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Commissioning of Micro-Bubble

Flotation Unit
PROCEDURE

Controlled Copy

EWS Project No.: 10-016


Project Specific Doc. No.: 10016-COM-020
Jaguar Produced Water Treatment
Project Description :
Plant
Client : CEPCOLSA
Location : Colombia
Revision 0

Approved By: Todd Kirk


Verified By: Jacob Denis
Created By: Cary Rice
Approved By: Todd Kirk
Verified By: Jacob Denis
Created By: Cary Rice
Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

REVISION INDEX
Revisio
Date Description of Changes Revised By
n
05-Aug-
0 Initial Issue Cary Rice
2011

COPYRIGHT © 2008 EXTERRAN WATER SOLUTIONS – GLR SOLUTIONS LTD . Paper copies of this document are uncontrolled. This copy is valid only at
the time of printing. The controlled version of this document is stored on the Exterran intranet Web site.

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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

TABLE OF CONTENTS
1.0 OBJECTIVE.......................................................................................4
2.0 SCOPE............................................................................................4
3.0 OWNERSHIP STATEMENT..................................................................4
4.0 REFERENCES...................................................................................4
5.0 DEFINITIONS...................................................................................4
6.0 RESPONSIBILITIES...........................................................................4
6.1 GLR................................................................................................................................ 4
6.2 Customers...................................................................................................................... 4
7.0 SAFETY & ENVIRONMENTAL..............................................................5
8.0 FIELD SITE PREPARATION.................................................................5
8.1 Pre-Commissioning......................................................................................................... 5
8.2 Gas Flotation Tank Inspection......................................................................................... 5
8.3 Revolift Inspection.......................................................................................................... 6
8.4 Site Readiness................................................................................................................ 7
8.5 Field Testing................................................................................................................... 7
9.0 START-UP PROCEDURE.....................................................................7
9.1 Micro-Bubble Generator ONYX™ Pump Start up.............................................................7
9.2 Micro-Bubble Generator GLR™ Reactor Start-up............................................................8
10.0 FIELD TESTING AND VERIFICATION....................................................9
10.1 Online Particle Analyzers................................................................................................ 9
10.2 ViPA Analyzer............................................................................................................... 10
10.3 Petro CAM Analyzer...................................................................................................... 11
10.4 Result Verification........................................................................................................ 12
11.0 TROUBLESHOOTING.......................................................................12
12.0 CONTACT INFO...............................................................................12
12.1 General........................................................................................................................ 12
12.2 Emergency................................................................................................................... 12

COPYRIGHT © 2008 EXTERRAN WATER SOLUTIONS – GLR SOLUTIONS LTD . Paper copies of this document are uncontrolled. This copy is valid only at
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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

1.0 OBJECTIVE
1.1.1 To define a generic commissioning procedure for Micro-bubble flotation systems
including the ONYX MB™ Pump and the GLR™ Reactor..

2.0 SCOPE
2.1.1 This document defines the procedure for the commissioning of generic Micro-
bubble flotation systems. This procedure shall be modified accordingly to suit
individual projects and will be named according to project document numbering
system.

3.0 OWNERSHIP STATEMENT


3.1.1 The Vice President Operations maintains ownership of this document and is
responsible for ensuring that this document is necessary and reflects actual
practice.

4.0 REFERENCES
4.1.1 Drawings (P & ID, GA)

4.1.2 Control Narrative

4.1.3 Pre-Commissioning Check list

4.1.4 TSS-MAN-CA-GLR-001 – ONXY MB 200 Series Pump Installation, Operation &


Maintenance Manual

4.1.5 TSS-MAN-CA-GLR-002 – ONXY MB 400 Series Pump Installation, Operation &


Maintenance Manual

4.1.6 TSS-MAN-CA-GLR-003 – ONXY MB 600 Series Pump Installation, Operation &


Maintenance Manual

4.1.7 TSS-MAN-CA-GLR-005 – GLR Reactor Installation, Operation & Maintenance Manual

4.1.8 TSS-PRC-CA-GLR-002 – Procedure for verifying Bubble Rise Velocity

5.0 DEFINITIONS

 GLR : Exterran Water Solutions - GLR Solutions Ltd., a division of Exterran


Holdings Inc.
 EXTERRAN : Exterran Holdings Inc. parent company of GLR based in Houston,
Texas, USA.

COPYRIGHT © 2008 EXTERRAN WATER SOLUTIONS – GLR SOLUTIONS LTD . Paper copies of this document are uncontrolled. This copy is valid only at
the time of printing. The controlled version of this document is stored on the Exterran intranet Web site.

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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

6.0 RESPONSIBILITIES

6.1 GLR

6.1.1 To ensure this document reflects actual practice and instructions

6.2 Customers

6.2.1 To comply with this document as described

7.0 SAFETY & ENVIRONMENTAL


7.1.1 All activities shall be in compliance with the local HSE regulations and site HSE
Requirements.

7.1.2 All users/operators to familiarize themselves with this document prior to start up

8.0 FIELD SITE PREPARATION

8.1 Pre-Commissioning

8.1.1 Before commencing with this procedure, items pertaining to the flotation package
must be ready for operation. This includes but is not limited to tank/vessel
inspection, piping connections, instrumentation, control valves, electrical and all
other process equipment

8.2 Gas Flotation Tank Inspection

8.2.1 The Gas Flotation Tank must be inspected internally & externally prior to filling with
produced water

8.2.2 Internal Inspection : As a minimum the following needs to be inspected

1. Coating – The coating must be checked to ensure all exposed metal is


covered and no cracking or damage has occurred.
2. Partition walls – The walls need to be checked for proper welding and
sealing between chambers. Any short circuiting between partition walls
will result in reduced performance.
3. Weirs – The water and oils weirs must be checked for correct dimensions
as per design, levelness and ensure that drain holes are present in
chamber 2. (3 and 4 also if a it is a 4 chamber design)
4. Chamber interconnecting piping – This must be checked for proper
dimension, elevations. Pipe going through chamber walls must also be
checked to ensure the weld is sealed and no short circuiting of water can
occur.
5. Skimming weir – Edges and notches are to be checked for proper
dimensions, elevations and leveling.

COPYRIGHT © 2008 EXTERRAN WATER SOLUTIONS – GLR SOLUTIONS LTD . Paper copies of this document are uncontrolled. This copy is valid only at
the time of printing. The controlled version of this document is stored on the Exterran intranet Web site.

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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

6. Wall extensions – This only applies to the 4 chamber tank design. Wall
extensions run perpendicular above oil weir to stop inter-chamber short
circuiting when skimming oil.
8.2.3 External Inspection : As a minimum the following needs to be inspected

1. Micro-Bubble recirculation valves – These are to be checked for type,


position and distance to tank. They must be within 4 meters or as per
design.
2. Balancing lines – These chamber equalizing lines are to be checked for
elevation and valve position. During filling or draining they must be
opened, then closed for operation.
3. U-tube – Elevation as per design.
4. Nozzles – All nozzles must be checked for size, elevation and orientation as
per design and drawing.
5. Micro-Bubble suction and discharge lines – This piping must be checked for
high point vents, valve type and location per drawings, sample point
location and the overall distance of the skid to the tank.
6. Check all instruments and transmitters for proper function. Check pressure
vacuum valves for proper function and piping.

8.3 Revolift Inspection

8.3.1 The Revolift vessel must be inspected internally & externally prior to filling with
produced water.

8.3.2 Internal Inspection : As a minimum the following needs to be inspected

1. Coating – The coating must be checked to ensure all exposed metal is


covered and no cracking or damage has occurred.
2. Partition walls – The walls need to be checked for proper welding and
sealing between chambers. Any short circuiting between partition walls
will result in reduced performance.
3. Weirs – The water and oil weirs must be checked for correct dimensions as
per design, levelness and ensure that drain holes are present in chamber
2. (3 and 4 also if it is a 4 chamber design)
4. Chamber interconnecting channel – This must be checked for proper
dimension and elevations.
5. Skimming weir – Edges and notches are to be checked for proper
dimensions and leveling.
6. Adjustable oil skimming weirs are installed correctly and are freely
adjustable. Ensure that the weir can slide completely up and down and
that the lock nuts are tightened securely.

COPYRIGHT © 2008 EXTERRAN WATER SOLUTIONS – GLR SOLUTIONS LTD . Paper copies of this document are uncontrolled. This copy is valid only at
the time of printing. The controlled version of this document is stored on the Exterran intranet Web site.

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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

7. Valve assemblies – Valve and connections to the adjustable skimming


weirs must be checked for full travel and smooth operation. Leveling from
side to side must also be checked.
8. Nozzles – There should be no additional nozzles outside of the original
design protruding into the working space of each chamber, these will
affect flow patterns.
9. Placement of Micro-Bubble inlet nozzles as per design
10. Gas vent – Gas release from chamber 5 underneath the discharge weir
must be hooked up.
11. Viewports – Check all external viewports for cleanliness and wiper
operation.
8.3.3 External Inspection : As a minimum the following needs to be inspected

1. Micro-Bubble recirculation valves – These are to be checked for type,


position and distance to vessel. They must be within 4 meters or as per
design.
2. Nozzles – All nozzles must be checked as per design and drawing.
3. Micro-Bubble suction and discharge lines – This piping must be checked for
high point vents, valve type and location per drawings, sample point
location and the overall distance of the skid to the tank.
4. Check all instruments and transmitters for proper function. Check safety
relief valves for proper function and piping.

8.4 Site Readiness

8.4.1 It is assumed that the Micro-bubble tank/vessel is to be filled with produced water
to the operating level after all inspection is completed and prior to the arrival of
commissioning personnel. Fluid should be available to the ball valve at pump
suction

8.4.2 All permits should also be in place for hot work and/or equipment operation.

8.4.3 Below is a list of non intrinsically safe equipment utilized during commissioning
activities.

1. Laptop(*See Note)
2. PetroCam/ViPA analytical instrument for online particle measurement (*See
Note)

3. Digital Still Camera for pictures

NOTE:

COPYRIGHT © 2008 EXTERRAN WATER SOLUTIONS – GLR SOLUTIONS LTD . Paper copies of this document are uncontrolled. This copy is valid only at
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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

1. In order to utilize the laptop and the online particle analyzer a power
supply of 110/240v 50/60Hz must be available at the sample points to be
used. Sample points are project specific and will be identified in design

8.5 Field Testing

8.5.1 All mechanical equipment shall be run tested and checked for performance.

8.5.2 All performance tests shall be recorded for future reference.

8.5.3 Performance tests include pump performance curve verification and Micro-Bubble
rise velocity tests.

1. Pump acceptance – 30hr run test


2. Bubble Rise Velocity tests as per TSS-PRC-CA-GLR-002 Procedure for
Verifying Bubble Rise Velocity.

9.0 START-UP PROCEDURE

9.1 Micro-Bubble Generator ONYX™ Pump Start up

9.1.1 The following procedure is utilized to start the MB Series ONYX TM pumps.

1. Ensure that the Micro-Bubble flotation tank/vessel is filled to the operating


height with produced water and the source water feed is turned off. It is
imperative that the balancing lines between chambers are fully open
during filling. The fill rate should be that each chamber fills equally as to
not put stress on the dividing chamber walls. Filling too fast or unevenly
could result in internal wall damage.
2. Open all suction and discharge valves to the micro bubble skid from the
tank. Throttling globe valves located on the Micro-Bubble skid should be
2/3 closed. Only opening the discharge valves 1/3 will help to ensure the
pumps do not run too far out on their respective curves. All other valves
should be open 100% including the ones to the tank.
3. Start pump #1 (if this is a multi pump set up only start one pump at a
time). Throttle the globe valve on the discharge until the desired
flow/pressure is reached according to the supplied pump curves. (Flow and
pressure is dependent on pump model).
4. Begin introducing gas to the pump at a rate specified by the model
number of the pump. (I.e. 12% for the MB200 or a rate of 3.2scfm @
200gpm).
5. Adjust the discharge valve for flow correction to the rate as determined by
the supplied pump curve.
6. Using the discharge sample point check for micro-bubbles using a small
sample bottle. Photograph and record results. Complete a bubble rise
velocity test and record results. Bubble Rise Velocity tests as per TSS-PRC-
CA-GLR-002 Procedure for Verifying Bubble Rise Velocity.

COPYRIGHT © 2008 EXTERRAN WATER SOLUTIONS – GLR SOLUTIONS LTD . Paper copies of this document are uncontrolled. This copy is valid only at
the time of printing. The controlled version of this document is stored on the Exterran intranet Web site.

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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

7. Once the pump is running steady begin closing the globe/control valves to
the inlet chambers, maintaining the prescribed Micro-Bubble ratio to each
chamber. Open the local throttling globe valve on the pump skid at the
same ratio. Continue until the globe valves on the skid are fully open and
the valves closest to the tank are partially open while maintaining flow,
pressure and the prescribed Micro-Bubble ratio to each chamber.
8. Micro-bubbles should now be being introduced into the Gas Flotation
Tank/IGF vessel. Maintain this flow for approximately 1hr.
9. Open the source water flow to the Gas Flotation Tank/IGF Vessel. Please
note that this water will be off spec, monitoring should not occur until the
source water has been introduced and three tank volume turnovers have
occurred.
10. Begin analyzing the inlet to the tank utilizing the online monitor. After
approximately 1 hr move to the outlet of the Gas Flotation Tank/IGF Vessel
and gather data.
11. Allow 3 full tank volume turnovers prior to making system changes to
achieve the full results of the micro-bubbles.
12. Analyze both the inlet and the outlet utilizing an online particle analyzer
which will calculate oil and solids PPM. Once the outlet reaches the target
range record system flows, pressures and valve settings for future
reference. Continue monitoring the inlet and the outlet for the duration of
commissioning.

9.2 Micro-Bubble Generator GLR™ Reactor Start-up

9.2.1 The following procedures are used to start the GLR Reactor

1. Ensure that the Gas Flotation Tank/IGF Vessel is filled to the operating
height with produced water and the source water feed is turned off. It is
imperative that the balancing lines between chambers are fully open
during filling. The fill rate should be such that each chamber fills equally as
to not put stress on the dividing chamber walls. Filling too fast or unevenly
could result in internal wall damage.
2. Open all suction and discharge valves to the Micro-Bubble skid from the
tank. Open bock and bleed valves on the inlet and outlet lines to bleed
trapped air. Throttling globe valves located on the GLR Reactor skid
downstream of the GLR unit should be 2/3 closed. Only opening the
discharge valves 1/3 will help to ensure the GLR feed pumps do not run
too far out on their respective curves. All other valves should be open
100% including the Micro-Bubble regulating valve to the Gas Flotation
Tank/IGF Vessel
3. Start pump #1 (if this is a multi pump set up only start one pump at a
time). Throttle the globe valve on the discharge until the desired
flow/pressure is reached according to the supplied pump curve. Start all
the designed working pumps to get the desired flow rate through the GLR
reactor

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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

4. Begin introducing gas to the GLR through the inlet line to the GLR; ensure
that the supply pressure of the gas is greater than the discharge pressure
of the pump by 5 to 10 psig. If not, the gas will not enter the pipe.
5. Adjust the rate of gas until the GLR vessel is approximately ½” full of
water. This level can be seen using the sight glass on the side of the
vessel.
6. Adjust the discharge valve for flow correction to the desired rate.
7. Using the discharge sample point check the Micro-Bubble quality using a
small sample bottle. Photograph and record results. Complete a bubble
rise velocity test and record results. Full bubble rise procedure can be
found in Appendix A of this document.
8. Once the pump is running steady begin closing the globe/control valves to
the inlet chambers maintaining the prescribed Micro-Bubble ratio to each
chamber and open the local throttling globe valve on the pump discharge
at the same ratio. Continue until the globe valves on the pump discharge
are fully open and the valves closest to the tank are partially open while
maintaining flow and pressure maintaining the prescribed Micro-Bubble
ratio to each chamber.
9. Micro-bubbles are now being introduced into the Gas Flotation Tank/IGF
Vessel. Maintain this flow for approximately 1hr.
10. Open the source water flow to the Gas Flotation Tank/IGF Vessel. Please
note that this water will be off spec, monitoring should not occur until the
source water has been introduced and three tank volume turnovers have
occurred.
11. Begin analyzing the inlet to the Gas Flotation Tank/IGF Vessel utilizing the
online monitor. After approximately 1 hr move to the outlet of the Gas
Flotation Tank/IGF Vessel and gather data.
12. Allow 3 full vessel volume turnovers prior to making system changes to
achieve the full results of the micro-bubbles. This time may very
depending on oil droplet size, chemical program and extent of the change.
Watch for a stable profile.
13. Analyze both the inlet and the outlet utilizing an online particle analyzer
which will calculate oil and solids PPM. Once the outlet reaches the target
range record system flows, pressures and valve settings for future
reference. Continue monitoring the inlet and the outlet for the duration of
commissioning.

10.0 FIELD TESTING AND VERIFICATION

10.1 Online Particle Analyzers

10.1.1 When fluid pass through online particle analyzers, results for free oil/sands
concentration and particle size distribution are displayed in real time. The benefit
of using online particle analyzers is a quick and efficient means to optimize the

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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

system to achieve the best results in a shorter time than it would take to wait for
lab samples to be analyzed. In order to provide real time online analysis of the
produced water being treated, Exterran Water Solutions utilizes online visual
particle analyzer.

10.2 ViPA Analyzer

Figure Field Testing and Verification-1: ViPA Analyzer

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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

Figure Field Testing and Verification-2: ViPA Analyzer Specifications

10.3 Petro CAM Analyzer

Figure Field Testing and Verification-3: : PetroCAM® Analyzer

COPYRIGHT © 2008 EXTERRAN WATER SOLUTIONS – GLR SOLUTIONS LTD . Paper copies of this document are uncontrolled. This copy is valid only at
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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

Figure Field Testing and Verification-4: PetroCAM Analyzer Specifications

10.4 Result Verification

10.4.1 It is known that not all procedures for oil in water concentrations are accurate.
Exterran Water Solutions utilizes various field techniques to further verify the
results obtained by the particle analyzers. By using sample bottles and an
extraction solvent such as Hexane, certain variables can be monitored to correlate
the data and provide visual confirmation of results.

1. Time to clear – This test is used to calculate the time it takes the oil in
produced water to rise to the surface. Using simple methods one can
determine the average (mean) particle size.

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Commissioning
Procedure
COMMISSIONING OF MICRO-BUBBLE FLOTATION UNIT
Revised: January 07,
Revision: 2 Number: TSS-PRC-CA-GLR-004
2010

2. 50/50 Extraction – Using this method can help determine how heavy the
oil is and help indicate the presence of oil coated solids (if any)
3. Color comparison to known sample – By utilizing an extraction solvent field
technicians can ascertain concentration based on color against a known
sample.
4. Turbidity – A portable turbidity meter is utilized to check the clarity of the
water.
5. Turner Designs Hydrocarbon Meter – This instrument is used to correlate
results of total hydrocarbons in the produced water.

11.0 TROUBLESHOOTING
11.1.1 In the event the system does not perform as expected we utilize the field testing
and verification techniques as described in section 10 to help better understand
water properties and identify probable cause of poor performance.

11.1.2 A full Process Flow Diagram and Piping & Instrumentation Diagram drawings as well
as site operation description should be made available prior to commissioning to
help understand the complete process and aid in troubleshooting.

11.1.3 Also, any chemical usage including type, dosage and injection location should be
provided. Certain chemicals can aid or inhibit performance.

11.1.4 If results of oil ppm are above guaranteed levels, oil particle size should be
measured by the online particle analyzer to determine the average mean size.
Please note that if the mean particle size is below 6 micron it may be necessary to
utilize chemicals such as a cross chain polymer or flocculants.

12.0 CONTACT INFO

12.1 General

12.1.1 Any questions or concerns with respect to the commissioning of Micro Bubble
Flotation, Please email as below and allow 24hrs for our response.

 Jacob Denis : jacob.denis@exterran.com

12.2 Emergency

12.2.1 If there is an emergency, please contact

Cary Rice, Field Services

Cell +1-403-589-0635, Work:+1-403-219-2273

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