Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

6 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

The produced liquids from the wellpads are cooled and diluent is added to assist with the
oil/water separation. The diluent and bitumen mixture (dilbit) is separated from the
produced water in one stage of gravity separation.
The Process Flow Diagrams are shown in Section 10 and the P&IDs are shown in
Section 11. The Material balances are shown in Section 9.

2.0

INLET FACILITIES AND OIL TREATING

2.1

PURPOSE AND SCOPE

The Inlet Facilities and Oil Treating facilities comprise the Inlet Separator,
Emulsion/BFW exchangers Emulsion trim coolers, the FWKO, Produced Water Coolers
and Treaters. The Hydrocarbon Tank Farm and VRU are also included in this section.
The Inlet facility provides means to separate flashed gases (in turn reduce diluent loss in
FWKO), control production of Emulsions from PADS, and maximize heat exchange with
BFW and desanding.
Reference Drawings for Inlet Facilities:
KBP-01-221-0001 Process Flow Diagram Emulsion Treating
KBP-01-220-8101 P&ID Main Pipe Rack / South B/L Process Interface
KBP-01-220-1101 P&ID Emulsion Production Inlet Header
KBP-01-220-1102 P&ID Inlet Separator
KBP-01-220-1103 P&ID Emulsion/BFW Exchanger
KBP-01-220-1104 P&ID Emulsion Trim Exchanger

2.2

PROCESS DESIGN BASIS

1-V-100 Inlet Separator
Parameter
Bitumen
SOR (dry)
Excess Produced water
Operating pressure
Operating Temperature

Design basis
6280 m3/d
3.0
0% (normal) and 10% (upsets)
2350 3000 kPag
208 -230 C

Remarks
Note 1

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

7 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

1-E-110/115 Emulsion/BFW Exchangers

Parameter
Emulsion inlet temperature
Emulsion outlet temperature
Emulsion outlet temperature
BFW inlet temperature
BFW outlet temperature

Design Basis
208 C
135 C
>140 C
92 C
187 C

Remarks
Normal condition
At normal condition.
At above 215C and upsets.
Normal Condition

1-E-120/121 Emulsion/ Glycol Exchangers

Parameter
Emulsion outlet temperature

Design Basis
135 C

Glycol outlet temperature

110C

Remarks
Normally, minimal cooling at
normal condition. Exchanger
designed for 10C cooling at
design throughput.

Notes: Plant turndown is 40% of total feed for inlet facility. .

2.3

PROCESS DESCRIPTION AND CONTROL

Produced emulsions from well pads will enter the Central Processing Facility (CPF).
Produced emulsions from PADS flow through the Emulsion Pipeline back pressure
control valve 1LV1000D before it enters the two-phase Inlet Separator 1-V-100 for
removal of any flashed vapours. Flashed vapours are routed to the produced gas system
where it is cooled and sent to the fuel gas system.
Inlet Separator is fitted an inlet deflector for primary separation of gas from liquids. An
internal weir provides means for utilizing Merpro desanding facility for removal of
bitumen-coated sands, clay and dirt in the produced emulsions. (Note: Desanding
internals is installed but external pipework is not installed). Frequency of desanding in
the Inlet Separator depends on detecting the sand using GWR and nuclear level
instrument in the FWKO.
The hot produced emulsions flows to 2 series x 3 parallel Emulsion/BFW exchangers 1E-110/115 to exchange heat with the BFW. Any excess produced emulsion temperature
is further cooled in the Emulsion Trim Coolers 1-E-120/121 exchanging heat with cooled
glycol before it is routed to the FWKO drum.

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

8 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

The intention of emulsion temperature control is to maximize heat recovery of produced

emulsions into the BFW whilst maintaining optimum emulsion temperature of 135C inlet
to the FWKO. Excess of cooling of produced emulsions is restricted by opening the BFW
bypass control valve. Also, over- heating of BFW temperature is controlled by opening
the BFW bypass control valve. Emulsion breaker chemical is injected at inlet of the
Emulsion/BFW exchangers to enhance water and oil separation.
Due to mechanical limitation, one set of Emulsion/BFW exchangers (1 X 3) can cool
70% of plant production. Emulsion/glycol coolers can cool produced emulsions by 10C
at design plant production rates.
Normally, minimal or no heating is required by the Emulsion trim coolers. However, at
high energy case Emulsion inlet temperature (215- 220 C), BFW upset scenarios and
a steam generator shutdown the Emulsion trim coolers will provide additional cooling.
During Inlet Separator bypass operation, one set of Emulsion/BFW and Emulsion trim
cooler are adequate to handle 40% production through a 14 bypass across the Inlet
Separator.
Inlet facility is designed for 3500 kPag / FV and 260C. The equipment in the Inlet
Facility is protected by a PSV set at 3500 kPag for fire case.
The Emulsion pipeline pressure control 8PC-8000 will normally control the pipeline back
pressure control valve 1LV-1000D to maintain the back pressure on the inlet emulsion
pipeline to keep the emulsion in the liquid phase.
The pressure in the Inlet Separator is maintained slightly below the pipeline back
pressure control by 1PC1020D to flash off the non-condensable gases by lowering it by
a small margin. Any increase in Inlet Separator pressure will first open 1PC1020D to
relieve excess pressure. Any further increase in pressure in the Inlet Separator 1-V-100,
1PC1020E will throttle 1LV1000D through a low select. Decrease in pressure in the Inlet
Separator 1-V-100, 1PC1020D will first force close 1PV1020D to restore the pressure.
Any further loss in pressure, the blanket gas pressure control 1PC1020C will partially
compensate to allow blanket gas flow in to the Inlet Separator. Depending on the
operating pressure of the Inlet Separator the set points of pressure controllers are
adjusted retaining the same set point margin.
The basic principle of level control is to maintain level in the Inlet Separator. Any further
increase in level in the Inlet Separator 1LC1000D will cut back feed by throttling the
pipeline back pressure control valve 1LV1000D through a low select...

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

9 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

When the Inlet separator 1-V-100 is bypassed for maintenance, the production of inlet
emulsion is reduced to 40% of plant throughput. Inlet emulsion is routed to
Emulsion/BFW exchangers for cooling the emulsion. Selector switch 1PY-1020A shall
select 1PC1050 which will act as a constraint control the pipeline back pressure control
valve 1LV-1000D through a low select 1LY100D. The pressure controllers 1PC1020C,
1PC1020D, 1PC1020E and level controllers 1LC1000C and 1LC1000D are bypassed.
The Inlet Separator has a temperature indicator (1TI1010) with high and low temperature
alarms at DCS. Local temperature gauge is also provided on the vessel.
Emulsion temperature is maintained at an optimum temperature downstream of
Emulsion/BFW coolers by opening the BFW bypass control valve 1TV1131A. Loss of
BFW will cause a substantial increase in emulsion temperature which will result in feed
via inlet separator level control. Overheating of BFW is avoided by opening the BFW
bypass control valve.
Fouling of Emulsion/BFW exchangers is likely, so therefore, regular monitoring of
differential pressure 1PDI1105/1135 is required. Any imbalance in pressure differential
across the exchanger banks will lead to mal-distribution of flows across the two
exchanger banks and will lead to reduced cooling.
The temperature of dilbit inlet to FWKO is controlled at 135C using Emulsion/trim
coolers which use cold glycol for cooling. During upsets, high dilbit temperature inlet to
FWKO 1TC1205B will cut back feed by closing inlet separator level control valve
1LV1000D.
2.4

FREE WATER KNOCK-OUT DRUM (FWKO 1-V-130)

Reference Drawings:

KBP-01-221-0001 Emulsion Treating

KBP-01-221-0005 FWKO Inlet Header

KBP-01-220-1106 Free Water Knockout Drum

The cooled produced emulsion from Emulsion Trim Cooler (1-E-120/121) mixes with
diluent and chemicals (Invert Emulsion Polymer (IEP), Emulsion Breaker (EB) and
Reverse Emulsion Breaker (REB)) through FWKO Mixer (1-M-125) with the following
chemical dosing rate (info from BAKER HUGHES):

EB:

Polymer: 5 ppm based on the water fraction in the emulsion;

200 ppm based on the oil fraction in the emulsion;

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

10 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

REB : 50 ppm based on the water fraction in the emulsion.

Injected diluent to bitumen ratio is 0.22 for approximately 17 API in the hydrocarbon
phase. Diluted emulsion then enters the free-water knockout drum (FWKO, 1-V-130),
which is a 4572 mm OD by 24384 mm S/S horizontal vessel normally operating at 930
kPag and 130 C. The FWKO drum is designed to remove the bulk of the produced
water from the inlet emulsion by providing the required hold up and gravity separation.
Separation depends on viscosity, interfacial tension, and density differences between
the oil phase and the water phase. Injected chemicals and diluent enhance oil/water
separation. Produced water leaving the bottom of the vessel will typically contain less
than 2000 ppm oil. Higher oil content could upset the produced water deoiling system.
The oil emulsion leaving the FWKO is expected to contain finely dispersed water at a
concentration of about 5 to 20%.
FWKO normal pressure is maintained by pressure controller 1PC1302C which provides
blanket gas make up (1PV1302C) and pressure controller 1PC1302D which vents
produced gas (1PV1302D) to the Diluent Recovery System. During normal steady-state
operation, there will be little or no make up or vent flows. High and low pressure alarms
are provided to warn if the operating ranges have been exceeded. A separate high-high
pressure shutdown is triggered before the pressure safety valves lift. When triggered,
emulsion feed and fuel gas make up to the FWKO are shut down (close 1XV1290 and
shut down pumps prior to 1XV1290, close 1PV1302C).
The FWKO has a DCS temperature indicator (1TI1300) with high and low temperature
alarms. Local temperature gauges are also provided at various locations on the vessel.
The output of 1-V-130 oil level controller (1LC1301) controls the Treater inlet flow
controllers (1FC1600 and 1FC1700) in CASCADE mode. High-high and low-low level
shutdowns are provided on 1LC1301. On high-high level shutdown, emulsion feed is
shut off (close 1XV1290 and shut down pumps prior to 1XV1290), which prevents the
FWKO from flooding. The low-low level fully closes 1FV1400/1600/1700.
The water/oil interface level in the FWKO is controlled (1LC1300) over the design
operating range using one nuclear and one guided wave radar (GWR) level transmitters.
High-high and low-low level shutdowns are provided on 1LC1300. On high-high level
shutdown, emulsion feed is shut off (close 1XV1290 and shut down pumps prior to
1XV1290), which prevents high water content emulsion flowing to the Treater. The lowlow level fully closes 1LV1300C.
Details of pressure and level HH & LL interlocks refer to Cause & Effects Diagram KBP01-284-1101/1102/1103 and KBP-04-284-4101.

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

11 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

A manual interface draw off system is provided on the FWKO to enable removal of
stable emulsions that accumulate at the oil / water interface. These stable emulsions,
often referred to as rag layer, can hinder oil / water separation. Two connections are
provided along the vessel to allow removal of the rag layer. Decanted rag emulsion is
routed to the slop system for further processing. Draining of rag layer has to be a
controlled operation by cracking open the globe valve so as not to overload the Wet
VRU compressors capacity.
Two PSVs protect the FWKO from over-pressure from fire. Fire case is the governing
case used to size these relief valves. Car sealed block valves, upstream and
downstream of the PSV, allow the relief valves to be serviced with the vessel in
operation.
A manual desanding system with provision for changing to automatic is provided for the
removal of sand and sludge in the FWKO.
Eight (8) sample connections are provided on the FWKO. These connections allow
operators to monitor ongoing operation as well as establish operating profiles over the
vessel height and length. All samples are routed to a sample station.
2.5
2.5.1

TREATERS (1-V-160/170)
Normal Operation
Reference Drawings:

KBP-01-221-0001 Emulsion Treating

KBP-01-220-1109 Treater Feed Header

KBP-01-220-1110 Treater

KBP-01-220-1111 Treater

The Treaters (1-V-160/170) are 3048 mm OD by 13764 mm S/S operating at

approximately 830 kPag and 120C. Each Treater is designed to accommodate 50% of
the emulsion output from FWKO vessel. Emulsion from the FWKO is blended with
additional diluent, EB (50 ppm based on oil fraction in emulsion) and REB (50 ppm
based on water fraction in emulsion) through Treater Mixer (1-M-140). Electrostatic grids
are also provided in each Treater to allow for enhanced oil-water separation. The vessel
separates the inlet emulsion into an overhead vapour stream, produced water with
normally less than 1000 mg/l of dispersed oil and Dilbit with less than 0.5% basic
sediment and water (BS&W).

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

12 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

The Treaters produced water is blended with the FWKO produced water downstream of
the produced water coolers and transferred to the Skim Tanks. The Dilbit mixture is
flashed across the outlet flow control valve before entering Gas Boot 1-V-190. The
vapour stream leaving the Treater is combined with the produced gas from the FWKO
and flashed vapor from Gas Boot then piped to Diluent Recovery System. The Treaters
are also equipped with three (3) manual interface draw-off connections for rag layer
removal. This process stream is combined with the interface draw-off from the FWKO
and is conveyed to the Slop Oil Tank for further treatment.
Nominal operating pressure in the Treaters is maintained by pressure controller
1PC1601C (for 1-V-160) & 1PC1701C (for 1-V-170) which provide blanket gas make up
(1PV1601C for 1-V-160, 1PV1701C for 1-V-170) and pressure controller 1PC1601D (for
1-V-160) & 1PC1701D (for 1-V-170) which vents produced gas (1PV1601D for 1-V-160,
1PV1701D for 1-V-170) to Diluent Recovery System. During normal steady-state
operation there will be little or no make up or vent flows.
Total liquid level in the de-gassing compartment of the Treater is controlled by 1LC1600,
which receives signals from one GWR level transmitter. High-high and low-low level
shutdowns are provided on 1LC1600.
The water/oil interface level in the de-gassing compartment of the Treater is controlled
by 1LC1601A, which receives signals from one nuclear and one GWR level transmitter.
High-high and low-low level shutdowns are provided on 1LC1601A.
The water/oil interface level in the electrostatic grid compartment of the Treater is
controlled by 1LC1603, which receives signals from two GWR level transmitters. Highhigh and low-low level shutdowns are provided on 1LC1603 as well.
For details of the pressure and level HH & LL interlocks refer to Cause & Effects
Diagram KBP-01-284-1101/1102/1103 and KBP-04-284-4101.
A manual desanding system with provision changing to automatic is provided for the
removal of sand and sludge in each Treater.
Two PSVs protect each Treater from over-pressure from fire. Fire case is the governing
case used to size these relief valves (Blocked outlet case has been eliminated, because
pressure increase in the Treaters will cause pressure in the FWKO to rise up to HH and
cut of emulsion production to plant). Car sealed block valves, upstream and downstream
of the PSV, allow the relief valve to be serviced with the vessel in operation.

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

13 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

Eighteen (18) sample connections are provided on each Treater. These connections
allow operators to monitor ongoing operation as well as establish operating profiles over
the vessel height and length. All samples are routed to a sample station.
2.5.2

FWKO By-pass Operation

In FWKO by-pass operation mode, plant will be operated at about 25-35% turndown and
only one Treater is online, and some control valves will be manually closed according to
the table below:
Treater on line

1-V-160

1-V-170

Valve to be closed
1LV1603
1LV1601A
1FV1700
1LV1700
1LV1701A
1LV1703
1PV1701C
1PV1701D
1FV1400
1LV1703
1LV1701A
1FV1600
1LV1600
1LV1601A
1LV1603
1PV1601C
1PV1601D
1FV1400

The cooled produced emulsion from Emulsion Trim Cooler (1-E-120/121) mixes with
diluent (supplied through 1FV1250, 1FV1400 will be fully closed in FWKO by-pass
operation), Invert Emulsion Polymer, Emulsion Breaker (EB) and Reverse Emulsion
Breaker (REB) through two Mixer (1-M-125/140), and then enters one of the two (2)
Treaters (1-V-160 or 1-V-170). All chemicals are injected before 1-M-125, Chemical
injection points between 1-M-125 and 1-M-140 will be closed. Diluent addition and
chemical dosing rates will be manually adjusted to make produced water and dilbit from
Treater meeting the same spec as normal operation. Dilbit from the top of Treater flows
to Gas Boot 1-V-190, which is same as normal operation. While produced water from
both compartments are combined and routed to the inlet of Produced Water Cooler
cooling below 80 C before entering Skim Tanks 1-T-300/301.

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

14 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

In FWKO by-pass operation, Treater operating pressure will be adjusted and set to have
no vapor venting to diluent recovery system. Pressure in the Treaters is maintained by
pressure controller 1PC1601C (for 1-V-160) & 1PC1701C (for 1-V-160) which provide
blanket gas make up (1PV1601C for 1-V-160, 1PV1701C for 1-V-170) and pressure
controller 1PC1601D (for 1-V-160) & 1PC1701D (for 1-V-170) which vents produced gas
(1PV1601D for 1-V-160, 1PV1701D for 1-V-170) to Diluent Recovery System. High-high
pressure shutdown is triggered before the pressure safety valves lift. When triggered,
emulsion feed and fuel gas make up to Treater are shut down (Close 8EV8000 and
1XV1290 and shut down pumps prior to 1XV1290, close 1XV1600/1XV1700 and
1PV1601C/1PV1701C. This configuration also eliminates blocked outlet case as the
controlling scenario for PSV sizing).
Total liquid level in the de-gassing compartment of the Treater is controlled by 1LC1600
with 1LC1600/1LC1700 HH shutting off feed to the Treater and 1LC1600/1LC1700 LL
closing outlets from the Treater.
The water/oil interface level is controlled by 1LC1601A/1LC1701A through 1LV1300C.
1LC1601A/1LC1701A HH will cut off feed to Treaters, and 1LC1601A/1LC1701ALL will
close 1LV1300C and trip Desanding Pump 1-P-390 if it is in operation.
For details of the pressure and level HH & LL interlocks for the FWKO by-pass operation
refer to Cause & Effects Diagram KBP-01-284-1104.
2.6

PRODUCED WATER COOLERS (1-E-150~154 AND 1-E-260~263)

Reference Drawings:

2.6.1

KBP-01-220-1107~1107F Produced Water Cooler

Normal Operation
Produced water from FWKO 1-V-130 is fed to Produced Water Cooler 1-E-150~154 and
1-E-260~263 (total 9) through a common header. Tie-ins for future BFW/PW exchangers
have been provided on this common inlet header. These coolers are spiral type heat
exchanger with design duty of 6.45 MW each. Cooling glycol (mixture of cold and hot
glycol) is used as cooling media. Produced water is cooled from about 130 C to
75-78 C through these coolers, collected in the outlet common header, and then
combined with produced water from Treaters 1-V-160/170 routing to Skim Tanks 1-T300/301.

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

15 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

1TI1590 monitors produced water outlet temperature high alarm, and 1TC3090 adjusts
cold glycol flow rate through 1TV3090J or 1TV3090H to control Skim Tanks inlet
temperature at set point. 1TC1505 with high and low alarms controls cooling glycol
temperature at 60 C through hot glycol supply control valve 1TV1505.
2.6.2

FWKO By-Pass Operation

In FWKO by-pass operation mode, produced water from Treater (1-V-160 or 1-V-170) is
routed to the inlet header of PW coolers. The number of coolers required will be reduced
due to less produced water from Treaters (25~35% turndown). In this operation mode,
temperature control is the same as normal operation.

2.7

CHEMICAL INJECTION FOR EMULSION TREATMENT

The produced emulsion is treated with Emulsion Breaker, Reverse Emulsion Breaker
and Invert Emulsion Polymer. These chemicals are injected upstream of the FWKO and
Treaters. The Emulsion Breaker injection rate is proportional to the net oil flow rate. The
Reverse Emulsion Breaker and Invert Emulsion Polymer injection rates are proportional
to the total produced water flow rate.
The produced oil and water rates are measured and the data is used to adjust the speed
of the chemical injection pumps. These pumps are equipped with variable frequency
drives. If the production rates drop below the design rate, the pumps will slow down and
reduce the chemical injection rates correspondingly.

2.7.1

Emulsion Breaker
Reference Drawings:

KBP-01-220-1120 Emulsion Breaker Storage Tank

KBP-01-220-1121 Emulsion Breaker Injection Pumps

Emulsion Breaker is designed to break the water-in-oil emulsion of the produced

emulsion. It is stored in a 70 m3 Emulsion Breaker Tank (1-T-700) with working volume
of 50 m3 located outside of Oil Treatment Building. This will provide approximately
32 days of storage capacity.
1-T-700 is a low temperature carbon steel atmospheric storage tank. 1LI7000A monitors
the liquid level inside the tank with high & low alarms and HH & LL trips. Emulsion
Breaker is loaded by truck through an environmental box.

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

16 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

Emulsion Breaker Injection Pumps (1-P-705/706/707) are designed as two (2) working
(one supplies EB to FWKO inlet header and one supplies EB to Treater inlet header)
and one in stand-by mode. These pumps are diaphragm positive displacement type
pump with VFD motor. EB injection flow is controlled by VFD motor speed. Each pump
has designated drawdown assembly. 1FI7050 and 1FI7070 monitor the EB injection
rates to FWKO and Treaters separately with high and low alarms. Provision has been
provided to inject EB before Emulsion/BFW Exchangers (1-E-110~115).
2.7.2

Reverse Emulsion Breaker

Reference Drawings:

KBP-01-220-1122 Reverse Emulsion Breaker Storage Tank

KBP-01-220-1123 Reverse Emulsion Breaker Injection Pumps

Reverse Emulsion Breaker is designed to break the oil-in-water emulsion of the

produced emulsion. It is stored in a 44.5 m3 Emulsion Breaker Tank (1-T-710) with
working volume of 30 m3 located outside of Oil Treatment Building. This will provide
approximately 15 days of storage capacity.
1-T-710 is a FRP atmospheric storage tank with glycol heating coil inside. 1LI7100A
monitors the liquid level inside the tank with high & low alarms and HH & LL trips.
Reverse Emulsion Breaker is loaded by truck through an environmental box.
Reverse Emulsion Breaker Injection Pumps (1-P-715/716/717) are designed as two (2)
working (one supplies REB to FWKO inlet header and one supplies REB to Treater inlet
header) and one in stand-by mode. These pumps are diaphragm positive displacement
type pumps with VFD motor. REB injection flow is controlled by VFD motor speed. Each
pump has a designated drawdown assembly. 1FI7150 and 1FI7170 monitor the REB
injection rates to FWKO and Treaters separately with high and low alarms.
2.7.3

De-oiling Polymer to FWKO

Reference Drawings:

KBP-01-220-1313 Polymer Injection

KBP-00-290-0001,Rev.A: Chemical Consumption Summary

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

17 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

De-oiling Polymer is supplied from a TOTE tank located inside Oil Treatment Building.
Two of the Polymer Injection Pumps (1-P-723/724) are used to inject polymer to the inlet
header of FWKO in one working and one stand-by mode. The polymer is diluted with
utility water before entering the FWKO inlet header. These two pumps are progressive
cavity positive displacement type pump with VFD motor.
Flow signal 1FI7230 on pump discharge of Polymer Injection Pump1-P-723/724 and deoiled produced water flow signal from 1FI1509 is ratioed through a ratio calculation block
1FY7230 and the resultant of this ratio calculation block will be sent as a set-point to
1PM7230 VFD/ 1PM7240 VFD through1FC7230. The input to the ratio calculation block
can be sourced from the Chemical Injection Summary referenced above.
Utility Water Booster Pump 1-P-721 feeds dilution water into the Polymer Injection Pump
discharge line downstream of flow transmitter 1FT7230.Utility water flow signal from
1FI7231 and the polymer flow signal from 1FI7230 is tied into a ratio calculation block
1FY7231 and diluted to a 100: 1 ratio. This dilution rate shall be preset and will only be
changed if directed by chemical supply vendor. The resultant signal from this ratio
calculation block will be sent as a set-point to 1FC7231 which will adjust the VFD pump
controller through 1PM7210.
Under normal operating condition 1FV7231 is manually set in the Control Room and
adjusted (opened) only if the VFD is at maximum operating speed.
The Utility Booster Water Pump will supply utility water to Desand Flush Pump 1-P-390
seal (Seal Plan 32). The Desand Flush Pump operation is an intermittent service. An
operating procedure shall be put to address utility water supply to Desand Flush Pump
seal. 1PCV7211 regulates the pressure to the pump seal. It shall be set at 1010 kPag.

2.7.4

Desanding System
Reference Drawings:

KBP-01-220-1317 Desanding Flush Pump

KBP-01-220-1102 Inlet Separator

KBP-01-220-1106 FWKO

KBP-01-220-1110 Treater

KBP-01-220-1111 Treater

KBP-01-220-1708 Desanding Drain Header

Document No:

CNRL Kirby In-Situ Oil Sands

Project

Page:

CE414040-P-24-08-00002
Supersedes:

18 of 77
Rev.
A

Process Description and Control

Philosophy

Previous Rev. Date:

Current Rev. Date:

18-Oct-12

Desanding of FWKO (1-V-130) and Treaters (1-V-160/170) is an intermittent operation

as required, which is selected by 1HS1000/ 1HS1300/ 1HS1600/ 1HS1700.
Desanding Flush Pump (1-P-390) takes suction from the minimum flow line (before min.
flow control valve) of ISF Discharge pumps (1-P-355/356) and directs the deoiled
produced water to the vessel assigned for desanding.
Desanding flush water supply pressure requirement for FWKO and Treaters is about 250
kPa higher than the operating pressure in these vessels. This is controlled by 1FC3901A
through 1FV3901A. 1PC3901 downstream 1FV3901A has A HH shutdown that trips
1-P-390 to protect FWKO and Treaters from overpressure.
Desanding drains from the three vessels are routed to the Slop Tanks (1-T-350/351)
through a common desanding drain header.
Note:
Desanding operation is not operated without a quench system in place. Flashing of high
temperature produced water produces steam and water hammer, and two-phase steam
water in contact with water at 80C in the Slop Tanks will turn water in to steam
creating potential boil over phenomena.
2.7.5

Oil Treatment Building Sump

Reference Drawings:

KBP-01-220-1710 Oil Treating Building

The Oil Treatment Building Sump (1-V-790) collects liquids from oil treatment area (Oil
Treatment Building, Dilbit Building and BFW Building) and floor drains and LP
condensate from Pipe-rack. 1-V-790 is 2438 mm ID by 6073 mm OAL.
BPCS logic controls the operation of the Treater Building Sump Pump 1-P-795 in
ON/OFF mode. When the level in the sump reaches the high level, the pump is started.
When the level in the sump reaches the low level, the pump is stopped. Liquid level LL
trips 1-P-795. Sump liquid is pumped to Slop Tanks (1-T-350/351).

3.0

DILBIT TREATING AND DILUENT RECOVERY SYSTEM

3.1

PURPOSE AND SCOPE