key switch.
Fire & Gas system is separate for GGS and GTP. Data transfer between GTP and GGS
F&G systems is through fibre optic cable.
The following types of Detectors are used:
o
Flame detectors
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o
Smoke detectors
Heat detectors
HSSD
Operations
Page 146 of 275
Alert Instruments
o
Beacons/Lamps
Sounders
7.2
FIRE DETECTORS
Flame Detectors (DFR) are Infra Red radiation type or UV type. In some places
fusible plugs are also used as flame detectors
Heat detectors (ROR) are used inside buildings in non-hazardous area only and
they are rate of rise semiconductor type
Toxic Gas Detectors (DGT) are semiconductor type and are installed only
in GTP
Smoke detectors are optical type and used in non-hazardous area only
7.3
o
ALERTING EQUIPMENT
Beacons (DAL) are the lamps for alerting the personnel in case of fire or gas leak.
Red lamp is to indicate Fire. Yellow lamp is to indicate Gas leak
Manual fire Alarm call points (DMC) to initiate Fire Alert Sounders (DAS) are dual
tone type. It sounds in different tones, during fire and gas leak. These dual tone
sounders are mainly used in plant area only. Fire alarm bells are used for the
buildings
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1.
2.
Int 660 1.8 sec on 1.8 sec off for Fire and Gas
3.
Operations
Page 147 of 275
On actuation of the Manual Call Point, the following actions are envisaged:
o
A Zone alarm & a common Confirmed Fire alarm are indicated at the matrix
panel and ICSS
Also a common alarm is generated in ICSS and displayed in graphic display; the
event is recorded
If the detector is at fault, the event is printed and displayed in the graphic display.
Also a detector fault common alarm is sounded in ICSS.
In the case of IR3 type flame detection, 2oo3 Voting is carried out.
A single IR3 Flame detector signal initiates the following actions:
o
Also a common alarm is generated in ICSS and displayed in graphic display; the
event is recorded
If the detector is at fault, the event is printed and displayed in the graphic display.
Also a detector fault common alarm is sounded in ICSS.
The single flammable gas detector (LOS) signal initiates the following actions:
o
A common alarm is generated in ICSS and displayed in graphic display; the event
is recorded
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If the detector is at fault, the event is printed and displayed in the graphic
display; also, a detector fault common alarm is sounded in ICSS
The single Hydrogen Gas detector/Point type flammable gas detection signal initiates
the following actions:
o
A Flammable Gas Low alarm is indicated at the matrix panel and ICSS in the case
of 10% LEL
A Confirmed Flammable Gas High alarm is indicated at the matrix panel and ICSS
in the case of 20% LEL
Also a common alarm is generated in ICSS and displayed in graphic display; the
event is recorded
If the detector is at fault the event is printed and displayed in the graphic display. Also
a detector fault common alarm is sounded in ICSS.
Refer Fire & Gas System Cause & Effect Diagram (GGS) (300-EHS-CNE-002).
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FIRE ZONES
GGS is divided in to 14 fire zones. Well heads are divided in to 5 fire zones and GTP is divided in to 15 fire zones.
Fire Zones in GGS
Fire
Zone
Description
300-01 Common
Gate House/
300-02
Accommodation
Diesel Storage/
300-03
Methanol Storage
300-04 Methanol Injection
300-05 Ware House/Workshop
300-06 Main CCR
300-07 Substations
300-08 Power Generators
Potable/Utility Water/
300-09
Plant Instrument Air/N2
Oily Water/
300-10
Open Drain System
300-11 Gas Inlet Facilities
Separator/Fuel Gas
300-12
System/Cooler
Compressor Area/
300-13
Dehydration Area
300-14 Flare Area
Total
Flame
Detection
IR 3
HC Gas
HC Gas
HC Gas Point
Open
Hydrogen
Heat
Smoke
Point
Detectors,
Path
Detector Detector Detector
Detectors Duct-Mounted
Detectors
Manual
Alarm
Call
Point
HSSD
9
3
35
14
4
2
2
2
2
2
2
4
10
9
7
8
1
3
3
5
1
3
1
1
1
1
22
14
3
39
0
19
4
40
1
57
17
59
2
3
2
1
4
1
Local
Local
Audible Pneumatic Visual
Alarm
Sounder Alarm
Sounder
Beacon
1
1
1
2
1
12
4
1
20
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In well heads, the fire and gas detectors are connected to the local RTUs which
communicate the status of detectors to GGS via fibre optic cable. Confirmed Fire is
assumed as a result of any of the following in any single fire zone:
o
Confirmed Gas Leak is assumed when any two gas detectors from a single fire zone
gets actuated. When any two gas detectors get actuated at 10% LEL (low level alarm),
then it is called confirmed low gas leak. When any two gas detectors get actuated at
20% LEL (high level alarm), then it is called confirmed high gas leak.
On confirmed detection of fire or gas, the F&G system will initiate executive action
such as release of extinguishant , fire damper control, electrical isolation, fire water
control or shutdown. Executive action shall be initiated manually also.
When electrical isolation is performed as part of executive action, power to the
following equipment is not disturbed:
o
On failure of power, UPS power will be supplied to these equipment. Well head and
GGS Fire & Gas System is connected to the ICSS in GGS. Well-sites have RTU based
system that will carry out all necessary functions and interface with the ICSS via SCADA
unit located in the GGCR to allow monitoring and safety executive actions. The
following page shows a tabulation of the fire zones in GGS.
7.5
The HSSD system is an addressable system in which each fire zone, fire detector and
smoke detector can be addressed independently. HSSD is the High Sensitivity Smoke
Detection System located inside buildings of non-process area only. This is of aspirator
type, so it has a pump for suction of smoke along with air from different corners of the
building.
The system aspirator pipeline is designed in such a way that the air through the
farthest point will not be less than 70% of that of the nearest point and the time taken
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by the air to travel to the detector unit from the farthest sampling point will be less
than 120 sec.
The HSSD system has a battery backup. The system is capable of detecting the
incipient fire by detecting the air-borne particles generated during pre-combustion
stage. It consists of an aspirating pump with balanced air sampling pipe network to
transport air to the detection unit, a particle knockout and particle counting unit. The
system has a laser-based smoke detection unit. The system communicates with the
ICSS system via dual redundant data links.
The HSSD system is programmable for:
o
Smoke alarms
Alarm delays
Fault levels for airflow, detector monitoring and power failure etc.
Air flow supervision with High and Low flow fault setting
The aspirator pump, detector unit etc are housed inside the wall-mounted panel of the
HSSD system. The system has built-in facility to store event logging, smoke alarms and
system alarms. The HSSD panel has the following features:
o
Reset capability
Over-rides of outputs
Substation building
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Accommodation and Gatehouse have separate HSSD systems. Control room and
substation have individual HSSD systems. The HSSD system panels have indication to
show the status of detectors. They will transmit information to the F&G element of the
ICSS via dual redundant data links.
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8.0
TELECOMMUNICATION
Operations
Page 153 of 275
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TELECOM SUBSYSTEMS
Fibre Optic Transmission System (SDH) to provide voice, video, data and
telemetry signalling transmission among various sites
Environment
Monitoring
System
for
monitoring
critical
weather
parameters
o
Power Supply System for reliable power supply to all the telecom
subsystems
42-core, single mode (SM) redundant Fibre Optic Cable is installed between GTP and
GGS. 24-core SM redundant FOC are installed on separate routes between GGS and
well heads. At both ends, the FOCs are terminated on suitable Optical Distribution
Frames (ODF)/Fibre Optic Patch Panel (FOPP). In ODF, fibre terminations are sealed to
prevent entry of dust or other contaminants into the fibre end.
Reliable, fault-tolerant fibre optic transmission network telecommunication services
between GTP & GGS are provided. The system is designed to carry a variety of
telecommunications protocols such as TCP/IP and Ethernet. The system is designed to
give alarm, critical system functions and pending faults.
Following are the data communication equipment and ancillary equipment:
o
Ethernet switches
Equipment enclosures
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The SDH transmission system is based on 155 MBPS, STM-1 Multiplexer. Dual redundant
STM multiplexers (one each) are provided at GTP, GGS. The system contains two
optical transceiver cards to provide redundant transmission path in the event of a fibre
break or laser failure. Dual redundant load-sharing power supply cards provided for the
sub-rack, which contains dual redundant controller cards in order to provide true 1+1
protection. The following services are extended to GGS through SDH Network:
o
1 x 2 Mbps channel for Trunk Radio System between GGS & GTP
FO Patch Panel
FO patch panels are provided at well-sites for transmission of telemetry signals of
control & instrumentation to GGS through the FO cable (24 Fibre FOPP per well-site).
The FOPP are mounted in instrumentation panels at the well-site. At GGS, the FOPP
shall be provided in a 42-RU cabinet within the Telecom Equipment Room. Media
converters are used to convert the signals from FOPP to electrical form.
Synchronization Plan
The SDH network; Pipeline Monitoring System (PMS) & DCS are synchronised with the
GPS clock. This synchronisation is to ensure network stability and correct event-logging
of plant systems.
8.3
TELEPHONE SYSTEM
The new telephone system equipment (PABX) is located in the GTP- TER which will
provide telephone service within plant areas. Telephone network, including telephone
sets, are provided for other sites as remote/extended subscribers through FO
transmission system. Digital PABX has PCM time-division switching, central control with
dual microprocessor and stored program on flash memory, redundant CPU & full
redundancy for major parts & power supply.
A supervisory system PC for operation, maintenance & programming of PABX is also
provided. The system scan supports both Analogue Lines and Digital Lines.
8.3.1 Telephones
Normal telephones are provided in offices. Weatherproof telephones are provided in
external safe areas. In hazardous areas, explosion0-proof telephones certified for use
in Zone 1 IIB T3 area are provided.
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RADIO SYSTEM
Meteorological systems are provided at GTP and GGS for weather monitoring purpose.
The weather package shall comprise a server based data gathering system that will
collect and display instantaneous, average and trend analysis of data received from
sensors located in the plant. The weather monitoring system consists of the following:
o
One PC based work stations along with a printer and weather monitoring
system software at TER
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
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Page 157 of 275
One PC-based work station, with user level rights, at GTP CCR
One PC-based work station, with user level rights, at GGS Control Room
Office area PCs are connected through LAN. The LAN is based on Ethernet switches.
Cat5e structured cable network support distribution of LAN services to the PCs, system
computers etc. Dual RJ45 socket outlets for voice and data are provided for each
work-station. The following buildings in GGS are connected by LAN: Living Quarters,
Control Room, IER and Communications Room.
8.7
A Telecoms Supervisory System is provided with an equipment rack located in the GTP
TER, with capacity for 80 digital inputs, cabled to a desk-mounted PC. The system can
provide the status of any equipment connected to the system to an operator on the
Ebla WAN, with appropriate password protection. The system can transmit a general
major or a general minor alarm to the DCS to alert the operator and enable him to
take necessary action.
PETRO-CANADA EBLA
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00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
9.0
PRODUCT SPECIFICATION
Operations
Page 158 of 275
PETRO-CANADA EBLA
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9.1
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Page 159 of 275
Dry Gas Outlet from Gas Dehydration Unit: 1.5 lb/MMSCF (31.5 ppm)
Condensate Outlet from Condensate Coalescer: 200 ppmv
9.2
GAS
Gas
Pressure
Temperature
Molecular Weight
Mass Flow Rate
Std. Vapour Volumetric Flow Rate
Unit
bara
C
kg/kmol
kg/h
Sm3/h
Maximum
86.06
51.93
19.27
106191.00
130589.00
Minimum
68.10
7.83
18.75
46213.00
58376.00
Maximum
87.3
41.1
36.7
Minimum
85.9
7.86
7.86
Gas Composition
Major Components
H2S
Water
TEG
Nitrogen
Carbon dioxide
Methane
Ethane
Propane
i-Butane
n-Butane
i-Pentane
n-Pentane
n-Hexane
Methanol
9.3
% mol
0.00133
0.00197
0.000107
1.42
3.27
87.43
3.95
1.92
0.39
0.69
0.28
0.24
0.00
0.00
CONDENSATE
Condensate
Pressure
Temperature
Flow Rate
Unit
bara
C
m3/h
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
CONDENSATE COMPOSITION
Major Components
H2S
Water
TEG
Nitrogen
Carbon dioxide
Methane
Ethane
Propane
i-Butane
n-Butane
i-Pentane
n-Pentane
n-Hexane
Methanol
% mol
0.00
0.0862
0.00
0.19
2.2
27.43
4.07
4.62
1.70
3.91
2.92
2.99
0.00
0.94
Operations
Page 160 of 275
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 161 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
10.1
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Operations
Page 162 of 275
PRE-REQUISITE SAFETY
10.1.1 Introduction
The prerequisite activities detailed below, shall be followed for restarting the Process
units and utilities, after annual turnaround or long shut down. Also the Operator is
encouraged to read the individual manufacturers Operation Manuals. The procedure
presented here will only serve as a guideline. All standard Procedure for Plant Leak
testing and purging of Hydrocarbon section of the plant shall be followed for safe and
smooth start up of the plant. The PTW system of the Company shall be followed, as
applicable for restart up the plant.
10.1.2 Safety
All personnel should be familiar with the work permit issue system, location of safety
equipment, portable fire extinguishers, safety shower and eye wash system. They
should be familiar with proper usage of Personnel Protective Equipment (PPE).
Similarly, the operator should be thorough with PTW system. The operator should be
familiar with isolation of equipment and preparation of Blind Lists. The operator
should know to do gas test and the minimum levels of oxygen required before giving
permits for vessel/column entry. Operators should know about the various levels of
harmful gases like SO2 and H2S, and about pyrophoric iron and the disposal of the
pyrophoric iron wastes. Accumulation of pyrophoric iron wastes may catch fire when
exposed to atmosphere. Hence it becomes essential to wet the Production Separator
and all the vessels in the GGS during vessel maintenance so that fire hazards are
avoided.
Process equipment operating machinery, such as pumps and compressors, should be
isolated, depressurized and purged before work is started. Electrical connections
should be locked out at the MCC or switchgear. Electrical equipment should be tagged
for proper identification and other personnel should know that it should not be
switched ON when maintenance work is in progress for the particular electrical
equipment. The loading systems, storage tanks and the diesel tankers should be
ensured for proper grounding to avoid accumulation of static charges.
10.2
PRE-REQUISITE ACTIVITIES
Before the start-up of the plant, there are several pre-start-up checks and operations,
which must be performed in order to prevent damage to the equipment and injury to
operating personnel. The attention devoted to preliminary preparations for start-up
contributes greatly to a safe and successful startup. Various Pre-requisite activities
before inert gas purging are as follows.
10.2.1 Vessels and Pipelines
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00180-PCP-300-PDMan-12503-01
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Operations
Page 163 of 275
Ensue adequate quantities of diesel is unloaded and stored in the storage tank for
start up of Emergency Diesel Generator
Ensure supply of instrument air and the Instrument air headers are lined up
Ensure DCS system is taken on line with UPS power and then supported with Power
from EDG/GTG (once lined up with Fuel Gas from trunk Line)
Check F&G functional check at the field and Fire alarm Panel in control room
EDG
GTGs
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GGS Operating Manual Vol #1
Operations
Page 164 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
11
Operations
Page 165 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
11.1
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
SEQUENCE OF START-UP
1.
2.
3.
4.
5.
6.
7.
Nitrogen system
8.
Flare system
9.
10.
11.
12.
13.
14.
Methanol system
11.1
Operations
Ensure the diesel tank 322-T-001 is ready to receive diesel (If taken for
maintenance)
2.
3.
Ensure F&G system and all instruments such as 322-LI-3400 and High & Low level
alarm tapings 322-LAHH-3402 and 322-LALL-3402 are ready
2.
Take sample of diesel from the truck and check whether the diesel meets
specification
3.
Close 3 valve in the pipe line for diesel transfer pump suction 322-P-001
4.
5.
Park the truck carefully. Connect the truck to earthling provided at the truck
unloading point
6.
Install unloading hose to the truck discharge line and connect it properly to
unloading line of pump 322-P-002
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Unit : GGS
7.
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Slowly open truck valve and fill pump suction and casing (Notice for any leak at
the joints and close truck valve if any leak is noticed)
8.
9.
10.
Open discharge valve and note down the discharge pressure and check the flow
to tank through the minimum-flow line
11.
12.
13.
14.
15.
Disconnect the hose connection and earthling connection. Advise the truck
operator to leave the point with utmost care
2.
Close drain and vents in suction and discharge line for pumps 322-P-001A/S
3.
4.
Open valves for Diesel Filter 322-F-001A/B. (Only one filter will be on line)
5.
6.
7.
Ensure to close valves at diesel supply header for Power Generation Packages
323-X-001A/B and Emergency Power Generator package 323-X-002
8.
Ensure the spill-back line from 322-P-001 to diesel storage tank is lined up
9.
10.
Check the 322-FO-3406 in the recycle line by watching the flow and discharge
pressure of the pump
11.
12.
All level indications in Tank 322-T-001 shall be monitored at DCS. Also note down
the local level indication of tank whenever diesel is transferred to avoid
spillage/overflow
Normal Operation
13.
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00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 168 of 275
water. After the Diesel unloading into the Diesel tank 322-T-001receipt, proper
settling time to be given so that water settles and water is drained out from the
bottom drain of the tank. Again check diesel quality by taking a sample at the
outlet of Diesel Filter Coalescer. The water content shall be less than 100 ppm.
This sampling should be done during normal operation to ascertain the quality of
diesel and proper functioning of Diesel Filter Coalescer. Hence proper monitoring
of Diesel quality shall be ensured. Otherwise water in diesel more than
specification will cause loss of ignition in EDG.
14.
15.
Monitor and record diesel level in the tank and storage tank.
16.
17.
18.
Clean strainer in the suction line for pumps 322-P-002 and 322-P-001A/S
19.
Clean filters 322-F-001A/B if the pressure drop increases more than 0.5 bar
20.
21.
22.
23.
24.
Keep the diesel system on line for start-up of the power unit/emergency diesel
generator
11.2
1.
2.
3.
4.
5.
6.
PETRO-CANADA EBLA
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00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 169 of 275
possible fire hazards. Hence an operator has to manually check and ensure
proper coordination while filling day tank of EDG.
7.
Ensure that incomer breakers and outgoing feeders of the Plant Emergency MCC
are all open.
8.
Start manually the emergency diesel generator set from the local power panel or
EDG control panel of the EDG set
9.
Black Start: The EDG set can be started if the starting batteries are in fully
charged condition. The starting batteries of the EDG set are rated for 3-starts
with an interval of 10 sec before lockout. Alternatively, the EDG can be started
on compressed air with 3-starts with an interval of 10 seconds
10.
Energize the Emergency MCC by closing the DG incomer breaker on to the deadbus. The closing of the breaker is automatic if DC-UPS power is available and is
carried out manually from the LV switchboard if the DC-UPS supply is not available
11.
Based on the process requirement the following process loads can be started
from ICSS through the PMS as the case maybe:
a) Outgoing feeder to Instrument Air Compressor-A/B/C (only one allowed to
start)
b) Outgoing feeder to HP & LP Methanol Injection Pump Electric Motor
PETRO-CANADA EBLA
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Unit : GGS
c)
00180-PCP-300-PDMan-12503-01
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Operations
Page 170 of 275
Outgoing feeder to other critical process loads (if any) connected to the
Emergency Switchboard
2.
3.
Ensure 326-P-003A/B utility water pump motors are solo run and coupled
4.
5.
6.
Start 326-P-001A/S from local pushbutton and check the discharge pressure at
326-PG-4731
7.
8.
9.
10.
326-LIC-4760 gives command to 326-P-001 bore well pump to start at Low level
and stop at High level of water in the utility water tank
11.
12.
Ensure suction strainers for 326-P-003A/B utility water pumps are cleaned and
reinstated
13.
14.
Energise 326-P-003A
15.
Open the suction valve and keep the pump discharge valve closed
16.
17.
Open pump discharge valve and control the discharge flow and pressure by
controlling 326-PV-4723 in the recycle line to utility water tank
18.
Gradually open the utility header battery limit isolation valve and charge the
header
19.
PETRO-CANADA EBLA
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Unit : GGS
11.4
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Operations
Page 171 of 275
1.
Ensure Potable Water Tank 326-T-003 is cleaned and ready to receive water
2.
3.
Ensure 326-P-004 water tanker unloading pump and 326-P-005A/B potable water
pump motors are solo run and coupled
4.
Ensure lubrication for the pumps. Ensure power supply to 326-P-004A/S water
tanker unloading pump
5.
Ensure suction strainer at water tanker unloading pump is cleaned and lined up
6.
Park the water tanker at designated place, nearer to the unloading pump
7.
8.
Start 326-P-004A/S from local pushbutton and check the discharge pressure at
326-PG-4775
9.
10.
11.
12.
13.
Ensure suction strainers for 326-P-005A/B potable water distribution pumps are
cleaned and reinstated
14.
Open the suction valve and keep the pump 326-P-005A discharge valve closed
15.
16.
Open pump discharge valve and control the discharge pressure at 4 barg
17.
18.
19.
PETRO-CANADA EBLA
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Unit : GGS
11.5
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Operations
Page 172 of 275
General
Ensure the pre-start and functional checking activities are successfully completed.
When the system is started, the entire system should be checked at regular intervals
for abnormal conditions. If an abnormal condition is observed, the system must be
shutdown immediately and the cause investigated as given in Operation & Maintenance
Manual of the package unit. All pertinent operational data and observations must be
recorded.
The following are the sequential steps for start-up of plant air system:
Start-up of Plant Air System
1.
Ensure all instruments for the package and connected auxiliary systems are
operable from Local control panel and DCS
2.
3.
Line-up Plant air header and air receiver instruments:325-PI-4732 & 325-TI-4660
4.
5.
6.
Following the start-up procedure as per the vendors Installation, Operation &
Maintenance Manual. Start Compressor No. 1 from local control panel.
7.
Confirm lube oil circulation and check operation of the lube oil separator
8.
9.
10.
11.
12.
Ensure all isolation valves in the field utility station are closed
13.
Once the compressor performs and meets the design criteria, slowly pressurize
the Plant Air Receiver 325-V-001
14.
Close 2 vent valve and blind it. Open outlet valve of 325-V-001 for admitting
Plant Air to the system network. Blow air through main header and each utility
station header to confirm the Plant Air system is clean
15.
A service test is carried out at 8.5 barg to check the joint integrity of the system.
Gradually pressurise the plant air distribution network
PETRO-CANADA EBLA
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00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 173 of 275
16.
17.
18.
Line-up 325-PV-4660 manually and charge the plant air header. Check the flow at
325-FI-4663
19.
Set 325-PV-4660 at 8.5 barg and take the controller on AUTO mode
2.
3.
Open the outlet valve of Instrument Air Dryer 325-X-002A to Instrument Air
Receiver 325-V-002
4.
5.
6.
7.
8.
Ensure drain valve and bypass valve for Instrument Air Receiver 325-V-002 are
closed
9.
Open 4 vent valve on Instrument Air Receiver 325-V-001 and close outlet valve
10.
11.
12.
Open outlet valve of 325-V-002 for admitting Instrument Air to the system
network. Blow air through main header and each utility station header to confirm
the Instrument Air system is clean and dry
13.
Check the dew point at the farthest point and ensure the dew point is 35C at
7.5 barg
Hazop Action No: 550
Monitor the dewpoint analyzer (325-AI-4520 for Train-A and 325-AI-4570 for TrainB) for Train-A continuously and ensure the dewpoint is maintained at -35 0C at 7.5
barg. If the dewpoint increases to -340C at 7.5 barg, immediately high alarm 325AIH-4520 is activated. Always keep the standby Air Drier regenerated and kept
ready so that it can be lined-up immediately if there is high dewpoint alarm.
Excessive content of moisture in Instrument air may create acclerated corrosion
in downstream users.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
14.
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 174 of 275
15.
Normal Operation
Ensure the dew point 35C at 7.5 barg is maintained through On-Line Analyser
The following are set for the Auto-Start of the Running Compressor and Start/Stop
of the Standby Compressor:
Unload Compressor-B
Unload Compressor-A
Load Compressor-B
Load Compressor-A
Plant Shutdown
11.7
: 8.6
: 8.4
: 8.0
: 7.7
: 4.5
barg
barg
barg
barg
barg
b)
Check for installation of all instruments in the system and control loops are
checked (if taken for maintenance)
Start-up
1.
2.
Ensure the Instrument Air Receiver is under normal pressure (7-9 barg)
3.
Check Instrument Air dew point and confirm it is within specification limits
(-35C @7.5 barg)
4.
5.
6.
7.
8.
Line-up the inlet block valve and outlet ball valve of the membrane unit
324-M-001, 324-M-002 and 324-M-003
9.
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 175 of 275
10.
11.
12.
The product will automatically be vented through the product vent valve
324-XV-4620 & 324-HCV-003 until On-Specification N2 (98% purity) is generated
13.
Adjust purity control valve until the purity of product nitrogen is achieved
14.
When the O2 level in N2 product stream reaches 2%, the system will automatically
switch product valves 324-XV-4616 and 324-HCV-002 to OPEN and product vent
valve 324-XV-4620 & 324-HCV-003 to CLOSE
16.
Open block valve in the product outlet line from nitrogen generator and slowly
admit nitrogen to Receiver 324-V-001.
17.
Pressurize the receiver and vent the nitrogen through drain from receiver
18.
Open outlet valve for the receiver and charge the nitrogen header
19.
20.
Stop flushing and check for any leak at flange and valves
21.
22.
Check the controls of nitrogen generator, both on Manual and Auto from PCS
23.
1.
2.
3.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
11.8
1.
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Operations
Page 176 of 275
Ensure lining up of all instruments in Flare Headers, Flare KO drum, Flare KO Drum
Booster Pumps and KO Drum Pumps to DCS
2.
Ensure to line-up PSVs as shown in the P&IDs and equipment blowdown valves as
given in P&IDs
3.
Purging of Flare Header shall be done with nitrogen .Ensure O 2 level is reduced
to 2.5%
4.
5.
6.
7.
8.
Ensure the flare is started with propane gas; keep the flare with propane supply
until LP fuel gas system is established
9.
10. Start the heater if the level is above 50%; Start the heater; Line-up all instruments
for the heater
11. Heater shall maintain 50C. The heater will start at 40C and stop at 60C
12. Keep ready KO Drum Booster Pump 331-P-001A (B as standby) on recycle by setting
331-FV-5160 on auto.
13. Line-up condensate from Booster Pump to suction of 331-P-002A
14. Check the operating pressure of Production Separator
15. Reset 331-XV-5129 and open the shutdown valve.
16. Start Flare KO Drum Pump 331-P-002A,if condensate level is more than 50%
17. Check the performance of the pump. Ensure condensate flows to production
separator
18. Keep 331-P-002B as hot standby (keep open both suction and discharge valves
open).
11.9
1.
Check the oil skimmer 332-Z-001 is positioned properly, after the shut down job
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 177 of 275
2.
3.
4.
5.
6.
Production Separator
2.
Check and confirm lube oil level is at the correct level for the pumps
3.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
4.
00180-PCP-300-PDMan-12503-01
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Operations
Page 178 of 275
Set 333-LICA-5304 to AUTO mode. Line-up the pump discharge to 331-V-001 Flare
KO Drum
2.
3.
4.
Ensure the level of liquid is at Low Low level before draining from any process
equipment
5.
6.
Drain out the liquid by pump 333-P-001A/B, if the liquid level is above Low Low
7.
8.
9.
Assess the quantity of liquid to be drained. If the inventory is more than liquid
hold-up volume, then there is the possibility of overflowing or back-up of liquid
in HC Drain Header
2.
3.
4.
5.
Ensure liquid level in the Closed Drain Vessel before starting heater
6.
Switch OFF the heater manually from DCS when there is no liquid level in the
Closed Drain Vessel
7.
Frequent start-up and stopping will damage the heater. Switch off the heater
when not required
8.
Also switching on heater element without liquid will damage heater (Level shall
be above Low-Low level alarm)
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Operations
Page 179 of 275
Gas Export Header: After start-up and stabilization of GGS for normal operation of
plant
1.
Ensure fuel gas system is purged with nitrogen (if the line is opened up with the
resultant air ingress)
2.
3.
4.
5.
6.
Ensure supply of fuel gas from trunk line (large sink of gas)
7.
8.
Line-up fuel gas through 3 line from trunk line to fuel gas system
9.
Drain the condensate from the pipe line to closed drain header
10. Gradually open 321-PV-3306 and admit fuel gas to KO Drum 321-V-001
11. Drain the condensate from the KO Drum 321-V-001 to Flare Header through the
level control valve 321-LV-3311. Take 321-LV-3311 on Auto mode
12. Line-up fuel gas superheater 321-H-002A
13. Line-up 321-F-001A or B Fuel Gas Filter
14. Drain out the condensate from filter (first time) and close the drain valve
15. Energise heat tracing
16. Reset and start the heater 321-H-001A
17. Set 321-TIC-3352 at 15C and take it on AUTO
18. Ensure gas flow to superheater 321-H-002A
19. Start the heater 321-H-002A by switch 321-HS-3420
20. Set heater temperature at 321-TDIC-3323 at 15C and take it on Auto
21. Check the pressure drop across filter at 321-PDI-3319.
22. Fuel gas is ready to be admitted to GTG
23. Line-up fuel gas to field gas compressor (seal gas)
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GGS Operating Manual Vol #1
Operations
Page 180 of 275
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Operations
Page 181 of 275
After initiation of any start, the turbine Operating state changes to Active. Within
this Active state, there are a number of further sub-states:
Start Stage 1: The enclosure is purged and any other processes that dont require
the enclosure to be fully purged are carried out (e.g. testing of the emergency
lubricating oil pump)
Start Stage 2: Processes that require a fully purged enclosure are carried out.
(e.g. testing of fuel valves)
Acceleration to Spin Speed: The starter motor is engaged and the turbine is
accelerated to spin speed
Spin Period: The engine is held at its nominal spin speed to allow for the exhaust
and associated duct work to be purged of any gas fuel vapour from previous
operation (Nominally 3000 RPM)
Pre-Ignition: Any processes that are required prior to ignition are carried out
(e.g. priming of liquid fuel system)
Ignition: The igniters are energised and fuel is introduced. A failed ignition on gas
fuel will cause the start sequence to revert back to the spin period in order to
PETRO-CANADA EBLA
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Page 182 of 275
allow ignition to be attempted several times. On liquid fuel the unit will trip in
the event of a failed ignition attempt
Acceleration to Dwell Speed: The fuel and starter motor demand is increased to
cause the engine to accelerate. During this phase the starter motor will be
disengaged once the speed exceeds a required limit
Dwell Period: The engine is held (if required) at dwell speed to allow for warming
of the engine (Nominally 8500 RPM)
Stop Holds: The engine is held for any processes that need to be carried out
following the initiation of a normal stop sequence. (e.g. change to gas fuel for a
short period on gas to purge liquid fuel nozzles)
The typical start sequence for the twin shaft generator unit is shown in the Fig 14. A
twin shaft mechanical drive unit would be similar except that the PT speed would vary
dependant on loading. A single shaft generator set would only have a single speed
curve which is similar to the GG speed curve for the twin shaft up until the breaker is
closed when it will then behave in the same manner as the PT speed of a twin shaft
generator. Typical start times are given in Table. 1.
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
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Control Modes
Various engine speed/load control modes are available (dependant on configuration/
running condition).The various operating modes and output demand can be controlled
either from the HMI or remotely (either via hard-wired connections or over a
communications link). The output demand may be adjusted by using either raise/lower
commands or by supplying an analogue demand signal.
PETRO-CANADA EBLA
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Operations
Page 184 of 275
Starter Motor
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00180-PCP-300-PDMan-12503-01
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Operations
Page 185 of 275
All these feeders are located in the respective Gas Turbine Generator MCC Switchboard
fed from the Emergency MCC.
The first GTG is brought into circuit by dead bus closing of its 11 kV incomer breaker.
The incomer circuit breaker close command in the GCP is routed through a PMS close
permissive contact which will ensure that the NER of the first GTG that is being
brought into circuit is connected to the system, thus ensuring that the 11 kV System is
earthed.
On closing of the first GTG incomer breaker on to the HV switchboard, the 11 kV
System gets energized and the 11 kV bus Voltage, kW and current feedback along with
breaker status is available to the PMS and selectively to ICSS.
Refer Section 5 of this manual and Vendor Operating Manual for more details.
11.13 START-UP OF PRODUCED WATER SYSTEM
1. Ensure Produced Water Storage Tank 334-T-001 is cleaned of sludge
2. Line-up all instruments for the produced water degassing drum and produced water
storage
3. Ensure flare system is in operation
4. Ensure the tank and degassing drum are purged and under nitrogen pressure
5. Take the following control valves and keep them closed
o 334-PV-5409 to Flare, 302-LV-1114 Production separator level control valve and
334-LV-5444 for degassing drum
6. Open Suction valve for 334-P-001 LP Produced water disposal pump
7. Line-up tank vent valve 3354-PCV-5409 and fuel gas line control valve to tank
3354-PCV-5408
8. Line-up blanket fuel gas to 334-T-001 by opening 334-PCV-5408
9. Control the tank pressure by operating 334-PV-5409 to TEG incinerator
10. Line-up Degassing drum 334-PCV-5449 to flare
11. Take all controllers on Auto
12. Keep the degassing drum and the produced water tank to receive produced water
ready for operation
13. Keep the water disposal pump ready for normal operation
11.14 START-UP OF METHANOL SYSTEM
1.
Ensure Methanol Storage Tank 329-T-001 is cleaned and ready to receive water (if
taken for maintenance)
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
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2.
3.
Line-up blanketing (LP Fuel gas) gas to methanol storage tank by taking
329-PCV-4905 on line
4.
5.
6.
7.
Ensure suction strainer for methanol unloading pump is cleaned and lined up
8.
Park the methanol tanker at designated place close to the unloading pump
9.
10. Connect unloading hose from tanker to suction of the unloading pump
329-P-001A/S
11. Ensure 329-LT-4901 is taken on line (trips unloading/loading pump at Low-Low
level and High-High level of the tank
12. Start 329-P-001A/s from local pushbutton and check the discharge pressure at
329-PG-4905
13. Check the methanol flow to methanol storage tank. Control the tank pressure
Hazop Action No-300
The Methanol transfer to Tank 329-T-001 as well as tote tank is carried out using
329-P-001A/S. Ensure there is always continuous supply of LP fuel gas for the
blanketing of Methanol Storage Tank 329-T-001. During methanol transfer ( Either
to storage Tank 329-T-001 or to tote tank) if there is outage of LP fuel gas, stop
the methanol transfer immediately. The transfer/unloading of methanol during LP
fuel gas outage will lead to oxygen ingress into the tank and mix with oxygen to
form a potentially explosive mixture.
14. Fill up the tank to 80%
15. Monitor the level at 329-LI-4900
16. Ensure valves at methanol loading point are closed
17. Loading of the tote tank is done by running 329-P-001A/S. Earth tote tank before
filling with methanol.
Start-up of Methanol Injection Package
18. Ensure adequate level of methanol in the supply tank
19. Line-up the suction from the Methanol Supply Tank to Methanol Injection Pump.
20. Line-up the suction strainer and flow meter at the discharge by opening isolation
valves and close bypass valve.
21. Ensure priming of the pumps by draining water through the pump upstream drains.
PETRO-CANADA EBLA
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Ensure Glycol Storage Tank 305-T-001 is cleaned and ready to receive Glycol
2.
3.
4.
5.
6.
Ensure 305-V-001 drain vessel is ready to receive drains from dehydration and
regeneration sections. Line-up drain vessel to flare
7.
Keep the drain pump 305-P-001 ready and line-up TEG regeneration system
8.
9.
Ensure suction strainer for make-up pump 305-P-002is cleaned and lined up
10. Park the glycol tanker at designated place close to the unloading pump
11. Connect the earthing of truck and tote tank
12. Connect unloading hose from tanker to 305-T-001 glycol storage tank
13. Start the truck pump and fill the glycol storage tank
14. Stop filling once the tank level reaches 80%. Close tanker side valve and unloading
valve
15. Make sure the requirement of glycol in dehydration system
PETRO-CANADA EBLA
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16. Start 305-P-002 from local pushbutton and check the discharge pressure at
305-PG-4905
17. Run the make-up pump on recycle to glycol storage tank
18. Line-up 305-F-001. Open make-up pump discharge and transfer glycol to
regeneration section. Stop the pump once desired quantity is transferred
19. The glycol from drain vessel is recovered by running 305-P-001 and the glycol is
transferred to regeneration section.
PETRO-CANADA EBLA
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00180-PCP-300-PDMan-12503-01
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Operations
Page 189 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
12.1
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Line-up one Well head to start with (subsequent Wells are lined up after start-up
of Production Separator)
Set all the Fail-Closed valves to the open position and all Fail-Opened valves to
their closed position.
PETRO-CANADA EBLA
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Activate each one of the unit blocks for ESD Level-1, ESD Level-2 & ESD Level-3
and check for the sequence of tripping. Refer Cause & Effect Diagram No:
250-EPR-CNE-05001 for all the ESD-1, 2 & 3.
Verify that the ESD valves function as per the ESD logic. The ESD Level-1 will
open depressurizing valves; ESD Level-2 will enable depressurization and ESD-3 is
used to only isolate or shutdown systems.
Reset the system and verify all valves have returned to normal operating
positions.
Similarly activate Fire & Gas Shutdown System and check whether the indicated
After the nitrogen purging of the total GGS plant is completed, arrange for the
leak test at 7 barg
2.
Keep the Flare system ready and commission all the utilities
3.
Ensure all vessel drains, level control valves, PSV bypass valves, vent and bleed
valves, and instrument bleeds to atmosphere are closed
4.
Ensure all the PSVs are lined up to flare to take care of any pressure surges in the
system
5.
Inform and readily keep Fire Trucks for any fire contingencies near the Well heads
as well as near the GGS plant area
6.
Confirm the ESD valve 302-XV-1100 U/S of the Production Separator is kept closed
and 302-XV-1157 (bypass of 302-XV-1100) and 302-HV-1158 are kept in open
condition (to control the pressurization rate at downstream system)
7.
8.
PETRO-CANADA EBLA
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Unit : GGS
12.3
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After purging and leak testing of the Production Separator, the Production Separator is
started up as per the following sequence:
1.
2.
Keep the level control valves at condensate line and produced water closed on
Manual
3.
4.
5.
6.
7.
8.
9.
PETRO-CANADA EBLA
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Unit : GGS
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14. Control the Production separator pressure at 87 barg with 302-PV-1137. Stabilise
the separator pressure
15. Set the pressure controller 302-PIC-1137 to Auto. Continue flaring till stabilising
the operation of separator
16. Commission the condensate level transmitter 302-LIC-1119 and the local level
gauge 302-LG-1118; check both show the same level
17. After the condensate level 302-LIC-1119 reaches 30% level, this would require the
following valves to be opened:
PETRO-CANADA EBLA
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Unit : GGS
12.4
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After purging and leak testing of the Condensate System, it is started up as per the
following sequence.
1.
After the condensate level reaches the weir height of the Production Separator,
the condensate overflows to the condensate chamber in the production separator
302-V-001.
2.
3.
Line-up the suction valves of the Condensate Pumps 302-P-001A/B (LP Phase) or
302-P-002A/B (HP Phase).
4.
After the condensate reaches the Level Low height of 610 mm on the condensate
side of the Production Separator, the ESD Valve 302-XV-1102 is forced open and the
condensate flows to the suction side of the Condensate Pumps.
5.
Start the Condensate Pump 302-P-001A and commission the condensate system
through the minimum-flow line 302-LV-1119.
6.
After the Condensate Pump performance is satisfactory, open the inlet block
valves of the Condensate Solid Filters (302-F-001A) first and pressure up the
A-filter. Commission the differential filter 302-PDI-1144. Line-up the isolation
valves for the safety valve 302-PSV-105. In the same way, commission the
Condensate Solid Filter (302-F-001B) and the safety valve 302-PSV-106.
7.
After start-up of the condensate solid filters, crack open the inlet valves of the
Condensate Coalescer (302-F-002A) and slowly fill the Condensate Coalescer.
8.
Crack open the safety valve bypass of the safety valve 302-PSV-107 to release any
nitrogen hold-up in the system.
9.
Water droplets start to coalesce in the mesh of the condensate Coalescer and
develop a level in the boot of the Condensate Coalescer. Line-up the Interface
Level Controller 302-LIC-1156A. As Level starts to appear as indicated in the Level
Controller 302-LIC-1156A, open the level control valve 302-LCV-1156 manually and
maintain the interface level.
10. In the similar way, Line-up the Condensate Coalescer (302-F-002B) as per steps 6,
7, 8 & 9. Start analysing the condensate samples; once it meets the specification
it can be routed to the GTP trunk line. The condensate normally meets the
specifications earlier than the dry gas from gas dehydration system; normal delay
will not affect the Slug Catcher in receiving a bigger slug at GTP. If there is more
delay in the Gas Dehydration and TEG Regeneration system, condensate can be
drained to the Closed Drain Drum.
PETRO-CANADA EBLA
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Unit : GGS
00180-PCP-300-PDMan-12503-01
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Page 195 of 275
11. After the condensate meets the specification, adjust the Condensate Flow
Controller 302-FIC-1182 flow such that the level in the Production Separator 302LIC-1119 is maintained at a normal level of 1510 mm. Then the condensate flow
controller 302-FIC-1182 can be put in cascade with the Production Separator Level
Controller 302-LIC-1119 (LP Mode operation).
12. In HP mode, level in the production separator is maintained by recycle line to
production
separator
through
302-LV-1119
as
302-P-002A/B
are
positive
displacement pumps.
13. Check the condensate specification and it shall be lined up to trunk line.
14. Start corrosion inhibitor injection, after lining up condensate to Trunk line.
12.5
2.
Open the 2 valve to admit nitrogen into 302-V-001 and observe the pressure
increase by observing 304-PI-1208.
3.
Force open 304-XV-1202. Take 304-LV-1210 in Manual mode and open fully to drain
the condensate in 304-V-001A. Ensure that the condensate is drained fully; force
close 304-XV-1202 and close 304-LV-1210 fully.
4.
Remove the blind for the 2 vent line for FG Compressor Suction KOD 304-V-001A
and crack open the block valve for 5 minutes. After minutes, close the vent block
valve and blind it.
5.
6.
Open the casing drains of the compressor and keep it open for 15 minutes to drain
any condensate in the casing of the FG Compressor-A. After 15 minutes, close the
casing drains of Compressor-A.
7.
PETRO-CANADA EBLA
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Unit : GGS
8.
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Collect sample and analyse for oxygen content. If the oxygen content is less than
2.5 vol%, stop the purging operation.
12.5.2 Start-up
The Start-up sequence takes care of all necessary controls and valve sequencing during
the start-up. The Compressor is started with an open Antisurge valve. Once the motor
is running at minimum speed, the Compressor can be loaded and the antisurge control
will be switched from SEQUENCE to AUTO.
12.5.2.1 Start-up requisites
Prior to initiating the Start sequence all trips have to be cleared and all start
interlocks have to be fulfilled.
The casing and seal cavity shall be drained before every start-up.
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Compressor Motor
Testing will be in accordance with vendor instructions.
Remote Control Panel
Testing will be similar to standard Control Panel.
Energization of Electrical Equipment
11 kV, 6 kV Switchboards along with remote control panel located in CRU substation.
Ensure that load side Equipment e.g. VSD, bypass transformer and motor are ready
for energization.
Insert the circuit breaker in test position for initial checks and then in service
position for energization.
Bypass Transformer
Ensure the load side equipment e.g. motor is ready for energization.
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Page 198 of 275
For any fault on VSD or maintenance, Compressor Motor will operate in bypass mode
(through bypass transformer) in fixed speed.
For more detailed operation sequence of VSD in all the above modes, Auto/Manual
Synchronous Transfer of VSD to Bypass and vice versa, please refer vendor VSD
Operation philosophy
Line-up of Instrumentation for Compressor
Ensure N2 as seal gas is lined up to the secondary seal and as separation seal gas
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00180-PCP-300-PDMan-12503-01
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Page 199 of 275
Ensure lubrication for cooler fans; Start the fans and check performance.
2.
3.
4.
Ensure lube Oil Filters are cleaned; line up one filter with the other as standby.
5.
Ensure trial run of the oil system is completed and ready for continuous operation
6.
7.
Open Oil inlet valves to bearings and other points. Open all valves in the return
line to tank
8.
Open the valve in the bypass line of Oil pressure control valve 304-PV-1510
9.
Check the oil temperature in the oil tank (to keep the desired viscosity of oil)
2.
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Unit : GGS
3.
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Check the operation of anti-surge valve 304-FV-1212 and flare vent valve
304-PV-1294 from local control panel
4.
5.
Ensure trial run of VSD is completed and coupled to compressor (initial start-up)
6.
Ensure healthiness of motor local control station, remote control panel, ESD
panel, Compressor PLC system and VSD switchgear
7.
Power up VSD and check the readiness of motor (Check the interlock for start-up is
active). Refer the section on operating instruction manual of vendor
2.
3.
4.
5.
6.
7.
8.
9.
Ensure the pressure drop is less than 2 barg. 304-PDT-1206 automatically opens
304-XV-1200 and suction of the compressor is pressurized
10. Drain the condensate from compressor casing, pipe lines and KO drum
Starting of Compressor
1.
2.
Make sure that start-up interlocks have been released by the control system of the
compressor unit.
3.
4.
5.
Check for any alarms and healthiness of start-up system. In case of malfunction or
start-up conditions are not achieved, take corrective action and ensure Ready for
Start is indicated in the panel. Ready for start-up permissive appears as
indicated by 304-XA-1693.
6.
PETRO-CANADA EBLA
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Unit : GGS
7.
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Ensure compressor discharge cooler fans are running and 304-TIC-1215 on Auto
mode.
8.
9.
2.
3.
4.
5.
6.
7.
Check the speed, discharge pressure, lubrication, seal gas pressure and secondary
seal gas pressure.
8.
9.
10. Check the gas temperature at the discharge cooler outlet of first stage.
11. Monitor the gas cooler outlet temperature and control at 60C by taking
304-TIC-1215 in Auto Mode.
12. Raise the compressor speed by selecting speed increase.
13. Raise the speed of the compressor to 1200 rpm and check the compressor
discharge pressure at 304-PI-1232.
14. Gradually raise the compressor discharge pressure to 87 barg, with careful
monitoring of compressor for vibration, temperature at the bearings, discharge
pressures and the gas outlet temperature at the outlet of gas coolers.
15. Set the discharge pressure at 87 barg and take the compressor operation on Auto
mode.
16. Check the performance of the compressor for vibration, discharge pressure,
bearing temperature, gas flow etc as detailed in the compressor vendors
instruction manual.
PETRO-CANADA EBLA
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00180-PCP-300-PDMan-12503-01
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Page 202 of 275
17. Now the speed of the compressor is controlled by the suction pressure 304-PI-1221
of the compressor.
18. Monitor liquid level 304-LIC-1210 in suction KO Drum
19. Take electrical tracing heater on Auto mode.
20. Monitor the condition of the compressor and its auxiliaries.
21. Check Dehydration column operating pressure.
22. Open 304-XV-1219 at the compressor discharge and allow the gas to Dehydration
Column.
23. Control 305-C-001A Dehydration Column pressure by taking 305-PV-3024 on
Manual. Set 305-PIC-3024 to Auto mode after stable operation of dehydration
column.
24. Take 304-PIC-1294 on Auto mode.
25. Monitor the seal gas flow and pressure. Maintain the seal gas vent to flare through
304-PV-1464 by maintaining 1 barg above flare header pressure.
26. Once the compressor performance is established, change the selector switch in
VSD to DCS position (or change the selector switch in motor LCS to DCS position).
27. Now the compressor control shall be taken over by compressor PLC in control
room.
28. Monitor the performance of the compressor from compressor PLC in control room.
29. Once the compressor is loaded, the anti-surge and performance controllers will be
switched from SEQUENCE to AUTO.
Line-up of Seal Gas from Process Gas
1.
Isolate nitrogen supply. Commission the seal gas supply from 1 seal gas take-off
from the Compressor discharge side. (In case of settle-out pressure (46.4 barg),
the seal gas supply is supplied from the HP Fuel Gas tapped from the D/S of Fuel
Gas Heater (321-E-001A/B) to ensure dry heated gas supplied to Dry Gas Seals.
2.
3.
4.
Refer the section operating instruction of Vendor Operating Manual for more
information.
12.6
The glycol regeneration and circulation systems should be started prior to passing
process gas through the glycol column. Once the glycol is present on the chimney tray
PETRO-CANADA EBLA
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00180-PCP-300-PDMan-12503-01
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Page 203 of 275
inside the column, the gas flow and glycol flow may be started or stopped
independently with no harm to the system. With the column charged with glycol, the
pump may be stopped for some minutes without seriously affecting the drying of the
gas, which will be effective to a decreasing extent as the glycol standing on the
structured packing becomes saturated with water. Glycol system shall be started prior
to lining up gas to Dehydration column.
Pre-Start-up Requisites
Inspect all glycol and gas lines; ensure they are all tight. Hot glycol can leak
through connections which might be considered tight when cold. Hence it is
necessary to re-tighten some connections once the hot glycol is being circulated
under pressure.
Check the pressures of the Gas Dehydration Column 305-C-001 to be atleast upto 7
barg.
Check the availability to operate of all electric motors (Pumps, Blowers and Air
Fans)
Drain the Blowers casing of the selected Vent Gas blowers 305-K-002A/B or C/D by
opening eight ball valves on each Blower casing assuring that all possible
condensate is drained off before burner ignition and then close the drain valves.
PETRO-CANADA EBLA
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00180-PCP-300-PDMan-12503-01
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Page 204 of 275
During the early phase (HP Phase) as the pressure is on the higher side, the Field
Gas Compressor section is kept in bypass condition. Ensure the following valves are
kept in closed condition.
The block valves upstream of ESD valves 304-XV-1200 and 304-XV-1201 for
Field Gas Compressor-A is kept in closed condition. Install blind in the D/S
flange of second block valve.
The block valves upstream of ESD valves 304-XV-1300 and 304-XV-1301 for
Field Gas Compressor-B are kept in closed condition. Install blind in the D/S
flange of second block valve.
2.
Open the 2 Nos 6 Ball valves on the Feed Gas line from the Production Separator
to the Gas Dehydration Column (305-C-001).
3.
4.
Slowly admit Feed Gas to the Dehydration Column (305-C-001) and pressurize
305-C-001 up to 7 barg.
5.
Take 305-PIC-3024 on Auto mode with a set point of 7 barg to HP flare. After this,
take 305-PIC-3009 on Manual mode and set 305-PV-3009A and 305-PV-3009B MV to
zero. Closely watch the pressure in the column as indicated by 305-PIC-3024 and
305-PIC-3009 maintaining 7 barg. During the first start-up and every time the Gas
Dehydration Column is depressurized, restarting of pressurization is done manually
for checking of leak
Charge the TEG Reboiler (305-H-001) and TEG Surge Drum (305-V-005) through the
2 glycol filling connection line 2-305-GY-1818-11J-E.
2.
During winter months, when air temperature might fall to -15C (min. ambient
temperature) ascertain that Gas Dehydration Column bottom, the wet
condensate outlet line and the chimney tray portion of the column are heated
by electrical tracing.
PETRO-CANADA EBLA
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00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 205 of 275
Switch on the electric tracing system on the level instruments installed on the
Flash Drum 305-V-002, on the TEG Reboiler 305-H-001, TEG Surge Drum
305-V-005, stand-by pump and in general where electrical tracing is given.
Increased viscosity of glycol in Surge vessel may affect the pumping and
potentially damage the glycol circulation pumps at cold operating conditions. As
the glycol lines are heat traced and insulated to retain the hot condition, it
becomes necessary to restart the electrical heat tracing and then start the
Glycol Pumps especially after prolonged shutdown and cold winter conditions.
3.
Start filling to about two-thirds level in the TEG Surge Drum (305-V-005) as
indicated in level gauge (305-LG-3114), leaving one third empty space for liquid to
expand on heating.
4.
The TEG Reboiler has an internal overflow weir through which the glycol will flow
into the TEG Surge drum, through the stripping column.
5.
Continue to fill the TEG Reboiler, until a liquid level appears in the surge drum. Stop
filling when the surge drum level reading on the level gauge 305-LG-3114 is 500 mm
(from lower part of Surge). Reset Low-Low shutdown level 305-LALL-3116.
Make sure that that the ball valve on the outlet line from the Pumps
305-P-003A/B (going to 305-E-004) is kept closed.
2.
3.
Open the isolation valves on the start-up line 2-305-GY-1023-11A-P on the Glycol
Circulation Pumps (305-P-003A/B) discharge line which routes the glycol to the
Flash drum (305-V-002).
4.
Start one glycol pump 305-P-003A. While the pump is running visually check the
pipelines. If any leaks are present tighten the bolts and arrest the leak.
5.
Continuously monitor the level inside the Surge drum and the Flash drum. The
level in the Surge drum (305-V-005) should be topped up before reaching the
minimum level of 300 mm.
6.
When the level in the Flash drum (305-V-002) reaches the normal level of 750 mm
or is higher than 370 mm (LLLL), stop the Glycol Pump. Top up the Surge drum
level if required.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
7.
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Pressurize the Flash drum with the blanketing gas upto 3.8 barg by opening the
manual valves around 305-PV-3201. Manual valves around 305-PV-3211 must also
be opened.
8.
Once the Flash drum is pressurized to 3.8 barg, reset the LLLL and then open the
shutdown valve 305-XV-3213 on the Glycol outlet line.
9.
Open the manual valves upstream of the TEG Catridge Filters (305-F-003A/B).
Slowly open vent valve to completely fill the filter and vent. Fill and vent both
the filters so that one will be on service and the other active stand-by.
10.
Slowly line up the TEG Carbon Filter (305-F-002) as explained above for the Rich
TEG Catridge Filters.
11.
Line up the Hot Lean/Rich Glycol heat exchanger (305-E-002) upto the TEG Still
column (305-C-002) and check for any leaks. Arrest leaks if any.
12.
Line-up 305-LV-3210 and glycol can be kept under circulation in order to establish
the levels inside both the vessels. Top the surge drum if required.
2.
Line-up one of the Glycol Circulation Pumps 305-P-003A/B. Open suction and
discharge valves of the pump 305-P-003A which is selected for use. Line-up block
valves on 305-E-001, 305-E-002 and 305-E-004 exchangers and Gas Dehydration
Column (305-C-001).
3.
Select the Local mode by pressing 305-MHSM-3121 on the Local panel and start the
pump 305-P-003A by pressing start pushbutton 305-MHSH-3121. Check for the
Running indication 305-MIXI-3121 of 305-P-003A in the DCS Panel.
4.
Lean Glycol starts flowing to the Dehydration column. Check the Glycol pressure
and the flow as indicated by 305-PI-3129 and 305-FI-3113.
5.
The Glycol lines get filled up before a glycol level appears in the chimney tray of
Gas Dehydration Column at 305-LG-3018 and in DCS by 305-LIC-3017. Observe the
pump (305-P-003A) for lubrication, discharge flow and discharge pressure.
6.
TEG entering the Gas Dehydration absorber passes through the structured packing
and then it is collected at the bottom of chimney tray. When the glycol level
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appears on the Level Gauge 305-LG-3018, stop the glycol circulation pump
305-P-003A.
7.
8.
When the level inside the Chimney tray is higher than LLLL of 4320 mm, reset the
Low-Low Level trip and the shutdown valve 305-XV-3002 can be opened allowing
the glycol to be discharged from the Dehydration Column.
9.
Observe level build-up in the chimney tray of 305-C-001. Once the normal liquid
level of 4780 mm level reaches on the chimney tray, put level controller
305-LIC-3017 into Auto with 305-LV-3017 to return TEG back to the Glycol
Regeneration Package.
10. Shut-off the Glycol Pumps 305-P-003A and top up the TEG Surge Drum if level is
low. Once the Glycol Pump is stopped, the glycol level control valve 305-LV-3017
closes.
11. Ensure 305-PCV-3211 to flare from Flash drum is set 4 barg and taken on Auto.
12. Line-up the manual block valves in Blanketing Gas Line to Flash Drum (305-V-002)
and pressurize to 3.8 barg by setting 305-PCV-3201 at 3.8 barg.
13. Put the level controller 305-LIC-3017 on Auto and return the rich TEG to the TEG
Reflux Condenser (305-E-003). Rich TEG will then flow down to the Flash Drum
through the Exchanger (305-E-002).
12.6.1.5 Heating of Glycol in the TEG Reboiler
1.
The gas burner assembly for the TEG Reboiler can be started either from DCS or
from Local panel.
Pilot ignition will be carried out with Ignition Electrode through Ignition HighEnergy Transformer.
Temperature Control will be carried out through an air/gas ratio control valve
actuated by Temperature controller 305-TIC-3109.
The burner can be lighted only after the complete filling of the Reboiler with
glycol. Attempt to light on the burner without Glycol will damage the firetube.
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The logic sequence describes the starting and fully automatic controlling with
ESD for the forced draft burner.
Ignition sequence can start only if none of the following shut-off causes occurs:
305-LAHH-3209 High- High Rich TEG Level in Glycol Flash Drum (305-V-002)
The flame detector tag 305-BE/BSL-3163 does not signal flame presence.
The limit switch 305-XZSL-3169 does signal that the Shutdown Valve
305-XV-3169 in the pilot fuel gas line is closed.
The limit switch 305-XZSL-3168 does signal that the Shutdown Valve
305-XV-3168 in the pilot fuel gas line is closed.
The limit switch 305-XZSH-3165 does signal that the Shutdown Valve
305-XV-3165 in the pilot fuel gas vent line is open.
The limit switch 305-XZSL-3167 does signal that the Shutdown Valve
305-XV-3167 in the main burner fuel gas line is closed.
The limit switch 305-XZSH-3166 does signal that the Shutdown Valve
305-XV-3166 in the main burner fuel gas line is closed.
The limit switch 305-XZSH-3170 does signal that the Shutdown Valve
305-XV-3170 in the main fuel gas line is open.
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The limit switch 305-XZSL-3171 does signal that the Shutdown Valve
305-XV-3171 in the stripping gas line is closed.
Press Start Burner pushbutton and the following operation are done in automatic
sequence:
Start the selected Burner Air Fan (305-K-001A/B)
Start the Burner Air Fan 305-K-001A by pressing the Start pushbutton
305-MHSM-3182.
The Burner Gas Blower 305-K-001A running indication is displayed on DCS
panel by 305-MXI-3182.
Start the selected Vent gas Blowers (305-K-002A/B) by the following actions
and line-up to the TEG Incinerator.
Select Local mode by pressing the Local/Remote Selector switch
305-MHS-3131 and 305-MHS-3132 in the Local Panel.
Start the Vent Gas Blower 305-K-002A by pressing the Start pushbutton
305-MHS-3131B in the local panel.
The Vent Gas Blower 305-K-002A running indication is displayed on DCS
panel by 305-MXI-3131.
Similarly start the other Blower 305-K-002B and ensure the two Vent gas
Blowers are running in series
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If the flame scanner detects the flame within 30 seconds Pilot On lamp
(305-XL-3157) glows on the local panel.
Check the pressure of the pilot gas to 0.3 barg and adjust 305-PCV-3176 if
required.
Check the flame quality adjust the gas flow and the air flow using dedicated
valves on the pilot gas Assembly.
Once the Pilot flame is detected, following operations are done in automatic.
After the Pilot flame is stabilized, open shutdown valves 305-XV-3167 and
305-XV-3166 and close 305-XV-3170 on the main gas burner line.
When the Main flame stabilization time is over and the burner start-up
sequence is completed, Burner On indication appears on the local panel
(305-XL-3156B) and on DCS (305-BAH-3156A).
At this point the automatic sequence should remove the force controls on
305-TIC-3109 but some adjustments on the main burner shall be required.
Therefore it shall be convenient to keep the control in manual mode since the
main flame is properly adjusted.
2.
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Set maximum temperature gradient of 60C/hr and set point for 305-TIC-3109
at 204C.
After performing the Burner start-up, progressively increase the set point for
305-TIC-3109 up to 204C. (If the heating process is slow, then the inventory in
reboiler is heated, raise the temperature to 204C and circulate through the
system).
Open the valves on the start-up line 2-305-GY-1015-11A-P and start the glycol
circulation starting a pump and allowing the warm up of the Reboiler and
surge drum.
When the temperature inside the Surge drum reaches approximately 90C,
open the valves on the start-up line 2-305-GY-1023-11A-P and close the line
2-305-GY-1015-11A-P allowing to warm-up the Flash drum and the glycol
filters.
When the temperature inside the Reboiler reaches 150 0C, start the Glycol
circulation to the Gas Dehydration Column 305-C-001.
Open the shutdown valve 305-XV-3003, then close the valves on the
recirculation line previously opened (Globe valve first then the Ball valve).
The pressure on the pump outlet will increase upto the required pressure to
allow the glycol enter the column and then open the shutdown valve on the
outlet line 305-XV-3002
The level inside the Chimney tray shall be controlled by the valve 305-LV-3017.
2. The glycol circulation is complete and the glycol temperatures should reach the
design values. Do not exceed 204C in the reboiler and increase the temperature
at a rate of 60C/hr. During this operation, care should be taken for the free
expansion of equipment and piping. Sliding supports shall be free to slide and no
stress or constraint shall develop on equipment saddles, nozzles or pipes supports.
3. During this heating operation, one shall also check for leaks and tight wherever
necessary (the low surface tension of glycol at high temperatures encourages
leakage). Check the liquid level in particular inside the Surge drum because of
thermal expansion.
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The process gas flow is established through the Gas Dehydration Column soon after
the Glycol circulation. It is also important to circulate glycol through 305-C-001
before the gas is introduced and then contactor is pressurized. Experience have
shown that too long a circulation of Glycol in the Gas Dehydration Column without
process gas counter-flow could cause foaming. As a result of this, process gas flow
shall be established through the Gas Dehydration Column soon after the glycol
circulation.
2.
Introduction of process gas through 305-C-001 should be established soon after the
hot glycol circulation is established to avoid potential foaming problem in the
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column. Feeding the feed gas to the Gas Dehydration Column should be as smooth
as possible.
2.
Increase the feed gas rate in steps of 25% of the maximum flow, each step reached
in 30 seconds or more.
3.
As the process gas feeds the internal Gas/Liquid separator of the Gas Dehydration
Column (the bottom section of the Column), the water droplets trapped will form
a level at the bottom of the Contactor. When the level is above LLLL trip, open the
shutdown valve 305-XV-3001 and put in service the control valve 305-LV-3013. The
level control valve (305-LV-3013) can be put into service in Auto with the Level
Controller 305-LIC-3013.
4.
Continue routing dehydrated feed gas to HP Flare via 305-PCV-3024. Send gas
samples for analysis of water content. Slowly rise the gas feed rate up to 50% of
design gas feed rate.
5.
Coordinate with the Ash-Shaer Well head Personnel and maintain the choke valves
so as to maintain a pressure of 50 barg at the Gas dehydration Column. Set the
lean Glycol flow to 4.5 m3/h.
Collect samples at the outlet of the Gas Dehydration column SC-502 to find
out the dew point and the water content of the dehydrated gas.
Water is boiled off glycol at the TEG Reboiler and water & aromatic vapours
pass on to the tube side of the reflux exchanger.
Cold rich glycol from the glycol absorber passes through the shell side of the
exchanger and partly condenses the water vapours.
2. Too much reflux (condensation) will overload the reboiler; too little reflux or no
reflux will increase the glycol losses. For adjusting the reflux rate, it is necessary
to control the flow of Glycol through the reflux exchanger by a 3-way control
valve.
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When TEG Catridge Filter or TEG Carbon Filter will be plugged, the pressure
differential across the filter is readable on DCS by 305-PDT-3216/3122 for
cartridge filter and 305-PDT-3218 for carbon filter will increase.
2.
When the differential pressure reaches 0.8 bar, then it is necessary to put the
standby filter is taken into service.
Open the upstream and downstream valves of the Standby filter and open the
vent valve; the standby filter is in service.
The service filter can be isolated from the process by closing its own upstream and
downstream valves and drained. No relevant effects on hydrocarbon content are
expected during filter by-pass time.
Cartridges or carbon loads shall be replaced with new ones at that time. Estimated
by-pass time required for cartridge replacement is two hours. Carbon filter is
bypassed during change-over of carbon cartridge.
NOTE: It is advisable to start the glycol package with new sets of cartridges and
carbon loads in glycol filters. Also always, maintain new replacement cartridges and
carbon loads for the standby filters. During first start-up, cartridges with 25 microns
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Coordinate with the Well heads to open the choke valves so that pressure of 86
barg is maintained at the top of the Gas dehydration column. Maintain the
methanol and corrosion inhibitor injection flow rates as per the design flow of dry
gas.
2.
Maintain the lean glycol flow and temperature as per the increase of the gas feed
rate in the Gas Dehydration Column. Maintain the lean TEG temperature 5C above
the wet gas entering the Gas Dehydration Column.
3.
In case of foaming in the dehydration column, start the anti-foam and the
corrosion inhibitor injection to various points in the TEG regeneration system.
4.
Stabilise the TEG regeneration system with temperatures and flows optimised for
efficient operation of the gas dehydration system.
5.
6.
Check two or more samples to confirm the water content of the dry gas and
Condensate.
7.
8.
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Liquid trap installed on the drain line of the Vent Gas KOD for its operability.
Ensure to drain the liquid periodically with care to avoid gas blow-off. If the liquid
level is higher it should be drained to avoid carryover to Vent Gas Blowers
(305-K-002A/B/C/D) and causing potential damage to the Vent Gas Blowers.
9.
After the condensate and the dry gas meets the specifications, route both to the
GTP trunk line.
The operator will be alerted at 80.6 barg by Low pressure alarm 305-PAL-3009
and should take immediate action to identify the cause and close 305-PV-3024
The bigger control valve 305-PV-3009A closes fully and the pressure is
controlled only by smaller control valve 305-PV-3009B
However if the Operator does not respond to the above mentioned alarms at 80.6
barg, then at 76.3 barg, the actuation by 305-PALL-3012 will cause ESD-3 shutdown
which will cause unnecessary flaring at the upstream section of GGS.
Hazop Action No. 47
The ESD-3 shutdown of Gas Dehydration/TEG Regeneration unit closes 305-XV-3001,
the TEG Column 305-C-001 Bottom liquid outlet ESD valve. After the ESD shutdown the
steps of glycol circulation, Heat-up of Glycol and the pressurisation of feed gas and the
other requirements are to be followed as given below in Section 12.6.2. If the glycol
circulation, Gas pressurisation and other set of requirements are not followed, it will
lead to foaming which will cause glycol carry over to the trunkline.
12.6.2 Start-up at normal conditions
Subsequent start-up after a normal shut down requires less operations of a first start
up, since the operating parameters should be already set to their correct values.
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Assure that all the operating parameters (i.e. levels, pressures, etc.) are correct
and the plant is ready for start-up.
2.
3.
4.
5.
6.
Drain the blowers casing of the selected Vent Gas Blowers 305-K-002 A/B or C/D by
opening the eight ball valves installed on each blower case assuring that all the
possible present condensate vapour inside is drained off before burner ignition,
then close the drain valves.
7.
8.
After performing the burner start-up, progressively increase the set point of the
temperature indicating controller 305-TIC-3109 by DCS, then if the temperature in
the reboiler is lower than 90C.
Open the valves on the Start Up line 2-305-GY-1015-11A-P and start the glycol
circulation starting a pump allowing the warm-up of the Reboiler and Surge
Drum.
When the temperature inside the Surge Drum reach approximately 90C, open
the valves on the start-up line 2-305-GY-1023-11A-P and close the ones on
line 2-305-GY-1015-11A-P allowing to warm up also the Flash Drum and the
filters. This will allow all equipment to slowly warm-up and will avoid thermal
shock. When the temperature inside the reboiler reaches 150 C, can start the
Glycol circulation on the Gas Dehydration Column 305-C-001.
9.
Open the shut down valve 305-XV-3003 and then close the valves on the
recirculation line previously opened (globe valve first then the ball valve). The
pressure on the pump outlet line will increase up to the required pressure and
allow the glycol to enter the column.
10. Then open the shut down valve on the outlet line 305-XV-3002. The level inside
the chimney tray shall be controlled by the valve 305-LV-3017. The glycol
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circulation is complete and the glycol temperatures should reach the design
values.
11. Put the stripping gas in service by manual opening from DCS the shut down valve
305-XV-3171 on the stripping gas line.
12. Start circulation of process gas through the Glycol contactor soon AFTER the glycol
circulation is established to avoid potential foaming problem in the column. Feed
the glycol contactor with the process gas as smooth as possible.
13. It is not possible to indicate an accurate value on the feeding rate, it is advisable
to have few steps of 25% of the maximum flow, each step being reached in 30
seconds or more.
As the process gas feeds the internal gas/liquid separator of the glycol contactor
(the bottom section of the column), the water droplets trapped will form a level
at the bottom of the Contactor. When the level is above the LLLL trip, open the
shut down valve 305-XV-3001 and put in service the control valve 305-LV-3013.
Note: During heating the following parameters must be strictly followed:
Increase the temperature in the reboiler at a maximum rate of 60C per hour.
2.
3.
4.
5.
6.
7.
Dilution Air damper controlled by low value of Oxygen Analyzer and high
combustion chamber temperature.
8.
Normal operation.
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ESD system checks whether there is main burner start check failure BSL-6051
& BSL-6048 and detection of the burner main flames (alarm BAX-6051 and
BAX-6084) before the opening of the gas valves XV-6033A & XV-6033B and
closing of the vent valve XV-6033C.
ESD system checks whether there is pilot flame detection, start check failure
BSL-6070 before pilot ignition trial. Also, ESD checks if there is detection of
the pilot flame (alarm BAX-6070) before the start of its ignition
ESD system checks whether the air fan is not running before giving the start
command of the system.
Press the field push-button HS-6052B if none of the lock alarms listed in the
previous point 12.6.15 is appearing on the system.
2.
3.
Air fan 340-KM-001A is started and the sequence checks whether the air fan is
running.
4.
ESD checks whether the combustion air pressure PALL-6030 is not in alarm
condition after a short time period of 40 seconds (this alarm is overridden for
40 seconds from the time of starting the air fan).
5.
6.
Starts purge timer after FT-6031 confirms adequate purge airflow rate. During
purge time, LCP will illuminate Purge On lamp XL-6060.
7.
After completion of purge time Purge Complete lamp XL-6061 will illuminate in
LCP (Local Control Panel).
8.
Starts ignition transformer and continues sparking for 10 seconds. 2 seconds after
ignition has started, pilot valve XV-6032A, XV-6032B and XV-6032C are activated.
9.
ESD checks Pilot flame detection and de-energizes ignition transformer (both have
preset time periods). If the flame is not detected, it de-energizes XY-6032A,
XY-6032B and XY-6032C and raises an alarm.
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10. When the pilot flame is detected, it illuminates Pilot On lamp XL-6063 and
commences 20 seconds flame establishment period.
11. This is followed by activation of the main fuel gas valves XV-6033A, XV-6033B and
XV-6033C.
12. ESD checks whether main flame scanner has detected the flame and informs LCP
that the main flame is ON; ESD will enable Main Flame Present indication lamp
XL-6051.
13. ESD will enable PAHH-6056 function.
14. Heat incinerator up to a operating temperature of 750C.
15. DCS will send a signal to ESD (via HS-6055A) to activate valve XV-6041A, XV-6041B
and XV-6041C (TEG Off-Gas).
16. DCS will send a signal to ESD (via HS-6056A) to activate valve XV-6045A, XV-6045B
and XV-6045C (Produced Water Tank Off-Gas)
17. Once the burner is in operation, the next step is to increase the combustion
chamber temperature up to the minimum value for Off-Gas injection (pre-heating
of the incinerator). A temperature ramp-up control gradually heats up the
combustion chamber over a time period (to prevent thermal shock of the
refractory due to full burner output when refractory is cold).
18. The steps of off-gases feeding to incinerator are the following:
Opening TEG Off-Gas valves XV-6041A & XV-6041B and closing XV-6041C to
consent off feed.
Opening Produced Water tank Off-Gas valves XV-6045A, XV-6045B and closing
XV-6045C to consent off feed.
In case of burner shut-down for any reason or incinerator low temperature TI-6047, the
valves of TEG off-gas and Produced Water tank off-gas close immediately.
Open the shut down valve 305-XV-3003 then close the valves on the
recirculation line previously opened (globe valve first then the ball valve). The
pressure on the pump outlet line will increase up to the required to allow the
glycol enter the column then open the shut down valve on the outlet line
305-XV-3002. The level inside the chimney tray shall be controlled by the valve
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Put the stripping gas in service by manual opening from DCS the shut down
valve 305-XV-3171 on the stripping gas line.
Start circulation of process gas through the glycol contactor soon AFTER the
glycol circulation is established to avoid potential foaming problem in the
column.
Feed the glycol contactor with the process gas as smooth as possible.
As the process gas feeds the internal gas/liquid separator of the glycol contactor (the
bottom section of the column), the water droplets trapped will form a level at the bottom
of the Contactor. When the level is above the LLLL trip, open the shut down valve 305-XV3001 and put in service the control valve 305-LV-3013.
Note: During heating the following parameters must be respected:
Increase the temperature in the reboiler at a maximum rate of 60C per hour.
2.
Ensure the Produced Water system is ready for start-up as detailed in Section
11.13 above
3.
Ensure to line-up blanketing gas (Fuel Gas) to Degassing Drum and Produced Water
storage tank
4.
Ensure water separation in Production Separator 302-V-001 and the level controller
302-LIC-1114 is lined up to 334-V-001
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6.
7.
Set the level controller 334-LIC-3441 at 50% and take it on Auto. Check flow of
water to 334-T-001
8.
Ensure the tank is always kept under fuel gas blanketing and the pressure is
maintained by 334-PV-5409
9.
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13.1
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Page 224 of 275
The following are to be maintained and controlled for stable operation of Production
Separator:
o
Ensure that the pressure and level controllers of Production Separator are in Auto
mode. The operating pressure of the Production Separator shall be steady under
normal operating conditions. In case of frequent variations, check the
functioning of the pressure and level controllers.
Ensure that all methanol injection systems are running and the chemicals are
injected at the required rate during winter.
The vapour and liquid flows to and from the Production Separator may change
depending on the variation in Gas to Oil Ratio (GOR) of the production fluid and
the change in operating conditions of the plant like turndown etc.
Regularly check and ensure that the drain valves of Production Separator are
closed and the spectacle blinds are in closed position
Ensure free flow of produced water. Check heat tracing on regular basis. Prevent
maintenance of H.T.Coil shall be done as per schedule.
The pressure is maintained at 86.75 bara during the HP mode and 26.85 bara
during the LP mode. The pressure in the Production Separator is controlled by
back-pressure of the gas dehydration column. If for any reason, the Production
Separator increases beyond 86.75 bara, then the pressure control valve
302-PCV-1137 will open to flare to maintain normal pressure. If the pressure still
increases and leads to popping of Production Separator PSV, the choke valve
opening can be adjusted or isolate one of the well heads to control the pressure
immediately. If the Production Separator pressure reduces, this may be due to
tripping of any well head and can be normalised by restarting the well head after
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attending its fault. If the pressure is still low, then adjust the choke valve
opening to get normal pressure in the Production Separator.
The interface level is maintained by the Interface Level Controller 302-LIC-1114
which controls the Produced Water flow through 302-LV-1114 to Produced Water
Tanks. The interface level is maintained at a normal level of 650 mm. If the
interface level increases quickly, this may be due to increased production flow of
gas or increased water content of the well head fluids. Sometimes the bypass of
the control valve 302-LV-1114 is operated to control the increased level of water
level in the Production Separator.
Key Performance indicators for Production Separator and Coalescer Circuit
Tag No.
302-PI-1112
302-TI-1138
302-FI-1108
302-LIC-1119
302-LIC-1114
302-FI-1106
302-FIC-1182
302-PDI-1168
302-PDI-1169
13.2
Description
Production Separator pressure
Production Separator Gas temperature
Gas flow to Gas Compressor/Gas Dehydration
Column
Production Separator Condensate level
Production Separator Interface level
Production Separator Water flow rate
Condensate flow rate
Differential pressure for Coalescer 302-F-002A
Differential pressure for Coalescer 302-F-002B
Required
Value
86.75
42
131.0
50.0
50.0
40.0
36.0
0.2
0.2
Unit
bara
C
Sm3/h
%
%
m3/h
m3/h
bar
bar
The following are the main points for periodical checks of the normal operation of Gas
Dehydration and TEG Regeneration system.
Maintain the lean glycol flow and temperature as per the increase of the gas feed
rate in the gas dehydration column. Maintain the lean TEG temperature 5C
above the wet gas entering the gas dehydration column. Adjust the final
parameters so that the final moisture content of the dry gas is met.
Pressure drop across the Gas dehydration column should have a normal value of
0.2 to 0.3 bar. In any case, if the differential pressure reaches 0.35 bar, then it
indicates foaming problem in the dehydration column. Collect both lean and rich
glycol samples frequently to determine the purity of glycol and eliminate
foaming.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 226 of 275
During winter months when air temperature might fall to 15C (minimum
ambient temperature), ensure heating the Gas dehydration column bottom,
condensate outlet line and the chimney tray of the gas dehydration column
these are heated by electrical tracing.
When there is foaming in the column, start the antifoam and the corrosion
inhibitor injection to various points in the TEG regeneration system
Stabilise the TEG regeneration system with temperatures and flows optimised for
efficient operation of the gas dehydration system.
Check the two or more samples to confirm the water content of the dry gas and
condensate.
Do not operate the glycol reboiler above 204C as it will lead to premature glycol
degradation.
Chemical Requirement
o
Antifoam requirement is 10 litres per week. Regular TEG chemical analysis will
determine the exact requirement.
Key Performance Indicators for Gas Dehydration System and TEG Regeneration System
Tag No.
305-TI-3019
305-LIC-3017
305-LIC-3013
305-PIC-3009
305-PDI-3007
305-TI-3076
305-FI-3113
305-TIC-3102
305-TI-3101
305-TG-3100
Description
Gas Inlet to 305-C-001 Temperature
Lean TEG level in 305-C-001
Bottom Condensate level in 305-C-001
305-C-001 Top pressure
305-C-001 Packing differential pressure
Lean TEG to 305-C-001
Lean TEG flow to 305-C-001
OVHD temperature of 305-E-003
Rich TEG temperature to 305-E-003
Rich TEG Inlet temperature to 305-E-001
Required
Value
Unit
50.0
C
50.0
%
30.0
%
84.8
barg
0.3
bar
55
C
6.0
m3/h
95
C
53.5
C
62.0
C
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Tag No.
305-TG-3119
305-TG-3144
305-TG-3127
305-LIC-3210
305-PDI-3216
305-PDI-3222
305-PDI-3218
305-LI-3115
305-TIC-3109
305-PI-3178
305-PI-3174
305-PI-3189
13.3
Operations
Page 227 of 275
Description
Rich TEG Outlet temperature from 305-E-001
Lean TEG Inlet temperature to 305-E-001
Lean TEG Outlet temperature of 305-E-001
Flash drum TEG level
305-F-003A Differential Pressure
305-F-003B Differential Pressure
305-F-002 Differential Pressure
Lean TEG Surge drum level
TEG Reboiler vapour temperature
Stripping gas pressure
Main TEG Burner FG pressure
TEG Pilot burner FG pressure
Required
Value
Unit
150.0
C
103.0
C
73.8
C
50.0
%
0.2
bar
0.2
bar
0.15
bar
50.0
%
204
C
0.4
barg
0.5
barg
0.3
barg
Ensure all control and safeguarding functions of the Field Gas Compressor and its
auxiliaries are normal.
Check vibration and displacement at the compressor monitoring system and Human
Machine Interface (HMI).
The suction pressure controller sends a speed set-point signal to the VSDS (Variable
Speed Drive System).
The VSDS tends to decrease the speed of the compressor in case the suction
pressure is decreasing below the set point.
Lube Oil
The Lube Oil Reservoir temperature is controlled by 304-TIC-1527 which controls the
heater by a thermister control which switches the heater ON and OFF at a desired
temperature. The lube oil header temperature is maintained at 59C by a temperature
controller acting on a three-way valve 304-TCV-1503 which bypasses the lube oil across
the lube oil cooler (304-X-1500).
The lube oil supply pressure is controlled by self-actuated pressure control valve
304-PCV-1510 which maintains the header pressure at 2.5 barg by opening to the Lube
Oil Reservoir.
Seal Gas
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 228 of 275
Compressor
Check condensate level in the suction KO drum is controlled. Check the secondary
seal air pressure and quality.
Ensure field gas compressor cooler fans are running and the gas temperature is
controlled at 60C
Field
Field
Field
Field
Field
Field
Field
Field
Gas
Gas
Gas
Gas
Gas
Gas
Gas
Gas
In addition to the above, the compressor faceplate for DCS operations like compressor
start sequence, compressor motor start, lube oil standby pump start and lube oil
coolers start shall be disabled during HP mode.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 229 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
14.1
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 230 of 275
If it is ESD Level-1 shutdown, then after ensuring the reason for abnormal condition,
the CCR Operator should confirm with the operator concerned whether the condition
has returned to normal before proceeding with the start-up of the unit.
EDG is stopped or not getting started (Due to confirmed presence of 10% LEL)
Ensure the plant normalcy is returned and cleared by the supervisor for restart-up of
the plant.
PLANT START-UP (EDG not available due to presence of LEL > 10%)
1.
2.
Take all Level Control Valves and keep them closed. Take Pressure Control Valves
and keep them closed or control the pressure as the process warrants.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
3.
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 231 of 275
Ensure LEL 10% level at HVAC suction or 20% level at field is not active. Signal is
healthy.
4.
Check DCS and safety system are healthy with power supply from UPS.
5.
Check battery system is healthy and lube oil is powered. EDG control supply is
available.
6.
7.
Ensure all blowdown valves are closed. Check the indication at DCS.
8.
Check the diesel level in the day tank. Ensure the Emergency Diesel Generator
Local control Panel is powered from the battery
b.
9.
Start 326-P-001A/s from local pushbutton and check the discharge pressure at
326-PG-4731
Ensure suction strainers for 326-P-005A/B potable water distribution pumps are
cleaned and reinstated
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 232 of 275
Energise 326-P-005A
Open pump discharge valve and control the discharge pressure at 4 barg
Ensure drain valve and bypass valve for Plant Air Receiver 325-V-001 are closed
Ensure all instruments are lined up to DCS (No change made since shutdown of the
plant-ESD1 activation)
Open 2 vent valve on Plant Air Receiver 325-V-001 and close outlet valve
Following the start-up procedure as per the vendors Installation, Operation and
Maintenance Manual. Start Compressor No. 1 from local control panel.
Confirm lube oil circulation and check operation of the lube oil separator
Check the compressor for abnormal conditions (pressure, temperature, noise, etc.)
Once the compressor is started, slowly pressurize the plant air receiver 325-V-001
Ensure all isolation valves in the field utility station are closed
Close 2 vent valve and blind it. Open outlet valve of 325-V-001 for admitting Plant
Air to the system network
Line-up 325-PV-4660 manually and charge the plant air header. Check the flow at
325-FI-4663
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 233 of 275
Set 325-PV-4660 at 8.5 barg and take the controller on AUTO mode
Select Instrument air Dryer to be on line from the Selector switch. Line-up
325-X-002A; 325-X-002B goes to Standby mode
Open the outlet valve 325-X-002A of instrument air dryer to instrument air receiver
325-V-002
Start the Instrument Air Driers as per vendor operating and maintenance manual
Ensure drain valve and bypass valve for Instrument Air Receiver 325-V-002 are
closed
Close 4 vent valve and blind the pressure. Open outlet valve of 325-V-002 for
admitting instrument air to the system network
: 8.6
: 8.4
: 8.0
: 7.7
barg
barg
barg
barg
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Plant Shutdown
Operations
Page 234 of 275
: 4.5 barg
Ensure the instrument air receiver is under normal pressure (79 barg)
Check instrument air dew point and confirm it is within specification limits
(35C at 7.5 barg)
Ensure to line-up the inlet block valve and outlet ball valve of the membrane units
324-M-001, 324-M-002 and 324-M-003
The product will automatically be vented through the product vent valves
324-XV-4620 & 324-HCV-003 until on-specification N2 (98% purity) is generated
Adjust purity control valve until the purity of product nitrogen is achieved
When the O2 level in N2 product stream reaches 2%, the system will automatically
switch product valves 324-XV-4616 and 324-HCV-002 to open and product vent
valves 324-XV-4620 & 324-HCV-003 to close
Ensure drain and vent for the receiver 324-V-001 are closed
Open block valve in the product outlet line from nitrogen generator and slowly
admit nitrogen to the receiver 324-V-001
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 235 of 275
Pressurize the receiver and vent the nitrogen through drain from the receiver
Open outlet valve for the receiver and charge the nitrogen header
Check the controls of nitrogen generator, both on Manual and Auto from PCS
Line-up plant air header from instrument air receiver 325-V-002 by opening
325-PV-4660
Monitor the operation of plant air , instrument air and nitrogen systems; keep them
running for the start-up of the plant
Ensure lining up of all instruments in flare headers, Flare KO Drum, Flare KO Drum
Booster Pumps and KO Drum Pumps (Normally not disturbed after ESD1 shutdown)
331-X-001 Flare shall be lit as per vendor start-up procedure (if the flare is put off.
Normally the flare continues with gas hold up in the flare network)
Ensure flare is started with propane gas and keep the flare with propane supply
until LP fuel gas system is established
Start the heater if the Flare KO Drum level is above 50%. Start the heater. Line-up
all instruments for the heater
Heater shall maintain 50C. The heater will start at 40C and stop at 60C
Start KO Drum Booster Pump 331-P-001A (B as Standby) and keep it under recycle
by operating 331-FV-5160 to ensure minimum flow through the pump
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 236 of 275
Keep 331-P-002B as hot Standby (keep both suction and discharge valves open)
Check and confirm that the lube oil level is at the correct level for the pumps
Set 333-LICA-5304 to AUTO mode. Line-up the pump discharge to 331-V-001 Flare
KO Drum
Ensure the level of liquid is at Low Low level before draining from any process
equipment.
Drain out the liquid by pump 333-P-001A/B, if the liquid level is above Low Low
Ensure liquid level in the Closed Drain Vessel before starting Heater
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 237 of 275
Switch OFF the Heater manually from DCS when there is no liquid level in the
Closed Drain Vessel
The high pressure fuel gas is supplied from the trunk line to power generator
packages 323-X-001A/B
Ensure supply of fuel gas from trunk line (large sink of gas)
Line-up fuel gas through 3 line from trunk line to fuel gas system
Drain the condensate from the pipe line to closed drain header
Drain the condensate from the KO Drum 321-V-001 to flare header through the
level control valve 321-LV-3311.Take 321-LV-3311 on Auto mode
Drain out the condensate from the filter (first time) and close the drain valve
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
14.2.10
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 238 of 275
Starter Motor
All these feeders are located in the respective Gas Turbine Generator MCC Switchboard
fed from the Emergency MCC.
The first GTG is brought into circuit by dead-bus closing of its 11 kV incomer breaker.
The incomer circuit breaker Close command in the GCP is routed through a PMS
Close permissive contact which will ensure that the NER of the first GTG that is being
brought into circuit is connected to the system, thus ensuring that the 11 kV system is
earthed.
On closing of the first GTG incomer breaker on to the HV switchboard, the 11 kV
system gets energized, and the 11 kV bus voltage, kW and current feedback along with
breaker status is available to the PMS and selectively to ICSS.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 239 of 275
Refer Section 5 of this manual and the vendor operating instruction manual for more
details.
14.2.11
Keep the degassing drum and the Produced Water tank to receive Produced Water
ready for operation
Line-up blanketing (LP Fuel gas) gas to methanol storage tank by taking
329-PCV-4905 on line
For top of level in methanol storage tank, unloading shall be done as detailed in
Section 11 above.
Check the methanol flow to methanol storage tank. Control the tank pressure
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
14.2.12
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 240 of 275
Ensure Glycol Storage Tank 305-T-001 is cleaned and ready to receive water
Ensure glycol make-up pump 305-P-002 and TEG drain pump 305-P-001A/S are
ready for start-up of the plant after shutdown
Start 305-P-002 from local pushbutton and check the discharge pressure at
305-PG-4905
to
regeneration section. Stop the pump once the desired quantity is transferred
14.2.13
Take the pressure control valve 302-PV-1132 on Manual and keep it closed
Keep the level control valves at condensate line and Produced Water are kept
closed on Manual
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 241 of 275
Control the separator pressure at 87 barg with 302-PV-1132. Stabilise the separator
pressure
Set the pressure controller 302-PIC-1132 to Auto. Continue flaring till stabilising the
operation of separator
Commission the condensate level transmitter 302-LIC-1119 and the local level
gauge 302-LG-1118; check that both show the same level
After the condensate level 302-LIC-1119 reaches 30% level, this would require the
following valves to be opened:
Pump safety valve 302-PSV-0135A should be car sealed in the open position.
At this time, the plant should have been purged free of air and leak tested to
operating pressures.
Start Early Operation condensate pump 302-P-002A and line-up one of the
Condensate Solid filters (302-F-001A) and Condensate Coalescer (302-F-002A). Take
305-LCV-1119 in Manual mode and keep it 20% open.
Note: Initial level of condensate can be lined to Closed Drain header and later when
the dry gas from Gas Dehydration Column meets specification, it can be pumped back
from Closed Drain Drum and Flare K.O Drum to Production Separator and avoid slug
accumulation in the GTP trunk line.
Line-up of Gas to Fuel Gas System
(Separator gas is lined up if gas from trunk line is not available).
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
Operations
Page 242 of 275
14.2.14
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
After the condensate level reaches the weir height of the Production Separator, the
condensate overflows to the condensate chamber in the production separator
302-V-001.
Line-up the suction valves of the condensate pumps 302-P-001A/B (LP Phase) or
302-P-002A/B (HP Phase).
After the condensate reaches the Level Low height of 610 mm on the condensate
side of the Production Separator, the ESD valve 302-XV-1102 is forced open and the
condensate flows to the suction side of the Condensate Pumps.
Line-up the Condensate Solid Filters (302-F-001A) first and pressure up the A-filter.
Check the differential filter 302-PDI-1144.
Check the condensate samples; once it meets the specification, it can be routed to
the GTP trunk line. If there is more delay in the Gas Dehydration and TEG
Regeneration system, condensate can be drained to the Closed Drain Drum.
The condensate flow controller 302-FIC-1182 can be kept in cascade with the
Production Separator Level Controller 302-LIC-1119.
14.2.15
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 243 of 275
Since the Compressor discharge side is depressurised and the antisurge valve is
opened, the compressor will be in depressurized condition and the start-up will be
like initial start-up
Check the availability of seal gas. Alternatively, use nitrogen as seal gas for the
compressor
Check the operation of antisurge valve 304-FCV-1212 and flare vent valve
304-PCV-1294 from the local control panel
Ensure healthiness of motor local control station, remote control panel, ESD panel,
compressor PLC system and VSD switchgear
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 244 of 275
Power up VSD and check the readiness of motor (Check that the interlock for startup is active). Refer operating instruction manual of the vendor
Ensure the pressure drop is less than 2 barg. 304-PDT-1206 automatically opens
ESD-V1200 and suction of the compressor is pressurized
Drain the condensate from compressor casing, pipe lines and KO drum
Starting of Compressor
Make sure that start-up interlocks have been released by the control system of the
compressor unit
Check for any alarms and healthiness of start-up system. In case of any
malfunction, or the start-up conditions are not achieved, take corrective action
and ensure Ready for Start is indicated in the panel
Ensure compressor discharge cooler fans are running and TCV1215 is on Auto mode
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 245 of 275
Check the speed, discharge pressure, lubrication and seal gas pressure, and
secondary seal gas pressure
Check the gas temperature at the discharge cooler outlet of first and second stages
Monitor the Air cooler outlet temperature and control at 60C by taking
304-TIC-1215 in Auto mode
Raise the speed of the compressor to 1200 rpm and check the compressor discharge
pressure at PI-1232
Set the discharge pressure at 87 barg and take the compressor operation on Auto
Mode
However, the speed of the compressor is controlled by the suction pressure of the
compressor (tank pressure)
PETRO-CANADA EBLA
PALMYRA B.V
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Unit : GGS
Operations
Page 246 of 275
Open 304-XV-1219 at the compressor discharge and allow the gas to Dehydration
Column
Once the compressor performance is established, change the selector switch (SW1)
in VSD to DCS position (or change the selector switch in motor LCS to DCS position)
Now the compressor control shall be taken over by compressor PLC in control room
Monitor the performance of the compressor from compressor PLC in control room
Once the compressor is loaded, the anti-surge and performance controllers will be
switched from SEQUENCE to AUTO
(In case of Settle-out Pressure (46.4 barg), the seal gas supply is supplied from the
HP Fuel Gas tapped from the downstream of Fuel Gas Heater (321-E-001A/B) to ensure
dry heated gas is supplied to Dry Gas Seals).
Refer operating instruction of vendor manual for more information.
14.2.16
Start-up of Gas-Dehydration
Ensure the Depressurization valve 305-XV-3000 is opened due to ESD-1 trip. Reset
305-XV-3000 is reset and kept closed.
Ensure the regeneration system and dehydration system have adequate level of
glycol
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 247 of 275
Ensure both reboiler and glycol surge drum are charged with glycol
Line-up one of the Glycol Circulation Pumps 305-P-003A/B. Open suction and
discharge valves of the pump 305-P-003A which is selected for use. Ensure the
block valves on exchangers 305-E-001, 305-E-002 and 305-E-004, and gas
dehydration column (305-C-001) are lined up (normally not closed during ESD1
shutdown)
Select Local Mode by pressing 305-MHS-3121B on the local panel and start the
pump 305-P-003A by pressing Start pushbutton 305-MHS-3121A. Check for the
Running indication 305-MIXI-3121 of 305-P-003A in the DCS Panel
Check the level in the glycol surge drum and maintain it if required by top-up (If
there is loss of glycol during shutdown)
Line-up one of the TEG Cartridge Filters (305-F-003A/B) and the TEG Carbon Filter
(305-F-002)
Put the level controller 305-LIC-3210 on Auto and return the rich TEG to the Still
Column (305-C-002) through 305-LV-3210. TEG will then flow down to the reboiler
by passing through the Pall Ring Packing in the still column
Keep the surge drum level by make-up of glycol. Check the level in reboiler and
surge drum. When the reboiler is full, the surge drum level will remain constant
and should be half-full with glycol. Stop filling the reboiler and close the 2 valve
on glycol make-up line
Check the temperature of glycol (fuel gas firing is stopped during shutdown)
Start the gas burner assembly for the TEG Reboiler can be started either from DCS
or from Local panel. Follow procedure as detailed under Section 12 above
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 248 of 275
When the Main Flame stabilization time is over and the burner start-up sequence is
completed, Burner On indication appears on local panel (305-XL-3156B) and on
DCS (305-BAH-3156A)
After performing the burner start-up, progressively increase the set point for
305-TIC-3109 up to 204C
Stripping gas flow can be started manually by opening the shutdown valve
305-XV-3171 on the stripping gas line and is allowed only if the burner is ON. Once
the burner is switched off, 305-XV-3171 will close automatically. After burner
restart, the valve has to be re-opened manually by first resetting in the Local panel
and open by operating the switch 305-XHS-3171A in DCS panel
Feeding the feed gas to the Gas Dehydration Column should be as smooth as possible
Increase the feed gas rate in steps of 25% of the maximum flow. As the process gas
feeds the internal Gas/Liquid separator of the Gas Dehydration Column, the water
droplets trapped will form a level at the bottom of the Contactor. When the level
is sufficient, the level control valve (305-LV-3013) can be put into service in Auto
with the Level Controller 305-LIC-3013
Continue routing dehydrated feed gas to HP Flare via 305-PCV-3024. Send gas
samples for analysis of water content. Slowly raise the gas feed rate up to 50% of
design gas feed rate
Coordinate with the Ash-Shaer Well head Personnel and maintain the choke valves
so as to maintain a pressure of 50 barg at the Gas Dehydration Column. Increase
the lean glycol flow to 4.5 m3/h
Collect samples at the outlet of the Gas Dehydration Column SC-502 to find out the
dew point and the water content of the dehydrated gas
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 249 of 275
Line-up Reflux Condenser. The normal top operating temperature of the Reflux
Condenser will depend on the condensation temperature of the vapours. This
temperature is set at 9398C depending upon the amount of hydrocarbon
Monitor the pressure drop across the filter. The pressure differential across the
filter is readable on DCS by 305-PDT-3216/3122 for cartridge filters and 305-PDT3218 for carbon filter. When the differential pressure is 1 bar, then the Standby
filter is taken into service
Coordinate with the Well heads to open the choke valves so that the pressure of
87 bara is maintained at the top of the gas dehydration column. Maintain the
injection flow rates of methanol and corrosion inhibitor as per the design flow of
the multiphase gas flow
Adjust the flow and temperature of lean glycol as per the increase of the gas feed
rate in the gas dehydration column. Maintain the lean TEG temperature 5C above
the wet gas entering the gas dehydration column
Start the injection of antifoam and the corrosion inhibitor to various points in the
TEG regeneration system
Stabilise the TEG regeneration system with temperatures and flows optimised for
efficient operation of the gas dehydration system
Check two or more samples to confirm the water content of the dry gas and
condensate
After the condensate and the dry gas meet the specifications, route both to the
GTP trunk line
Start the TEG Incinerator manually from the field by operator by means of the
push-button HS-6052B or from DCS by pressing HS-6052A, and enable sequential
start-up of the incinerator. Refer Section 12 above for more details
Once the burner is in operation, the next step is to increase the combustion
chamber temperature up to the minimum value for off-gas injection (pre-heating
of the incinerator). A temperature ramp-up control gradually heats up the
combustion chamber over a time period (to prevent thermal shock of the
refractory due to full burner output when refractory is cold)
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
14.2.17
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 250 of 275
Ensure to line-up blanketing gas (fuel gas) to degassing drum and Produced Water
storage tank
Ensure water separation in Production Separator 302-V-001 and the level controller
302-LIC-1114 is lined up to 334-V-001
Set the level controller 334-LIC-3441 at 50% and take it on Auto. Check flow of
water to 334-T-001
Skim off HC condensate manually to Closed Drain by monitoring the interface level
at 334-LI-5400
The separated water from the Produced Water tank is disposed off to tankers using
Produced Water disposal pumps 334-P-001A/S
Open pressure control valve 305-PV-3009B and charge the gas up to 305-XV-3004
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
14.3
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 251 of 275
ESD-2 will close choke valve and isolate process vessels in boxed up condition.
Restart-up of GGS
1.
2.
3.
4.
5.
6.
7.
8.
Reset choke valve at Well head and line-up flow lines as detailed in Section 11
above.
9.
Production separator
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 252 of 275
Condensate system
GTP pipeline
2.
Line-up choke valve in Well head and allow well fluid to manifold.
3.
4.
5.
Flare the gas till the compressor is taken on line (LP Mode Operation).
6.
7.
8.
9.
Start-up of Field Gas compressor: During the ESD-3 shutdown, when the Field Gas
Compressor is tripped, the antisurge valves are opened immediately. The
Compressor will be blocked in and will remain pressurized at settle out conditions.
Open external seal gas will be lined up to maintain seal gas flow. Start Field Gas
Compressor as detailed in Section 11 above.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 253 of 275
The black start-up of GGS is similar to ESD1 shutdown. The power for start-up is made
available by starting Emergency Diesel Generator with diesel. The supply is given to
MCC for utilities and emergency supply panel. Assuming the EDG is supplied by the
battery system and the auxiliary can be started, the procedure shown on the following
page shall be adopted for start-up (Fig. 15).
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 254 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 255 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 256 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 257 of 275
Production Separator
Sr.
No.
1
Problem
Indications
Higher pressure
indication at
302-PAH-1110
Low pressure
indication as
indicated by the
Pressure alarm
302-PAL-1110
High level
indication as
indicated by the
High level alarm
302-LAH-1110
Diagnosis
Control Action
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
Sr.
No.
4
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Problem
Indications
Low level
indication as
indicated by the
High level alarm
302-LAL-1110
Operations
Page 258 of 275
Diagnosis
Control Action
High Interface
level indication
as indicated by
the High level
alarm
302-LAL-1110
valves.
Check whether the drain valves in the oily
water compartment are opened inadvertently.
Check the functioning of the control valves
(and controller wiring) in the oil outlet line
and ensure that they are not stuck open.
Check the flow rate of Condensate from the
separator, if it is much below the design flow,
increase the number of Well connections if
possible
Check whether the down stream SDV valves are
closed due to trip signals.
Check the functioning of the control valves
(and controller wiring) in the oily water outlet
line and ensure that they are not stuck closed
due to failure of instrument air tubing.
Check whether the drain valves in the
separator are opened inadvertently.
Check the functioning of the control valves
(and controller wiring) in the oily water outlet
line and ensure that they are not stuck open.
In case the water cut of the oil is very low, the
separators can be operated as 2 phase
separators.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 259 of 275
Glycol Losses
Sr.
No.
1
Problem
Indications
Frequent top up of
lean Glycol from
TEG tank
305-LV-3210 MV
gradually
increasing
Excessive gas velocity
due to increased gas
feed rate
Excessive collection
of Glycol in the
Glycol Vent Gas K.O.
drum (305-V-003)
Differential pressure
305-PDI-3007 is on
the higher side
Vaporization Losses
from Glycol Reflux
Condenser
Excessive
gas
velocity due to
increased gas feed
rate
Differential
pressure
Diagnosis
Control Action
Still
Column
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
Sr.
No.
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Problem
Mechanical leaks
Indications
305-PDI-3104 is on
the higher side
Lot of Glycol dripping
from the Glycol pump
(305-P-003A) glands
Abnormal opening of
the Condensate tank
LCV 305-LCV-3206
control valve
Frequent top up of
lean Glycol from
TEG tank
The inlet to Gas
Dehydration
Column is around
7C during the HP
cases.
Low Pressure in Gas Dehydration Column
1
Low Pressure in the
Low
pressure
Gas Dehydration
alarm from 305Column
PAL-3012
High flow alarm in
the Flare header
331-FAH-5126
8
Operations
Page 260 of 275
Diagnosis
Control Action
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
Sr.
No.
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Problem
Indications
Operations
Page 261 of 275
Diagnosis
Control Action
305-PV-3009A/B
High Water Content in the Treated Gas Outlet
Sr.
No.
1
Problem
Indications
Diagnosis
Excessive leakage
from Glycol Pump
Plunger glands
Insufficient
Concentration of
Glycol
Control Action
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
Sr.
No.
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Problem
Indications
Poor Glycol
distribution
Operating conditions
different from design
conditions
Operations
Page 262 of 275
Diagnosis
analysing dry Glycol sample
Check stripping gas rate
The dry gas outlet analyser
showing high value even though
correct Glycol circulation rate
and correct concentration is
maintained
Adjust the process variable to
find improvement in the dry gas
outlet
Control Action
Indications
325-PALL-4733 sounds
alarm
Diagnosis
Control Action
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
Sr.
No.
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Problem
Nitrogen
O2 more than 2% in
1
nitrogen product
Indications
Operations
Page 263 of 275
Diagnosis
Control Action
Check Regeneration
temperature/Heater
Check passing of 3 way valve
Check regeneration cycle
Higher pressure
drop/Channelling due to
deterioration of molecular
sieve
O2 analyser
324-AI-4819 indication
Cleaning of membrane
Calibrate analyser
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
16.0 SHUTDOWN
Operations
Page 264 of 275
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
16.1
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 265 of 275
PLANNED SHUTDOWN
Initial Status
Condensate and gas system is running and operating conditions of all equipment
are within limits.
Productions from all seven gas fields of Ash-Shaer are on and running at normal
rates.
The dry gas from the Gas Dehydration column is meeting the specifications and
the TEG Regeneration system is working normally.
All chemical injection systems are working normal and the chemicals are
injected at specified rates.
The gas and the condensate are mixed together and sent to GTP through the
trunk line.
Unit Shutdown
There are many local conditions within GGS that will shutdown particular process
equipment or whole of the Plant Equipment in GGS due to Process or Utility
outages as defined on the Cause & Effect diagrams Doc No: 250-EPR-CNE-05001
(High or low levels, pressures, temperatures, etc,.). In some cases like suction
filter choking or pump problem, the absence of spare unit will lead to shutdown.
Normal Shutdown of Production Seperator
As the shutdown is a planned one, the Operator will plan in advance the steps
involved in the normal Shutdown of the Production Seperator.
Inform the GTP Unit, Wellheads, Glycol Dehydration Unit and the TEG
Dehydration unit about the shutdown of the Production Seperator.
Reduce the capacities of the Producing wells by closing the Choke valves slowly
till the turndown capacity.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 266 of 275
components. The vessels are damped from a water source to avoid pyrophoric
iron burning. Naturally Occurring Radioactive Material (NORM) and Low Specific
Activity (LSA) Scale can appear during the drilling and process phases of Oil and
Gas exploration and production and tend to deposit along with other scale. Low
Specific Activity scale (LSA) which are found adhering to pipe and equipment
internals produce potential radiation illness mainly due to Radium-226
produced from the decay of naturally occurring Uranium-238. Hence
Radioactive Detection and PPEs for protection against potential radiation illness
should be used. The waste removed from Condensate storage/Produced water
storage tanks/catridge filter should be disposed off at locations specifically
marked/designated as Waste holdup/storage area. The Waste disposal area
shall be clearly fenced, marked and identified with safety tags/boards
indicating warnings/dangers due to radioactive substances.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 267 of 275
If the shutdown period is of longer duration, then the glycol contained in the Gas
Dehydration Column should be collected in the bottom head and evacuated under
level control to the flash drum and then to the surge drum where the glycol will be
built-up.
The glycol regeneration package and the gas dehydration column are now in a
standby condition, levels and pressures are still maintained close to the operating
conditions and if required, the unit start-up can be carried out immediately from
this condition.
If the standby period will be of longer duration, then it is necessary to proceed as
follows:
o
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 268 of 275
A spare tube bundle availability helps in quick start-up of the Gas Dehydration
plant in case of any leak
Provide isolation and bypass valves for both shell and tube side.
Note: During winter period (when the ambient temperature falls below 15C),
drain the column bottom and condensate outlet pipeline to column bottom, in
order to avoid liquid freezing. In case of longer shutdown during winter, glycol also
need to be drained for non- traced lines in order to avoid freezing due to the lower
ambient temperatures
(15C) and TEG freezing temperature of 7C.
Normal Shutdown of Field Gas Compressor
As the Field Gas Compressor boosts the pressure to 87 barg before the introduction
to Gas Dehydration column the feed rate reduction has to be done in steps upto
the turndown feed rate.
Inform the GTP Unit, Wellheads, Glycol Dehydration Unit and the TEG
Dehydration unit about shutdown of the Field Gas Compressor.
Reduce the capacities of the Producing wells by closing the Choke valves slowly
till the turndown capacity.
The Antisurge valves open automatically when the flow rates are reduced.
After the turndown of the Gas Dehydration column, the Field gas Compressor
can be tripped or can be kept running in recycle mode if it is a shorter
shutdown duration.
16.2
EMERGENCY SHUTDOWN
ESD systems will function to isolate inventory entering or exiting plant facilities, to
remove heat input to heaters and reboilers and stop associated rotating
equipment; this is necessary to ensure safe operation. A separate ESD system is
provided at each location i.e. at Well heads, GGS and GTP. While each system
operates independently, certain emergency situations at one site will activate a
shutdown at other location also. The emergency shutdown systems at GGS will
operate on three hierarchical levels. A shutdown at one level will typically cascade
to initiate shutdowns at the next level.
The ESD levels adopted for the facilities are as follows:
o
ESD Level-1 shutdown: ESD Level-1 shutdown will open all the
depressurizing valves at the same time.
ESD
Level-2
shutdown:
ESD
Level-2
shutdown
will
enable
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
o
Operations
Page 269 of 275
16.2.1
ESD Level-1 represents the highest level of emergency that may occur at the
facility. A confirmed fire at the GGS or any Plant emergency justifies manual
initiation. ESD Level-1 will shutdown and depressurize the process facilities.
ESD level-1 is initiated by the following:
o
Manually by an authorised Operator in the control room or gate house (GGS and
GTP)
Automatically via the F&G system on 10% LEL confirmed gas detection in the
HVAC inlet of the control room and substation of GGS.
Confirmed fire at the GGS will initiate ESD Level-1 at GGS due to extended
periods of unattended operation.
Confirmed high level gas detection (20% LEL) at the utilities area of GGS. This
represents the highest level ESD at the installations as these will trip the
Emergency Generator.
Close the GGS Well head chokes, GGS remains live with Compressors on recycle
for ESD level-1 at GTP
Opens all EDP (Emergency Depressurizing) valves after a time delay of 1 minute
to allow all XVs to close on ESD Level-1 at GGS. The system will enable the
CR/CCR Operators to over-ride the blowdown signal once initiated. This will be
achieved by normalizing the ESD Level-1 initiator and pressing the ESD Level-1
Reset button.
ESD Level-1 at the GTP will automatically initiate an ESD Level-2 shutdown at
the GGS via the fibre-optic link which will ramp close choke valves at Well
head. ESD Level-1 or ESD Level-2 at GGS will result in an alarm at GTP.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 270 of 275
AT GGS Automatically, on fuel gas KO drum Low Low pressure. All other fuel
gas ESD level-3 (like High High level and Low Low temperature) will switch
the main power generator to diesel operation. This takes 40-60 seconds but is
assumed not to be possible on fuel gas Low Low pressure. After successful
automatic change over of GTP to diesel operation, the ESD Level-2 shut down
can be RESET after over riding Low Low fuel gas KOD pressure.
AT GTP Automatically, on the fuel gas KOD pressure High High pressure, Low
Low pressure, High High liquid level, Low Low temperature will cause ESD
Level- 2.
20% LEL confirmed gas detection in the process area at GGS & GTP.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
o
Operations
Page 271 of 275
Confirmed 20% LEL gas in the generator area will trip or inhibit start
of the Main or Emergency Generators (for GGS & GTP)
Switch Main Power Generation to diesel and start the Emergency Power
Generator at GGS
Maintain fuel gas supply to the main generators by opening the buy-back fuel
gas XV at GTP.
Trip the main power generators only on low Instrument air pressure (loss of
control)
Start the Emergency Generator (except in case of 20% LEL gas in generator
area).
On Confirmed fire at the GTP or low pressure in the Firewater Ring Main, start
Fire Water Pumps (via the F&G system)
On GGS ESD Level 2 initiated by pipeline Low Low pressure, isolate 701-XV-3150
on the incoming trunk line at GTP to isolate the pipeline at both ends.
ESD Level 2 at either the GGS or the GTP will result in an alarm at the other
site.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
o
Operations
Page 272 of 275
The shutdown of a unit affected by an ESD-3 shutdown of another unit may not
occur automatically in all cases, some cascaded shutdowns may be permitted to
give the operators time to reset a unit upset condition before a plant wide trip is
initiated. An ESD-3 typically involves isolating the inlet and outlet hydrocarbon
streams to a unit via dedicated XVs and stopping input of heat energy. Emergency
shutdown isolation for non-hydrocarbon services shall be designed on a case by
case basis.
For pumped systems, a Low Low level trip will be provided on the suction vessel in
order to protect the pump from damage due to dry-running, regardless of the
system volume of fluid contained. The trip will stop/inhibit the pump (s) and close
XVs in the suction and/or discharge lines where provided. On mechanical seal
failure the operating pump should trip and Auto start stand-by pump (case by case
basis).
Pumps which are essential for the continuous operation of the plant will have
standby and will be provided with Auto-start facility for the standby pump. Lowlow discharge pressure trips operating pump and allow Auto start of stand-by pump
if Low Low pressure persists, it will trip both pumps.
Low-Low nitrogen pressure at compressors (nitrogen typically provides a final
barrier against gas leaks from the seals) will shutdown and EDP the compressor
concerned. Where possible, the remainder of the plant will be kept live and/or
operating in recycle mode.
ESD Level-3 Stoppages at GGS
There are several major system ESD Level-3 shutdowns at the GGS which will cause
loss of gas export from the plant due to isolating of the inlet or outlet XVs or which
trip the Field Gas Compressors. These are:
o
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 273 of 275
Well heads will be isolated by closing the chokes to avoid excessive flaring at
the GGS.
The remainder of the plant will remain live and, where possible, the Field
Gas compressors will continue to run on recycle mode via the anti-surge
recycle loop.
Emergency Shutdown
In the event of a complete unit shutdown, the sequence shall be as follows:
o
Stop the Burner. See Burner stop and sequence from the Vendor manual.
Planned Shutdown
Adjust Choke valve in the oil production Well heads for a reduced rate of
production and stop production from Wells one by one. Always gradually,
bring down the production rates.
The field operator should check the levels in Production Separator, Gas
Dehydration, TEG Regeneration and Condensate system.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 274 of 275
At the reduced rate of production, ensure that the Condensate and Gas
Dehydration systems equipment are operating in normal conditions, without
any abnormalities.
Reduce the chemical injection to required rates in the Well heads and the Gas
Dehydration/TEG Regeneration system. Further reduce the flow rate from the
production Well heads to Production separator. Monitor the operation of the
equipment in Condensate system.
The control room operator and field operator should co-ordinate effectively for
the shut down of the plant.
Ensure that all the equipment is running, without any abnormalities, in reduced
load condition. Further caution the GTP unit that the Gas/Condensate export
will be stopped.
Shut down the oil producing Wells and close their respective choke valves.
Levels in the Production Separator and Condensate system will reduce. Reduce
the level set points in Separators to the minimum acceptable levels such that
enough free volume will be available during restart.
For the Gas Dehydration system, refer Shutdown of Gas Dehydration system.
16.3
The drainage system shall be designed to allow disposal of liquid inventory in a safe
and environmentally acceptable manner.
Drain systems shall be designed to ensure proper handling of any contaminants that
may accidentally enter the system due to spillages or in advertent operations.
The drain systems that may be provided at each plant are described below:
Closed Drain (CD)
A Closed drain system is provided to receive hydrocarbon liquids drained from
process equipment prior to maintenance. Aqueous and hydrocarbon draining will be
segregated. Equipment drainings that are predominantly water will be run down to
Accidentally Oily Sewer/Open drain.
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 275 of 275
The Closed drain system will comprise a hard piped collection system with drain
liquids flowing by gravity to a Closed Drain Drum (Located in a Sump). Also the
Closed Drain drum is equipped with Electric heater to prevent icing/freezing. The
drum is designed to receive the largest single inventory to be drained. Collected
liquids will be pumped away with vapour in-breathing and out-breathing will be via
a vent line to the flare system. The system design pressure will be set to match
flare system. Liquids collected in the Closed Drain Drum will be pumped to Flare
KOD in GGS.
Hazop Action No. 360
The Closed system will be positively isolated from the process by closing of valves
at equipment during normal operation. The draining to Closed Drain drum is done
one equipment at a time to have a better control and draining so as to avoid
overflow of Closed Drain Drum. At any time, two equipments will not be drained
simultaneously. Draining of more than one equipment may lead to liquid build-up in
Closed drain drum and liquid carryover to the Flare header which is undesirable.
Hence proper coordination should be planned in advance regarding the draining of
liquids from equipments during shutdown.
Where equipment is connected to a Closed Drain System for draining prior to
Maintenance or inspection positive isolation for e.g. a spectacle blind will be
provided between the equipment and the drain. The drain will be positively
isolated during normal operation and the draining will be performed after
shutdown and depressurization of the equipment item. The only exception is
draining of Oil pad from Produced Water storage Tank (334-T-001) and
contaminated water storage tank (834-T-001) at GTP. Pressurized draining will be
allowed during start-up like draining of Compressor casing drains. For drains which
need to be used under normal operation like level instruments/bridle drains, the
spectacle blind is left in open position and operators will turn it closed as and when
required for equipment isolation. Consequently intermittent drainage required
during normal operation will be returned to the process.
Chemical Sewer
Injection chemicals such as methanol etc are present at the EBLA Gas Project
facilities in sufficient quantities to justify a dedicated chemical sewer. Storage
facilities will be bunded or kerbed to ensure containment of spills; spills inside
these areas will be collected in local pit and pumped out to drums. Chemical spills
outside containment areas will be dealt with by use of an appropriate absorbent.
TEG Drain System
TEG drain system is provided for collecting drain from TEG Regeneration system.
The system is comprised of a hard piped collection system with drain liquid flowing
by gravity to a TEG sump drum. The drum will be sized for hold-up of the entire
TEG inventory. Vapour out breathing will be through vent line to flare and pressure
relief will be discharged to flare. The system design pressure will be set to match
the Flare system.
The TEG drain system will be positively isolated from the process during normal
operation (only exception is drain connection for level instrument/bridle). Draining
will only be performed after shutdown, depressurization and cooling of the
PETRO-CANADA EBLA
PALMYRA B.V
Unit : GGS
00180-PCP-300-PDMan-12503-01
GGS Operating Manual Vol #1
Operations
Page 276 of 275
equipment item. The drain system will be positively isolated from the equipment
before the item is returned to service.
If the shutdown period is for longer duration, the glycol is collected in the Chimney
tray of Glycol contactor and transferred under level control to Flash drum and then
to Surge drum. If the shutdown involves repair work or Maintenance in the
Regeneration package, then it becomes necessary to isolate the equipment from
the rest of the system, drain and depressurize it.
Hazop Action No. 961
When the Gas Dehydration Plant is shutdown for longer periods during winter, then
TEG needs to be cooled sufficiently and drained to TEG Drain vessel.
Draining Hot TEG above 60C will damage drain piping and also hazardous for
handling.
Hence circulate TEG by the Glycol circulation pumps through Glycol Cooler.
Bring down the temperature below 60C and transfer to storage.
Drain liquid from vessels to TEG Drain drum and pump to storage.