Contents Of Gathering Center

CHAPTER-01 (MAIN PLANT) 1. Intro !"tion Of Gathering Center

1-1 Gathering Center Function 1-2 Gathering Center Overview

#. Oi$ Ro!te %ro& 'e$$hea To Main Hea ers

2-1 Bull plug 2-2 Remote control valve (RCV) 2-3 Flow line sample point 2- Ori!ice "o# 2-$ %ncoming mani!ol& hea&ers 2-' (mergenc) shut&own valves ((*+V)

(. Oi$ Ro!te %ro& )e*arators To Main Tan+

3-1 *eparators 3-2 ,an- !illing line mani!ol& 3-3 .ain tan-s

,. Gas Ro!te %ro& )e*arators To -ooster )tation

-1 /p gas route to "ooster station0 -2 1p gas route to "ooster station

.. %!e$ Gas )/ste&

$-1 ,an- pressuri2ing valve

0. H* 1L* f$are s/ste& 2. Test Cr! e Pro"ess 3. P$ant Area Che&i"a$s 4. Instr!&ent air s/ste& An %ire 'ater )/ste&

CHAPTER-02 (DESALTER) 1. Intro !"tion Of 5esa$ter Phase - I6

1-1 Gravit) separation 1-2 Chemical treatment 1-3 /eating 1- +ilution (washing with water) 1-$ 3gitation (mi#ing wash water) 1-' (lectrostatic coalescing (electrical treatment)

#. Metho s of eh/ ration

2-1 +eh)&ration 2-2 +esalting 2-3 O"4ective o! install &eh)&ration5&esalting plant

(. Theor/ of e&!$sion
3-1 ,ight emulsion 3-2 1oose emulsion

,. 5esa$ter *hase - I6 *ro"ess ro!t

-1 +egassing "oot (V-66 ) -2 7et tan- (,8-661) -3 Fee& pumps - Cru&e heat e#changer ((1615261) col& si&e -$ 7ater "ath heater (F-161-261) -' Fuel gas s)stem to "ath heater -9 1st : stage (Rec)cle water in4ection no22le - mi#ing v5v - vessel) -; 2n& : stage (7ash water in4ection no22le - mi#ing v5v - vessel) -< ,rivolte& electrostatic &esalting -16 Cru&e heat e#changer ((1615261) hot si&e -11 *alt-water content anal)2er -12 +iverting valves

.. 'ash 7ater 8 re"/"$e s/ste& 0. Che&i"a$s 2. 'aste 7ater s/ste& 3. )tart!* *ro"e !re of esa$ter 4. Tro!9$e shooting of esa$ter 10. C$ose rain s!&* :esse$ an !&* *!&*s

11. Instr!&ent air "o&*ressor (;-0(#1A< -)

CHAPTER-03 (C R U) 1. Intro !"tion Of CR= #. Pro"ess %$o7 Ro!te

2-1 G-161 2-1 G-162

(. CR= Main E>!i*&ents 5esign Con itions ,. C- GM'A-3 Engine 5es"ri*tion

-1 +e!inition O! CB G.73-; -2 =ower C)lin&er Operating =rinciple -3 1u"e Oil *)stem - Fuel Gas *)stem -$ %gnition *)stem

.. Gas Co&*ressor 5es"ri*tion 0. Instr!&ents An Contro$ )ettings 2. O*erating Pro"e !res

9-1 =re *tart Chec-list 9-2 *tartup =roce&ure O! CR>

CHAPTER-0, (R=)TON T=R-INE TA-1.00) 1. Intro !"tion

1-1 Operating C)cle

#. T!r9ine Main Parts (. Main )/ste&s Of T!r9ine TA-1.00

3-1 1u"e Oil *)stem 3-2 Fuel Gas *)stem 3-3 *ervo Oil *)stem 3- *tarting 3ir *)stem

,. Transit P!&* Intro !"tion

-1 Booster =ump -2 .ain =ump

.. T!r9ine Pre-)tart Che"+ List 0. )tart =* Pro"e !re

'-1 *ervo Oil Operate& Control *)stem '-2 7oo& wor& Control *)stem

2. A$ar&s 8 )h!t o7n )ettings

9-1 ,ur"ine 9-2 =ump >nit

CHAPTER-05 (DCS) 1. Intro !"tion 5istri9!te Contro$ )/ste&

1-1 =urpose ? Functions O! +C*

#. Rose&o!nt 5C)
2-1 Rosemount *)stem +escription 2-2 /ar&ware +escription

1. Introduction of

!t"#rin$ C#nt#r

*ince the oil pro&uction o! 8uwait oil !iel&s "egan in the )ear o! 1< $@,he oilA which is pro&uce& !rom the reservoirA !low through various well-&own-hole eBuipment an& sur!ace !acilities@ %t is collecte& in a place calle& a gathering center@ ,he oil gatherings s)stem !rom the wells to the GC ma) consists o! single !low line !rom a well to its separation eBuipment ") 'C !low lines@ Flow lines are usuall) terminate& at hea&ers@ ,he cru&e oil processesA through grove valve an& hea&ers into separators@ ,he separate& gas is sent to the Booster *tationA where the pressures is "ooste& up an& sen& to (1iBue!ie& =etroleum Gas) 1=G plant@ ,he cru&e oil either is route& to the &r) tan- or wet tan-@ ,he wet cru&e treate& at the &esalter plantA where water an& salt remove&@ ,he treate& cru&e is then route& to the &r) tan-s@ Finall)A cru&e oil is pumpe& !rom the &r) tan- to the 3/.3+% tan- !orm an& the tan- vapor gas is route& to the Con&ensate Recover) >nit (CR>)@ ,here were originall) 2' gathering centers &istri"ute& in eight 8OC (8uwait Oil Compan)) oil !iel&s@ ,he !irst center to "e commissione& was GCD1 at Burgan oil !iel& an& that was on Eune 9th 1< '@

2.%i& Rout# 'ro( )#&&"#!d To *!in H#!d#r+

,he cru&e oil !rom a wellhea& !lows into a GC through a !low line with man) &i!!erent valves an& other eBuipment on its wa)A such as "ull plugA remote control valve (RCV)A ori!ice "o#A incoming mani!ol& hea&er an& emergenc) shut&own valve@ 2-1 ,u&& -&u$ %t is locate& upstream o! the (RCV)@ %t is provi&e& !or two main reasons0 ,o suppl) water to a new !low line !or pressure testing the !low line at appro#imatel) 1;66psig@ ,o suppl) water to a &rilling rig on a new wellA i! reBuire& 2-2 R#(ot# contro& .!&.# (RC/) ,he RCV is provi&e& on each incoming !low line at a remote place insi&e or outsi&e a GCA it is use& to isolate the well !rom the GC in case o! emergenceA maintenance an& rig wor-@ 2-3 '&o0 &in# +!(-&# -oint >se& !or collecting a sample o! oil !or salt or water content chec-@ %t is normall) use when the salt content in &r) separator is ver) high@

2-1 %rific# 2o3 ,his is &evice !or measurement o! oil !low an& it is normall) !itte& insi&e with an ori!ice plate@ But at most GCFs these &evices are no longer use&@ 2-5 Inco(in$ (!nifo&d "#!d#r+ ,his is a hea&er pipeA which mi#e& cru&e oil !rom &i!!erent oil wells an& sta"ili2e& the pressure "e!ore sen&ing the oil into a separator@ ,here are up to si# oil hea&ers in some G*Fs such as0 /ea&er D 1 !or /p &r) wells /ea&er D 2 !or /p wet wells 1p hea&er D 3 !or 1p &r) wells 1p hea&er D !or 1p wet wells /ea&er D $ !or /= wet wells ,est hea&er !or testing /p ? 1= wells (+r)5 7et) !or "ac- washing the !low line with water@ 2-4 E(#r$#nc5 +"utdo0n .!&.#+ (ESD/) 3t each hea&er en& there is an ((*+V) provi&e&@ %t is air-operate& valve@ %t closes automaticall) when there is a !ault in the main plant such as high level in the separator or tan-s@ %t will also close in case o! emergenc) shut&own or low instrument air@ ,he grove valve will close in case o!0 /igh level separators /igh level main tan1ow instrument air Operating o! emergenc) air switch in control room when the plant on !ail-sa!e@ 7hen "oth grove valves shut the tan--pressuri2ing valve will open an& the Con&ensate Recover) >nit (CR>) will shut&own on an) o! the main grove closes@

'

3. %i& Rout# 'ro( S#-!r!tor To *!in T!n6+

,he cru&e oil route !rom separators to main tan-s !lows through the !ollowing@ *eparators ,an- !illing line mani!ol& .ain ,an-s

3-1 S#-!r!tor+
3 separator is a vessel in which a mi#ture o! two or more !lui&s that are not easil) mi#ing in each other are separate& !rom one another@ %n GC D1 have hori2ontal separator !or /p &r)A /p wetA 1p wet an& vertical separator !or 1p &r)@ +etails a"out the separators in GC D 1 Vertical separators %n this t)pe there are two !orces wor- to separate the oil an& the gas Gravit) Force (causes the heavier oil to &rop to the lower part o! the separator an& this !orce is utili2e& ") re&ucing velocit) so the liBui& can settle out in the space provi&e& an& Centri!ugal !orce o! the whirling action (causes the heav) oil particles to collect on the walls o! the separator an& this !orce is utili2e& ") changing the &irection o! !low)@ /ori2ontal separators ,his t)pe operates in much the same wa) as a vertical separatorA the unit in a hori2ontal position instea& o! upright@ ,he same gravit) an& centri!ugal !orce are use&A an& the oil is remove& !rom the "ottom o! the unit an& the gas !rom the top@ /ori2ontal separators ma) "e o! either the single :tu"e or &ou"le &esign@ /igh-=ressure *eparators (1st stage) ,hese separators are operating at high pressure@ =ressure control valves (=CVFs) -eep the pressure in the separators at 2;6 psig !itte& at the gas out let@ From the incoming mani!ol& hea&ers the oil enters into these separators at near mi& point o! the vessels@ 1ow-pressure separators (2n& stage) ,hese separators are operating at low-pressure control valves -eep the pressure in the separators at '6 psig !itte& at the gas outlet@ *eparator instrument controls ? setting .ain separator (/p sep) 1evel transmitter setting $6G o! level normall) maintaining 1evel switch high high @ !t setting !or shut&own .ain separator (1p sep) 1evel transmitter setting $6G o! level normall) maintaining 1evel switch high high 3@' !t setting o! shut&own

3-2 T!n6 fi&&in$ &in# (!nifo&d7

Oil passes !rom separator through 1CVFs (1evel Control Valves) an& tan- !illing line are to the !illing mani!ol&@ From !illing mani!ol& the oil go either &irection tan-s@ /p wet separators cru&e is going to wet tan-A &r) separator cru&e is going to &r) tan-@

3-3. *!in t!n6+ T8-10019100291003 (Dr5 t!n6)7

,he purposes o! main tan-s are to store the +r) cru&e oil@ %t consi&ere& as 3 r& stage separator where the pressure is -ept 2@$C o! water controlle& ") "utter!l)@ Gas 3'C line connecte& to CR> an& to 1p !lare@ Hormall) 16-12 !eetFs o! level is maintaining in the &r) tan-s an& this is to -eep su!!icient cru&e !low to the cru&e oil pumps@ 1@ +esign Con&ition +r) tan-0 tan- capacit)0 26A666 BB1* ,an- si2e0 '6!t @ 2!t /igh-level alarm0 32!t /igh-level shut&own0 3<!t 1ow level alarm0 ;!t 1ow-level shut&own0 9!t .ain tan-s eBuippe& with the !ollowing %nstruments an& control units0 Varic unit0 it is a relie! valve to release the tan- pressure at ( @6 !or ol& tan-s ? 9@6C w@g !or new tan-s) to atmosphereA an& enters air pressure (vacuum) i! the pressure &rops &own aroun& ($C w@g@) /igh level alarm (1*/) an& high level shut &own (1*//) 1ow level alarm (1*1) an& low level shut &own (1*11) .ercur) manometer0 to measure tan- level 1evel transmitter0 to in&icate level in +C* 2 pressure transmitter0 one !or CR> an& the other !or "utter!l) ,emperature transmitter0 to measure tan- temperature

1.

!+ Rout# 'ro( S#-!r!tor+ To ,oo+t#r St!tion

,he gas is route& !rom separators through the !ollowing /p gas s)stem 1p gas s)stem

1-1 H- $!+ +5+t#(7

,he amount o! gas comes out !rom oil in /p separators varies accor&ing to the amount o! oil pro&uce& !rom the wells@ /p gas outlet !rom each separator is connecte& in a common line@ ,he common line is route& through the !ollowing@ /p gas to Booster station /p gas to /p !lare 1. H- $!+ to ,oo+t#r +t!tion7 ,he /p gas !rom *eparators to "ooster station !lows through the !ollowing@ /p gas pressure control valve /p gas scru""er I /p gas s)stem =CV (=ressure Control Valve) 0 %t is control the all /p separators outlet gas with the set point o! 2'6 psig@ 3!ter the =CV gas will route& to scru""er@ Hote0 Be!ore the pressure control valve one CR> lean gas line is connecte& to /p gas common line@ I /p gas scru""er0 ,he purpose is to clean up the gas !rom oil "e!ore going to "ooster station where the gas is getting compresse& an& sent to the re!iner)@ 2. H- $!+ to H- f&!r#7 %t consists o! /p gas pressure control valve an& "ac-pressure control valve /p gas will go to !lare incase o!0 /p s)stem valve close Booster station shut&own I /p gas =CV to !lare0 =CV to !lare set at 2;$ psig open to "ac- pressure an& gas "ac- presser is set at 1$6 psig it is going to /p !lare

<

I Bac- pressure =CVFs (=ressure Control Valves) are !itte& !or0 ,o stop vi"ration in lines *top soun& cutting ,o prevent !ree2ing in winter *pill over connection0 %t is a line connecte& !rom /p to 1p s)stem provi&e& with =CV set at $ psig@ Bac- up 1p s)stem when its pressure &ecrease Gas &irection eBuipment 7hen /p gas trans!er line un&er maintenance

1-2 L- $!+ S5+t#(7

%t is same as the /p s)stem@ ,he 1= gas comes !rom 1st stage separators to 1= gas s)stem 1p gas outlet !rom each separator is connecte& in a common line@ ,he common line is route& through the !ollowing@ 1p gas to Booster station 1p gas to /p !lare 1. L- $!+ to ,oo+t#r +t!tion7 ,he 1p gas !rom *eparators to "ooster station !lows through the !ollowing@ 1p gas scru""er 1p gas pressure control valve 1p Gas *cru""er0 ,his !unction is same as /p gas scru""er@ 1p gas s)stem =CV (=ressure Control Valve) 0 %t is control the all 1p separators outlet gas with the set point o! $$ psig@ 3!ter the =CV gas will route& to "ooster station@ 2. L- $!+ to H- f&!r#7 1p gas will go to !lare incase through =ressure control valves I 1p gas =CV to !lare0 =CV to /p !lare set at '$ psig the valve will open incase o! /p s)stem valve close Booster station shut&own Hote0 3!ter the 1p gas scru""er ") C Compensating gas line connecte& to tan- !illing line to maintain pressure in the main tan-s set at 2@$C w@g@

16

5. 'u#& $!+ +5+t#(7

,here are two t)pe o! !uel gas 1ean gas Rich gas : L#!n !+7

%t is coming !rom *hua"ia with the pressure o! $66 psig@ ,his gas is regulate the pressure control valve to 296 psig an& sen&ing the gas to engine gas scru""er@ 1ean gas line is &ivi&e& into three lines@ ,he lines are going to the !ollowing +esalter heaters (ngine gas scru""er ,an- pressuring valve : Ric" !+7 ,his is "ac- up to the engine gas pressure@ %! incase o! shua"ia gas pressure is getting &rop the =CV !rom the /p gas s)stem will open an& pressure will "ac-up to engine gas scru""er@ : En$in# !+ Scru22#r7

1ean gas supplies to the ,ur"ine an& CR> !rom engine gas scru""er@ ,he engine gas scru""er inlet =RV controls the pressure at 19$ psig@ 3n& the outlet =RV controls the pressure to the engine at 12$ psig@

5-1. T!n6 -r#++uri;in$ .!&.#7

%t opens automaticall) when /p hea&ers ((*+) valves shut &own &ue to an) reasons to -eep main tan-s pressuri2e& at all times through a 35; choc ,o prevent the Varic-unit !rom opening vacuum allowing air insi&e the tanan& pro&ucing e#plosive mi#ture in the !lare line o! the tan-@ ,o prevent "ac-!ire !rom 1p !lare@

4. H-9L- f&!r# +5+t#(7

/p !lare s)stem consists o!0 /ot !lare Col& !lare /ot /p !are0 Gas !rom 1= ? /p separators "urns on /p !lare when "ooster station &own or /p s)stem =CV (=ressure Control Valve) trips@ Col& /p !lare0 Gas route& to Flare when the GC is shut&own or !lare line un&er maintenance@ 1p !lare s)stem0 ,he 1p !lare consists o!0 /ot !lare the stac- t)pe Col& !lare pit t)pe

11

<. T#+t -&!nt

,est plant is use& !or0 =ro&uction test o! one 2one or "oth Gas oil ratio (GOR) test o! one 2one or "oth@ +e--illing a 2one +e-pressuri2ing a !low line@ <-1. %i& Rout# 'ro( T#+t H#!d#r To T!n6+ ,he oil route !rom test hea&ers to test tan-s !lows through the !ollowing@ ,est hea&er to test separators@ ,est plant@ 1@ ,est hea&ers0 /p or 1p wells can !low through it@ (*+V0 acts similar as main hea&ers (*+V an& it shuts on0 1ine ;6 valve0 to use it when &epressuri2ing a well First stage separator *econ& stage separator 1CVFs ,est tan- !illing line 2@ ,est tan-0 ,o measure oil pro&uction o! a well on testA oil !rom test tan- must "e pumpe& "ac") the trans!er pump to wet tan- usuall) a!ter each test ,est tan- eBuippe& with the !ollowing instruments0 1ow level shut &own (1*11) !or stopping the trans!er pump@ 1evel transmitter0 to in&icate level in +C* =ressure transmitter !or measuring the tan- vapors ,emperature transmitter0 to measure tan- temperature Hote0 ,rans!er pump is pumping the oil in test tan- to 7et tan-@

12

=. P&!nt Ar#! C"#(ic!&+

,here are two t)pes o! chemical use& to in4ect the hea&ers +emulsi!ier s)stem@ *cale %nhi"itor s)stem D#(u&+ifi#r +5+t#(7 3ll hea&ers area +emulsi!ier storage in two tan-s ,8-66; 3A B an& ; &emulsi!ier pumps are use& to pump the chemicals into hea&ers@ +emulsi!ier pump =-611 3 to /= 7et hea&er@ +emulsi!ier pump =-611 C to /= +r) 5 7et hea&er@ +emulsi!ier pump =-611 B is spare pump to =-611 3A C@ +emulsi!ier pump =-611 + to ,est hea&er@ +emulsi!ier pump =-611 ( is spare pump to =-611 +@ +emulsi!ier pump =-611 F to 1= 7et hea&er@ +emulsi!ier pump =-611 G to 1= +r) 5 7et hea&er@ +emulsi!ier pump =-611 / is spare pump to =-611 FA /@ Sc!&# In"i2itor +5+t#(7 3ll hea&ers area *cale %nhi"itor is storage in tan- ,8-66< an& $ *cale %nhi"itor pumps are use& to pump the chemicals into hea&ers@ *cale %nhi"itor pump =-612 3 to /= 7et hea&er@ *cale %nhi"itor pump =-612 B to /= +r) 5 7et hea&er@ *cale %nhi"itor pump =-612 C to 1= 7et hea&er@ *cale %nhi"itor pump =-612 + to 1= +r) 5 7et hea&er@ *cale %nhi"itor pump =-612 ( is spare pump !or =-612 3A BA CA +@

13

4. Instr!&ent air s/ste& An %ire 'ater )/ste&

In+tru(#nt Air S5+t#(7
,he instrument air s)stem !or plant is maintaining the '6 psig o! &r) air is use& to operate instruments an& eBuipments@ Hote0 ,his s)stem is having one pressure switch@ ,he set point o! the switch is 3; psig@ %! the pressure is coming "ellow 3; psig the will shut&own the gathering center@ %nstrument 3ir Compressors0 ,here are two instrument air compressor are suppl)ing the air to the s)stem@ %! one is on &ut) the other one will "e on stan& ")@ Be!ore the instrument air is sent to s)stem tit passes through humi& &r)er to &r) the air@ ,he "oth compressor has it in&ivi&ual pressure switches !or operating the compressors cut o!! an& cut on@

'ir# )!t#r S5+t#(7

,he use o! !ire water s)stem is incase o! an) emergenc) situation in the gathering center@ Fire 7ater ,an-0 ,he use o! this water !or !ire !ighting an& tan-s are -ept !ull@ ,he water is !ille& through the (3?C valve) an& it must "e !ull at all timesA when tanis !ull shut the (3?C valve) an& in!orm to the operator@ Fire 7ater =umps0 ,hese pumps are operate& ") &iesel engine@ %t is use& to pump the !ire water incase o! emergenc)@

5esa$ter Phase - I6
Introduction7
,ill recentl) wet pro&uction was a pro"lem an& wor- over were reBuire& to shut o!! the wet 2ones@ ,his was loc-ing up recovera"le reserve an& a!!ecting proper pro&uction@ 3s a solution to thisA &eh)&ration5&esalting plants were installe& in those mostl) a!!ecte& GCFs to han&le the wet pro&uction@ +esalting process is achieve& ") various com"ination o! treatment such as0 Gravit) separation Chemical treatment /eating 7ashing with water (&ilution) .i#ing wash water (agitation) (lectrical treatment (electrostatic coalescing) 3 certain amount o! each o! these !actors wor-ing together can give a reBuire& result o! the treate& cru&e@

1-1.

r!.it5 +#-!r!tion7

,he removal o! !ree water or unemulsi!ie& water !rom cru&e oilA the !ree water when given opportunit) i@e@ resi&ence time an& enough spaceA %t rea&il) separates ") gravitational metho&@ ,he gravit) settling out o! this !ree water is mainl) accomplishe& in separatorsA wet tan-s an& &esalter vessels@

1-2. C"#(ic!& Tr#!t(#nt7

+emulsi!ies chemical is a&&e& into water in oil emulsion to "rea- or wea-en the thic!ilm o! emulsi!)ing agents aroun& water &ropletsA the "rea-ing o! the !ilm allows the water &roplets to come much closer together ") the natural o! molecular attractionA !orming a large &roplet witch is easil) separates !rom oil an& settles &own !aster@

1-3. H#!tin$7
3&vantage o! heating is to help wea-en or "rea- the !ilm aroun& the &roplets ")0 /elps to &issolveA wea-en or "rea- the s-in aroun& the &roplet ") e#pan&ing the water &rop it sel! Re&uces oil viscosit) i@e@ ma-ing the oil thinner to help water &roplets !all !aster (re&ucing settling time) /elp to sprea& &emulsi!ier an& increasing chemical reactivit) in the emulsion Creates thermal currents that !orce water &roplets to colli&e thus improving the rate o! emulsion "rea-ing an& 4oining together o! &roplets@ *o!tening an& melting the s-in aroun& the &roplet an& ma-e it easil) solu"le in the cru&e oil@

1$

+isa&vantage o! heating0 /igher operating temperature increases !uel costs /igher maintenance pro"lems an& costs %ncrease scaling through &esalting units %ncrease ris- o! in4ur) %ncrease volume an& 3=% gravit) loss o! the treate& cru&e@ 7hen oil is heate&A vapor pressure increase an& light en&s li-e (thaneA .ethaneA ButaneA evaporate (!lash out) resulting to the a"ove loses@

1-1. )!+"in$ 0it" 0!t#r (Di&ution 0!t#r)

3&&ition o! less salt water into wet cru&e is ver) important an& helps to &ilute its highl) salt water content@ 7hen wash water is well &istri"ute& in cru&eA it helps 4oin together smaller &roplets an& spee& up this separation !orm the cru&e@ +issolve cr)stal salts

1-5. *i3in$ 0!+" 0!t#r (A$it!tion)

,o mi# chemical with emulsion ,o help smaller &roplets to 4oin together ,o "rea- the !ree in4ecte& volume o! 7ash water into emulsion an& &istri"ute it evenl)@ *o wash water must "e &istri"ute& in ever) &irection insi&e the wet cru&e in or&er to let wash water &o@

1-4. E&#ctric!& tr#!t(#nt (E&#ctro+t!tic co!&#+cin$)7

%t is the most e!!ective metho& that provi&es a strong &riving !orce !or removing salt water !rom cru&e oil@ Basics o! electrostatic theor)0 ,he natural composition o! the water &roplet itsel! is the "asis o! this theor)@ ,he water &roplet is ma&e up o! man) polar molecules@ (ach water molecule has one part o#)gen an& two parts o! h)&rogen@ O#)gen has a negative en& an& h)&rogen a positive en&@ ,hese polar !orces are arrange& in a shape ver) much li-e a "ar magnet an& easil) respon&s to an applie& electrical !orce !iel&@

1'

2. *#t"od+ of d#"5dr!tion
7hen the pro&uce& water in cru&e is ver) salt) as in our case thenA straight &eh)&ration is not the onl) solution an& so the cru&e has also to "e &esalte&@

2-1 D#"5dr!tion7
*impl) it means removing o! salt water !rom cru&e oil to at least 6@1 o! 1 G@ ,his is accomplishe& ") gravitational metho& through 3 phasesF separatorsA wet tan-s an& &esalter vessels@ Gravit) settling o! !ree water can easil) "e achieve& i! su!!icient retention time is given to the emulsion in the vessels@

2-2 D#+!&tin$7
.eans removing salt !rom cru&e oil ") a&&ing less salt) water@ ,he less salt) water is relativel) !resh than the highl) salt) !ormation water pro&uce& with the cru&e@ 3&&ition o! thisA so calle& !resh water &ilutes an& lowers the salt concentration o! the !ormation water remaining in the cru&e to an accepta"le level@ ,he less salt) water a&&e& into cru&e is -nown as wash water or &ilution water@ ,he !ormation water pro&uce& with the 8uwaiti cru&s normall) contains salts in range o! 1$6A666 to 266A666ppm@ ,he main o"4ectives o! install &eh)&ration5-&esalting plant0 ,o maintain !iel& pro&uction potential Clean up &rille& an& wor-e& over wells ,o provi&e an e!!ective controlling metho& that will allow a "etter reservoir pro&uction &istri"ution@ 3llow pro&uce wet wells cause& ") in4ection o! water or steam o! help recover)@ ,o increase the !inal recovera"le receives@

%n 8uwait oil !iel&sA 8OC use& a mo"ile &esalter as test an& that was in 1<9;

19

3. T"#or5 of #(u&+ion7
3n emulsion is a com"ination o! tow liBui&s that &o not mi# together un&er normal con&itions@ ,hree con&itions are necessar) to ma-e a real an& sta"le emulsionA the) are0 ,he liBui&s must "e agreea"le to mi# ,here must "e enough "rea-ing !orce to sprea& one liBui& as &roplets in the other ,here must "e an emulsi!)ing agent or emulsi!ier present@ ,)pes o! emulsion0 normall)A there are two t)pes o! water in oil emulsion ,ight emulsion 1oose emulsion@

3-1. Ti$"t #(u&+ion7

*mall water &roplets sprea& in the cru&e oilA this violent mi#ing o! water in oil can "e cause& ") su"mersi"le pumps "ig &i!!erential pressure &rop at well hea& or at mi#ing valve in the &esalter plant@ ,ight emulsion is ver) eas) to ma-e "ut &i!!icult to "rea- one "ecause it reBuires higher operating temperatureA higher chemical in4ection rates an& higher e!!orts@

3-2. Loo+# #(u&+ion7

Forme& o! large water &roplets an& it cause& ") mo&erate an& su!!icient mi#ing an& it is not &i!!icult to treat@

1. D#+!&t#r -"!+# 1/ -roc#++ rout#7

D#$!++in$ 2oot (/-001) )#t t!n6 (T8-oo1) '##d -u(-+ (P-001 A> ,> C) Crud# "#!t #3c"!n$#r (E-1019201) co&d +id# )!t#r 2!t" "#!t#r ('-1019201) 1+t ? +t!$# (R#c5c&# 0!t#r in@#ction no;;&# - (i3in$ .9. - .#++#&) 2nd ? +t!$# ()!+" 0!t#r in@#ction no;;&# - (i3in$ .9. - .#++#&) Tri.o&t#d #&#ctro+t!tic d#+!&tin$ Crud# "#!t #3c"!n$#r (E-1019201) "ot +id# %i& 2!c6 -r#++ur# (P/-1039203) ,.S.A). An!&5;#r (,!+ic S#di(#nt And )!t#r) Di.#rtin$ .!&.#+.

1;

1-1 D#$!++in$ ,oot ( /-001)

,he &egassing "oot provi&es separation o! gas !rom cru&e oil "e!ore entering the wet tan-@ 3t the 2 C !ee&ing line to &egassing "oot C line connecte& !rom ma-e up gas@ (Compensating) Gas !rom top o! &egassing "oot !low into wet tan- ,8-661 through 3'F line@

1-2 )#t t!n6 T8-001

1@ +esign con&ition +iameter /eight Capacit) +esign pressure +esign ,emp Factor 16;@3 !t <@3 !t ;6A666 Barrels 16@6 7@G 2666F 1' 6 "arrels5!t

2@ 3&vantages o! having a wet tan-0 ,o remove the remaining gas !rom the cru&e oil ,o provi&e enough resi&ence time an& enough space !or !ree water to separate an& settle &own ,o provi&e e#tra storage capacit) in case o! &esalter shut &own or &ealters circulating@

3@ 7et tan- ,8-661 is eBuippe& with the !ollowing control instruments0 Oil-water inter!ace level transmitter 1%,-661 is showing the inter!ace level on +C*@ ,he normal set point o! inter!ace level is ; !eet@ Cru&e oil level transmitters an& in&icator 1%,-663 to control the cru&e oil !low to &esalter@ Cru&e oil level transmitter 1,66$ recor&ing the oil level in control room +C* an& signaling high-level alarm 13/-66$ at 9@2 !eet@ 3n& 1ow 1evel alarm will give set level o! 131-66$ at2<@$ !eet@ Cru&e oil high high level 1*// 662 at ;@1!t signaling ,8661 ver) high level on +C* an& interloc- panel in control room 13// 662 an& causing trip o! all wet cru&e tan- actual !illing sources as selecte& ") operator ") /*-6'$A 66'A6'9 an& also trip all chemical !ee&ing pumps in hea&ers mani!ol& area@ Cru&e oil low level switch 1*11-66 A at 2'@9!t signaling ,8 661 ver) low level on interloc- panel an& +C* in control room 1311-66 an& causing shut &own o! &esalter ,R1 ? ,R2@ =ressure in&icator an& transmitter =%,-661 with local in&icator =%-661 acting on =%C-661 witch control the tan- pressure ") =V-661 on wet tan- ma-e up gas line =ressure 5vacuum sa!et) valves veric units =*V-3A BA CA + to protect the tanagainst over pressure or vacuum in case o! !ailure o! tan- pressure controlling s)stem

1<

1i!ting at 9@6C w@g an& Vacuum at 1@6C w@g

1-3 Crud# %i& '##d Pu(-+ A> ,> C7

,he purpose o! !ee& pumps is to "e pumpe& the wet cru&e !rom wet tan- to &esalter trains@ Cru&e oil !rom wet tan- ,8 661 !lows to the cru&e oil !ee& pumps suction through 2 C line 3t each !ee& pump suction an& &ischarge valves !itte& at 1'C suction an& 16C &ischarge lines (ach !ee& pump ma#imum !low rate $$A666 B=+ +emulsi!ier JC line in4ecte& into the stream o! each !ee& pump@ 3t the 2 C suction line low suction pressure alarm =31 662 at ;@6 psi an& low suction pressure shut&own =*11 663 at '@;psi that will stop "oth trains@ Fee& pump high &ischarge pressure alarm =3/ 1615261 at 236psi an& high &ischarge pressure shut&own =*// 1625262 at 2 6 psi are provi&e& FK 161 35 261 3 provi&es reset !or FRC-1625262 on wash water pump &ischarge to control wash water !low rate at !i#e& ratio "etween cru&e oil an& wash water !low rate@ Fee& pump =-6613 will automaticall) stoppe& i! in case o! train 1 shut&own an& pump =-661 C will stoppe& incase o! train 2 shut&own@ ,he spare pump =-661 B can "e selecte& !or either o! trains ") /*-661B an& it stoppe& ") shut&own o! selecte& train@ 1@ +esign con&ition Fee& pump capacit)0 1'$6 %G=. +ich5pressure0 1<$ psi +rives0 2<$ /= 2@ Fee& pump !low control valve FV-1615261 %t !unction is to control the !ee& pump !low rate@ F, 1613-2613 is giving signal to the +C* an& F%C 16135261 3 is controlling the set point ") the operator selection through FV 1615261 will control the !low rate@ ,he !low control valves FV 1615261 will automaticall) close incase o! train shut&own (solenoi& valve to "e reset !or ta-ing normal con&ition)@ 1ow !low alarm F31 1615261 at 2$A666 B=+ an& low !low shut&own F*11 1615261 at 2 A666 B=+@

1-1 Crud# H#!t E3c"!n$#r E 1019201 co&d +id#

3!ter the !ee& pump control valve cru&e oil !low through 16C line is preheate& in heat e#changer ( 1615261 /eat e#changer is plate t)pe with 16C manual ") pass valve an& "ac- !lashing !acilities on "oth charge pro&uct si&e@

26

1-5. )!t#r ,!t" H#!t#r ('-1019201)

,he water "ath heater ma-es use o! convective t)pe heat trans!er@ ,he water "ath is maintaine& at a pre-set temperature ") !iring h)&rocar"on !uel into a > t)pe !ire tu"e immerse& in the "ath@ 3 coil "un&le o! car"on steel pipe or tu"ing in a serpentine arrangement is immerse& in the heater "ath@ ,he process !low through the coil an& heat is trans!erre& !rom the "ath to the process@ ,he heater is &esigne& with a coil "un&leA which is remova"le !rom one en& o! the vessel an& a > t)pe !ire tu"e remova"le !rom other en&@ Cru&e oil a!ter heat e#changer is !e& through 12C line to the water "ath heater@ Fresh water is use& !or "oth heatersL the "ath heater must "e alwa)s !ull with !resh water@ ,he &esatler process stream cru&e oil temp is controlle& at a"ove 1 66 F at the outlet line !rom "ath heater 2@ 7ater "ath heater is eBuippe& with the !ollowing instrument control an& settings0 ,%, 1625262 (temp transmitter) is measuring the inlet temperature@ Hormall) "ath heater temp is 1 6 F to 1$6 FA high temp alarm ,3/ 16 526 at 2666 F an& high temp shut&own ,*// 1635263 at 2636 F@ ,%, 1615261 is sen&ing signal to +C*@ From the +C* ,%C 1615261 is giving signal to ,CV 1615261 to control valve !or controlling the !uel gas !low rate to heater "urner@ 3t cru&e oil line inlet to water "ath heater low oil !low alarm F31 1635263 at 2$A666B=+ an& low !low shut&own F*11 163 at 2 A666 B=+ 3@ Fuel gas s)stem to "ath heater0 Fuel gas is ta-en &irectl) !rom *huai"ah !uel gas through 1 M N line with pressure o! 2$6 to 296 psig@ ,he re&ucer valves =CV 169516; are controlle& ") +C* =%C 169516; at ,rain 3 an& =V 269526; at train B@ ,hese valves are re&ucing the pressure !rom 296 to 1'6 psig@ Fuel gas 1 M N line entering to !uel gas -noc- out pot V 1615261@ 3t -noc- out pot sa!et) valves =*V 16$526$ 3A B set at 9$ psi open to relie! !lash vessel V662@ 3!ter -noc- out pot high pressure alarm =3/ 16 526 at 9$ psi an& low pressure alarm =31 16$526$ at ; psi Fuel gas enters to !uel gas !ilter F1 1615261@ 1 M N !uel gas line enters the pre-heating coil insi&e the water "ath heater@ 3!ter pre-heating the !uel gas &ivi&e& in two streams one is pilot gas an& other one is !uel gas to main "urner@ @ Fuel gas to =ilot0 ,he pilot gas pressure re&uce& at 1$ psi ") =CV113511 @ 1ine si2e is JC an& control valves 213521 train 2@ 21

%ncase o! heater shut&own two shut o!! valves KV 16335163 C at train1 an& KV 263 35263B train 2 will close& an& stop pilot gas !lowA while KV 163B5263B open to vent the gas to atmosphere@ 1ow pilot pressure alarm =31 1115211 at @6 psi an& low pilot pressure shut&own =*11 1125212 at 3@6 psi@ $@ Fuel gas to main "urner0 (line si2e 1 MC) Fuel gas pressure to heater "urner re&uce& to 6 psi ") control valves =V 11<5126 ") signal !rom local pressure controller =%C11<5126 !rom train 1@ ,he control valves =V 21<5226 ") signal !rom local pressure controller =%C 21<5226 !rom train2@ %n case o! heater shut&own two shut o! valves KV1 63516 C at train 1A an& 26 3526 C at train 2 will close& an& stop !uel gas !lowA while KV 16 B5 26 B will open to vent the gas to atmosphere@ '@ 7ater "ath heater *5+ an& alarm setting *ignal !rom 1ow !uel press@ alarm 1ow !uel press@ *5+ /igh !uel press@ alarm /igh !uel press@ *5+ 1ow pilot press@ alarm 1ow pilot press@ *5+ /igh "ath temp@ alarm /igh "ath temp@ *5+ 1ow "ath temp@ alarm /igh "ath temp@ *5+ 1ow air press alarm 1ow air press *5+ Flame !ailure /igh sta-e temp alarm Outlet oil high temp Outlet oil low temp %nlet oil low !low alarm %nlet oil low !low *5+ ,ag D =31-11'521' =*>-11$521$ =3/-1195219 =*//-11;521; =31-1115211 =*>-1125212 ,3/-16 526 ,*//1635263 131-1615261 1*>-1625262 =31-16<526< =*>-1165216 B(-1615261 ,3/-16$526$ ,3/-1615261 ,31-1615261 F31-1635263 F*>-1635263 *et point 3$ =*% 36 =*% 6 =*% $ =*% @6 =*% 3@6 =*% 2666 F 2636F 16@$ Ft <@$ Ft 6@ w@g 6@3$ w@g 9$26 F 1'66 F 1 66 F 2$A666 B=+ 2 A666 B=+ 3ction 3larm *hut &own 3larm *hut &own 3larm *hut &own 3larm *hut &own 3larm *hut &own 3larm *hut &own *hut &own 3larm 3larm 3larm 3larm *hut &own

1 2 3 $ ' 9 ; < 16 11 12 13 1 1$ 1' 19 1;

1-4. 1+t St!$# (R#c5c&# 0!t#r in@#ction no;;&# - (i3in$ .9. - .#++#&)
1@ %n4ection Ho22le0 3 3C rec)cle water in4ection line is ta-en !rom 2n& stage vessel ") rec)cle pumps =-663 3A BA C to 1st stage vessel in4ection spool into cru&e oil s)stem@ ,he in4ection no22le is to ma-e the wash water sprea& well with the cru&e oil@ 22

2@ 1st stage mi#ing valve =+V-12152210 Cru&e oil an& rec)cle water &eepl) mi#e& ") ma-ing &i!!erential pressure (16 to1$ psi)@ ,he mi#ing valve =+V 1215221 is connecte& ") =+%C-1215221@ %ts set point is at +C* in control room setting "etween 16-1$ psi@ ,oo low pressure &rop a cross the mi#ing valve will cause o! e!!icienc) o! &esalting operationA &ue to intimate contact "etween wash water an& cru&e oilA in this case an higher salt content in the treate& cru&e stream can "e e#pecte&@ ,oo high pressure &rop will create a mi#ture "etween water an& oil with a ver) high sta"ilit)A which will "e &i!!icult to separate even in the high voltages electrostatics !iel& insi&e the &esaterA in this case a higher water content in the treate& cru&e stream can "e e#pecte&@ 3@ 1st stage &esalter vessel *-16152610 Cru&e oil mi#e& with water enters to 1st stage vessel through 16C line@ ,he oil water emulsion is remove& ") intro&ucing it into a high voltage electrostatic !iel& ") three trans!ormers@ Oil)-water inter!ace out !rom 1st stage *-1615261 through two 3C lines an& sen& to water 5water heat e#changer an& then to waste water treatment unit or to wet tan-@ 3t the top o! the vessel 1C &rain line to "e use& !or &egassing the vessel an& to chec- that the vessel is !ull o! cru&e oil "e!ore starting the trans!ormer@ ,wo 3C &rain line at the vessel "ottom connecte& to sump vessel V-661@ C slu&ge &rains line connecte& to line ;6 pit or to sump vessel@ ,he 1st stage vessel is eBuippe& with the !ollowing instrument0 Oil-water inter!ace level transmitter 1%,-16'526' is sen&ing the signal to 1%C16'526' at +C*@ 1%C-16'526' will control the signal to 1evel control valve 1CV 16'526' Hormall) inter!ace level set at $-$6G@ 1ow cru&e oil level alarm switch 1*1-16$526$ at 13@!t@ 1ow cru&e oil level shut&own switch 1*11-16 526 at 12@6 !t@ /*-1;'52;' at local panel to over ri&e the shut&own switch@ =ressure transmitter =,-1235223 sen& signal to +C* at control room (normal pressure 166 psi)@ /igh-pressure alarm =3/-1235223 set at 126 psi@ ,emp0 transmitter ,%,-1695269 sen& signal to +C* at control room (normal temp0 1 $6 F)@ ,wo sa!et) relie! valves =*V-16'526' 3A B set at 2$6 psi connecte& to relie! !lash vessel V-662@

1-<. 2nd St!$# ()!+" 0!t#r in@#ction no;;&# - (i3in$ .9. - .#++#&)
23

1@ 7ash water %n4ection Ho22le0 Cru&e oil !lows !rom 1st stage vessel to 2n& stage vessel@ Be!ore entering the cru&e oil to 2n& stage vessel the wash water !rom wash water pumps =-662 3A BAC is in4ecte& into 2n& stage in4ection no22le@ ,he in4ection no22le is to ma-e the water sprea& well with the cru&e oil@ ,o ma-e more mi#ing o! water with cru&e oil "e!ore entering the 2n& stage vessel@ %t is calle& static mi#ing@ n& 2 stage vessel oil-water emulsion is remove& ") intro&ucing it into a high voltage electro static !iel& ") 3 trans!ormer@ 2@ 2n& stage mi#ing valve =+V-11252220 Cru&e oil an& wash water or &eepl) mi#e& ") ma-ing &i!!erential pressure (16-1$ psi)@ B) the mi#ing valve =+V-1125222@ %t is controlle& ") =+%C-1125222 on +C* &epen&ing on signal !rom =+%,-1125222@ 3@ 2n& stage vessel eBuippe& with !ollowing instrument@ Oil-water inter!ace level transmitter 1%,-16<526< an& sent signal to 1%C-16<526< at +C*@ 1%C-16<526< acting on the level control valve 1V-16<526<@ 1ow cru&e oil level alarm switch 1*1-16;526; at 13@' !t@ 1ow cru&e oil level shut&own switch 1*11-1695269 at 12@6 !tA /*-1;952;9 at local panel to over ri&e the shut&own switch@ =ressure an& temperature in&icator@ %nter!ace level sight glass@ =ressure transmitter =,-12 522 sen& signal to +C* at control room@ (Hormal pressure set at 96 psi)@ %nter!ace level0 ,he oil water inter!ace level is an important operating parameter since high level can cause poor oil-water separation@ %ncrease the water level will re&uce oil retention time an& increase water retention time@ 3n& in case o! low inter!ace level it will increase the 3C electrostatic !iel& "etween the electro&es an& oil-water inter!ace@ 3lso low level can cause higher content o! slu&ge in &ischarge& o! rec)cle water to 1st stage vessel@

1-=. Tri.o&t#d E&#ctro+t!tic D#+!&tin$7

3t each &esalter vessel electric power s)stem use& insi&e &esalter vessel is the trivolte& electrostatic &esalting@ ,hree trans!ormers are provi&e& !or each vessel@ (ach trans!ormer is connecte& across two phases o! a three-phase power suppl)A to ensuring a "alance& electrical loa&@ ,he trans!orms have two important &esign !eatures0 Full reactance0

,o ensure that the trans!ormer an& the electrical suppl) s)stem cannot "e over loa&e&@ ,he &esalter can remain on line un&er upset operation con&itionL in these case water or emulsion ma) enter the electro&es s)stem a transient short circuit con&ition@ Varia"le output voltage0 %t is an o!!-loa& tap changes to the &esalters voltage level to "e &ivine ,his allows the optimum voltage level to "e selecte& !or goo& &esalting at minimum power consumption@ ,rivolte& electrostatic gri& is installe& on the centerline o! the vessel an& e#ten&s into the vessel hea&s to give the minimum electro&e area availa"le !or &esalting@ %n the three gir&s the resi&ence time in the electrostatic !iel& is appro#imatel) &ou"le that allowing more e!!icient coalescing an& improve& &esalting@ ,rivolte& s)stem connects a signal output !rom each trans!ormer to each gri& insi&e the vessel@ ,rans!ormer0 /igh temperature resistant insulating oil an& i! it is provi&e& with an insulting oil &rain@

1-B. Crud# H#!t E3c"!n$#r+ (E-1019201) Hot +id#7

3!ter the 2n& stage vessel pro&uct cru&e oil through 16C line an& !lows to heat e#changer (-1615261(hot si&e)

1-10. %i& ,!c6 Pr#++ur# (P/-1039203)7

,he plant "ac-pressure is maintaine& at a"out ;6 psigA to prevent release o! vapor ") the heate& wet cru&e oil insi&e the &esalter vessel or heat e#changer@ ,he treate& cru&e pressure transmitter =,-1635263 is sen&ing the signal to +C*@ ,he treate& cru&e pressure controller =%C-1635263 at CC* control the cru&e pressure in the train ") the control valves =V-1635263@ ,he controllers =(C-1635263 are set at ;6 psi at *C* on control room@

1-11. ,.S.A). An!&5;#r (,!+ic S#di(#nt And )!t#r)7

1@ =urpose0 ,o give a continuous in&ication o! the B@*@?7 content in the &r) cru&e line ") measuring the &ielectric constant o! the pro&uct as it possess through a special pro"e in the !lui& stream@ Changes in the &ielectric constant are cause& ") variations in the amount o! water in the pro&uct rather than o! soli&s@ ,o provi&e an automatic controlA to assure cru&e oil is rec)cle& to the wet tan-A an) time water content e#cee&s 6@1G (salt content over $=,BL poun&s per thousan& "arrels)@

2$

,he s)stem consists o! three parts0 =ro"e *ensor 3nal)2er in&icator5recor&er@ 2@ *alt an& water content anal)2er0 ,he Bualit) o! treate& cru&e oil is monitore& ") the anal)2er 3%,-1615261 (to measure the water content in cru&e) B@*?7@ ,he anal)2er 3,-1625262 in is !or measuring the salt content in cru&e@

1-12. Di.#rtin$ .!&.#+7

+iverting valves are installe& &own stream o! the "ac-pressure control valve@ ,he purpose o! the &iverting valves is to automaticall) &ivert the cru&e oil !low !rom the &r) tan-s into the wet tan-sA an) time the salt content e#cee&s $ =,B (6@1 volume G water cut)@ +iverting signal comes !rom the B@*?7 anal)2er transmitter@ ,he 3V-1615261A 3@ are open to circulate the cru&e oil through 16C line to wet tan-@ ,he 3V-1615261 B@ is open to sent cru&e oil through 16C line to &r) tan-@

5. )!+" 0!t#r A R#c5c&# +5+t#(7

)!+" 0!t#r +5+t#(7
,his s)stem consists o! the !ollowing 7ash water tan- ,8-662 7ash water pumps =-662 3A B an& C@ Flow control valve (FV-1625262) 7ater heat e#changer (-1625262 col& si&e@ Filling line to wash water tan- through C line !rom "rac-ish water ring main s)stem@ 3t !illing line 1CV-66' to control the wash water tan- level ") tac-ing the signal !rom 1%C-66' at +C* normal set pint at 2<@6 !t@ 3t !illing line "ioci&e is in4ecte& ") JC line@ 12C line to !ire raiser connecte& to wash water tan-@ 'C line !rom wash water tan- connecte& to !ire pumps@ 3ll the 'C outlet line !rom wash water tan-A JC line o! o#)gen scavenger is in4ecte&@

2@ 7ash water tan- levels settings0 /igh level alarm /igh level shut&own 33@$ !t 3$@$ !t will close inlet valve 2'

1ow level alarm 1ow level shut&own

9@$ !t 3@$ !t will shut&own &esalter plant

3@ 7ash water pumps =-662 3AB ?C@ an& !low control instruments0 ,o pump the wash water !rom wash water tan- to 2n& stage vessel@ 3t the C suction line o! each pump JC scale inhi"itor an& JC "ioci&e are in4ecte&@ *trainers at each pump suctionA an& &i!!erential gauge pressure !itte& to checi! the strainers is &irt)@ 7ash water pump =-662 3 will stoppe& i! train 1 shut&own@ 7ash water =-662 C will stop i! trains 2 shut&own@ *pare pump =-662B can "e selecte& ") selector han& switch /*-662 B an& it stoppe& ") shut&own o! selecte& train@ 3t the 3C &ischarge line Flow ,ransmitter F%,-1625262 is sen&ing the signal to !low recor&er an& controller FRC-1625262 at +C*@ ,he FRC-1625262 is to give the set point to the !low control valve FV-1625262 &epen&ing on the ratio set !rom FK-1613 5 FK-261 3 with the !ee& pump !low rate@ ,he !low control valves FV-1625262 are !itte& at the 3C &ischarge line !rom wash water pump to control the wash water !low@ ,he water !low is controlle& at set ration with !ee& pumps cru&e oil !low rate ") a !low ratio controllerA an& the reBuire& ratio is normall) set at @6 to $@6 G an& it can "e change@ @ 7ash water-heat e#changer (-1625262 col& si&e0 ,he wash water pump into the wash water heat e#changer pumps col& wash water !rom the wash water tan-@ +isposal hot e!!luent water !rom 1st stage &eslter vessel enters water heat e#changer through the inter!ace level control valve to e#change heat with the col& wash water "e!ore in4ection into the 2n& stage &esalter vessel@ 3C wash water line is in4ecte& with cru&e oil inlet line to 2n& stage vessel@

R#c5c&# 0!t#r +5+t#(7

,he rec)cle water pumps ta-en their suction !rom the 2n& stage vessel through C line an& pumpe& ") rec)cle pump to 1st stage vessel@ ,hree pumps are provi&e&A one !or ,RA3 A one !or ,RA B an& C in common stan& ")@ 3t the C suction line to rec)cle pump strainer is !itte&A an& pressure &i!!erential gauge to chec- i! the strainer is &irt)@ Rec)cle water pump =-662 3 will stoppe& i! train 1 shut&ownA an& the pump =-662 C will stoppe& i! train 2 shut&own@ *pare pump =-662 B can "e selecte& ") selection han& switch /*-662 B an& will stoppe& with select train@

29

1ocal han& switch /*-163A /*-663 3A /*-263 !or starting an& stopping the rec)cle pumps@ 3t rec)cle pump 3C &ischarge line ori!ice plate F(-16;526; is sen&ing signal to !low recor&er FR-16;526; at +C*@ (1ow !low alarm F31-16;526; at 1$16 B=+)@ 1evel in&icator transmitter 1%,-16<526< at 2n& stagevessel sen&s the signal to level controller 1%C-16<526< at +C*A which sen& the signal to level control valve 1V-16<526<@ (1evel set point $-$6G)@ 7ater-water heat e#changer (-1625262 hot si&e0 (!!luent water !rom 1st stage ") C line an& !lows to heat e#changer (-1625262 hot si&e@

4. )!+t# 0!t#r tr#!t(#nt unit ().).T)

,he purpose o! wastewater treatment s)stem is to remove oil) &roplets !rom wastewater coming out !rom &esalter plants "e!ore it is sent to &isposal pits locate& outsi&e the GC@ ,he 77, s)stem receives waste water !rom the !ollowing sources0 7et tan- inter!ace level 1st stage vessel *-161 train 1 1st stage vessel *-261 train 2 Rec)cle pump train 1 ? 2@ ,he e!!luent water to 77, s)stem is treate& in two stages@ %n 1st stage (C=%) large oil particles are "eing separate& ") gravit) separation insi&e a special &esigne& tan-@ %n 2n& stage small oil particles are separate& ") using air !lotation unit@ 77, units are provi&e& in all &esalter plants to re&uce the oil) particles to less then 16 ppm@ 77, units wor-ing on the "asic o! gravit) separation an& !lotation principles@ ,here are two t)pe o! oil in waters one is !ree oil an& the other is emulsi!ie& oil@ 3t the 1 C inlet line to waste water treatment unitA two valves are !itte& inlet valve to (C=%) K*V-6$6 3A an& ") pass valve K*V-6$6 B will ") pass the 77, s)stem an& open to &isposal pit@ 3t the 1 C inlet line !low recor&er F(-66< with !low transmitter F%,-66< sent signal to FR-66< at +C*@

T5-#+ of -&!t# u+#d in ))T +5+t#(7

2;

,here are t)pes o! plate interceptors use& in waste water treatment units@ 3=%0 alternate plate interceptor *=%0 *Buare plate interceptor C=%0 Corrugate& plate interceptor ==%0 =arallel plate interceptor Air f&ot!tion unit )-0407 ,he !lotation process is improve& ") a&&ing coagulant chemical into the e!!luent water at inlet o! the !lotator unit@ ,his chemical "rea-s oil in-water emulsionA gather suspen&e& soli&A an& sta"ili2e the air "u""les !rom !roth that !loats on the sur!ace@ ,he capacit) o! 7-6'6 is '6A666B=+@ ,he outlet !rom C=%-7$6 through 12C line enters to !lotation unit 7-6$6 that will re&uce the oil water content to less than 16 ppm@ ,he sump tan- is eBuippe& with a level switch that operates a scum pumps automaticall)@ ,he scum pump =-61'A 3A B returns the scum to *=% separator at the e!!luent water inlet@

<. C"#(ic!&+
,here are t)pes o! chemicals mainl) using phase %V &esalter plant@ 1- +emulsi!ier chemical 2- O#)gen scavenger 3- *cale inhi"itor - Coagulant chemical

1. D#(u&+ifi#r7
+emulsi!ier chemical is in4ecte& into water-in-oil emulsion to "rea- an& remove a thic- !ilm o! emulsi!)ing agents aroun& water &roplets@ ,he &osage ppm o! &emulsi!ier is 26 ppm@ 3t &emlsi!ier plant area &emulsi!ier store in two tan-s ,8-663 3?B@ an& &emulsi!ier pumps =-66 3A BA C ? +@ +emulsi!ier pumps 3?B use& at - Hormall) at train 1 !ee& pump =-661 3 suction line - 3t train 3 2n& stage vessel *-162 inlet line@ - 3t "ath heater F-161 inlet line@ +emulsi!ier pumps =-66 CA + use& at - Hormall) use& at train 2 !ee& pump =-661C suction line - 3t train B 2n& stage vessel *-262 inlet line - 3t "ath heater !-161 inlet line@

2. %35$#n +c!.#n$#r7
%t is in4ecte& into wash water s)stem to remove !ree o#)gen to prevent o#)gen corrosion@ ,he &osage ppm o! o#)gen scavenges is ' ppm@ O#)gen scavenger is store& in tan- ,88-66$ an& two o#)gen scavenger pumps =-669 3?B@ O#)gen scavenger pump =-669 3 at wash water tan- ,8-662 outlet line an& pump =-669 B is spare@

2<

3- +c!&# in"i2itor7
%t is in4ecte& into "oth wash water s)stem an& wet oil s)stem in or&er to prevent !ormation o! scale &eposits@ ,he &osage ppm o! scale inhi"itor is 26-36ppm@ 3t &esalter plant scale inhi"itor is storage in tan- ,8-66 an& !our scale inhi"itor pumps =-66' 3A BA C ? +@ ,he &esign con&ition o! ,8-66 is same as ,8-66$@ *cale inhi"itor pump =-66' 3 at train 1 wash water pump =-662 3 an& =ump =-66' B at train 2 wash water pump =-662C@ =ump =-66' C at wastewater treatment s)stem inlet line an& =-66'" is spare pump !or =-66' 3A BA C@

1. co!$u&!nt c"#(ic!&7
%t is in!ecte& into wash water treatment unit at the !loatator inlet line@ %ts purpose is to "rea- oil in water emulsion@ 3t &esalter plant area coagulant is store& in tan- ,8-669 an& two coagulant pumps =-66; 3AB@ the &esign con&ition ,8-669 is same as ,8-66$@ Coagulant pump =-66; B is spare pump !or =-66; 3

=. C&o+#d Dr!in+ And Su(- /#++#&+ S5+t#(

Su(- /#++#&7
,he &rain sump is &esigne& to receive onl) sta"ili2e& liBui& !lows ") gravit) an& not surge !lows un&er high pressure@ ,he !ollowing &rain lines are connecte& to the sump vessel@ +esalter =lant 7et ,an ,est ,an Relie! Flash Vessel =lant +rain Flash Vessel ,he main inlet o! the sump is connecte& parallel to the sump tan- an& line ;6 pit@ %n normal con&ition the sump inlet valve KV-6293 is opene& to sump an& KV-629B is close& to line ;6 pit@ %! incase o! emergenc) con&ition or sump level ver) high comes the high level switch will actuate an& it will give signal to KV-6293 sump line will get closeA KV-6293 line ;6 pit valve will open@ Su(- Pu(-+ (P-01<A> ,)7 ,here are two pumps is pumping the oil !rom sump vessel to the wet tan-@

B. St!rtu- Proc#dur# %f D#+!&t#r

1. St!rtu- -roc#dur# of D#+!&t#r f##d -u(-7
36

Contro& roo(7 =ress R(*(, push "utton (/*-166 5 2663)@ At DCS Con+o&#7 *elect alarm histor) page an& veri!) status o! all eBuipments an& process points *elect group &ispla) (1<< 5 266) an& put the !ollowing settings *elect Fee& pump &ischarge !low controller F%C 161 5 261 to put in manual an& set the out put at 36 G@ *elect the 1st stage an& 2n& stage mi#ing valves controller(=+%C-121 5 221!or train 3A =+%C-112 5 222 !or train B) to put in manual an& set the output at $6G@ *elect the "ac-pressure controller =%C-163 5 263 to put in manual an& set the output at 9$G@ *elect 1st an& 2n& stages inter!ace level controllers 1%C-16' 5 26' an& put the set point at $G@ *elect the wash water !low controller F%C-162 5 262 an& -eep in remote@ *elect /eater temperature controller ,%C-161 5 261 to "e put in manual an& set the o5p at 6G@

(lectrical *u"-*tation an& !iel& si&e0 R(*(, the !ee& pump (=-661 3A BA C) power suppl) circuit "rea-er in the electrical su"-station an& chec- the !ault in&ication shoul& get OFF@ %n the !iel& manuall) R(*(, the !ollowing )ar& solenoi& switches o F*O-161 5 261 (7et cru&e !low controller) o F*O-162 5 262 (7ash water !low controller) o F*O-16' 5 26' (1st stage inter!ace controllers) o F*O-161B 5 261B (,reate& cru&e &iverting valves) *tart the !ee& pump (=-6613 5 C) an& esta"lish oil circulation through &esalter plant *tart the 7ash water pump (=-662 3 5 C) it is in4ecte& with cru&e oil inlet line to 2n& stage &esalter vessel@ *tart the trans!ormers !or "oth stages

31

3t +C* control station chec- 2n& stage train 3 5 B water inter!ace level a!ter reaching $G o! water level start the rec)cle pump(=-663 3 5 C)@

C"#(ic!& Pu(-7 *tart the o#)gen scavenger pumps (=-669 3 5 B ) to wash water tan- ,8-662 an& set in4ection stro-e rate percentage as reBuire&@ *tart Bioci&e pumps(=-66$ 3 5 B or C 5 +) an& corrosion-cum scale inhi"itor pumps(=-66'3 5 B or C 5 +) to wash water pumps =-6623 ? B an& set in4ection stro-e rate percentage as reBuire&@

Contro& roo(7 *elect the group &ispla) (1<< 5 266) an& put the !ollowing settings@ *elect an& slowl) a&4ust the cru&e !low rate on F%C-1615261 to reBuire& rates@ Raise the set point to match the actual !low an& then switch F%C on 3uto@ *et the mi#ing valve as !ollows@ 1st stage =+%C1215221 12 psi@ For 2n& stage =+%C-1225222 put 12 psi set point ensure the =+% controllers are on auto@ *elect the "ac-pressure controllers =%C-1635263 an& slowl) &ecrease the output to get ;6-psi process valueA an& then switch =%C on auto@

2. St!rtu- -roc#dur# of ,!t" H#!t#r7

*elect the &esalter heater graphic an& switch ,%C-1615261 to manual an& set ,CV Output at 2$G@ =ress *hut&own R(*(, push"utton on the heater control logic panel@ 3!ter press the R(*(, "utton wait until timer moves at 2ero position@ ,hen press the "urner *,3R, "utton /eater start seBuence will "egin 7ait until main !lame OH lights comes on the heater panel %n +C* chec- the heater status shoul& "e running in&ication comes %n +C* switch temperature controller ,%C-1615261 to auto an& set at 1 $ &egree F@ 3!ter two hours collect samples !rom 2n& stage cru&e outlet i! result :6@1G or less (7ater Cut) :$ B,= or less salt@ R(*(, the &iverting valve /*-1165216 R(*(, solenoi& valves o! &iverting classes

32

?Tro!9$e )hooting Of 5esa$ter

C%CDITI%C 1. '&uctu!tin$ /o&t!$#9Curr#nt P%SSIA,LE 'AULTS 1@ +amage& entrance "ushingA trans!ormer "ushingA electro&e insulator or trans!ormer@ C%RRECTI/E ACTI%C 1@ Call maintenance to carr) out the !ollowing@ a) +isconnect power to unit open "ushing housing an& &isconnect the copper wire "etween the entrance "ushing an& trans!ormer "ushing ") 7hen &one with the a"ove re-energi2e trans!ormer5reactor@ %t !ault has cleare&L the pro"lem is either the entrance "ushingA or an insulator@ %! !ault &oesnFt clearA the pro"lem is pro"a"l) the trans!ormer "ushing or the trans!ormer5reactor unit@ 2@ Chec- tr) coc-sA i! emulsion la)er is in&icate& in upper two tr) coc-sA lower water level as much as possi"le an& increase chemical rate@ %! la)er is not cleare& in ;-12 hrs &ump water an& emulsion la)er to pit an& re-esta"lish level@ 3@ Open mi#ing valve completel)@ 3llow voltage to return to a stea&) state an& re-esta"lish optimum mi# valve setting@ 1@ Chec- water level an& lower as reBuire&@ 2@ %ncrease wash water rate@ 3@ %ncrease wash water rate@

2@ (mulsion la)er inter!ace

3@ /igh &i!!erential pressure &rop at mi#ing valve@

2. Hi$" +!&t cont#nt in t"# d#+!&t#d crud#.

1@ 7ater carr) over high 2@ Fee& salt content high@ 3@ 7ash water in4ection rate low@

33

@ Cru&e oil !low rate e#cee&e& &esign capacit)@ $@ %nsu!!icient mi#ing o! cru&e oil an& wash water@

@ Re&uce cru&e !low rate to increase retention time@ $@ %ncrease mi# valve &i!!erential pressure@ '@

3. Hi$" ,SA) cont#nt in t"# d#+!&t#d crud#.

1@ %nsu!!icient mi#ing o! wash water in the cru&e@ 2@ /igh inter!ace level@

1@ %ncrease mi# valve &i!!erential pressure@

2@ Chec- these !ollowing@

i@ Chec- water level using tr) coc-s@ 1ower level i! necessar)@ Chec- water in4ection rate@ Re&uce i! necessar)@ Chec- water &ump valve an& a&4ust i! reBuire&@

ii@

iii@

3@ /igh water-cut in cru&e@

3@ Chec- these !ollowing@

i@ ii@ 7ater in4ection rateA i! too highA &ecrease the rate@ Chemical in4ection rate to hea&ers@ %! lowA increase@ Chec- wet tan!or possi"le emulsion la)er !orme& a"ove inter!ace levelA uses tr) coc-s@ Following wells !or a"normal change@ (i@e@ high water-cut or tight emulsion@

iii@

iv@

@ Ba& sampling@

@ Flush sample pointsA use clean sample "ottles an& ta-e !resh sample@ 3

1. Introduction %f CRU
,he process o! liBue!)ing the tan- vapors5gas is &one within a unitA -nown as C@R@> (con&ensate recover) unit)@ ,he purpose o! CR> is to recover tan- vapors in the !orm o! con&ensate5 liBui& that woul& otherwise have "een !lare&@ CR> is manl) consists o! muti-stage compressors a &river an& cooling s)stem@ ,he &river is an internal com"ustion engine@ ,he engine t)pe mostl) use& in *(8 is a cooper Bessemer G.73-; NVC integral gas engine &riving 3 stage compressors@ %nter-stage cooling o! compresse& process gases is &one through shell an& tu"e heat e#changer@ Cru&e oil !rom the transit pump s)stem or !rom the separators is use& as the process-cooling me&ium@ ,wo !orce& air &ra!t !ans are use& to provi&e cooling &ut) !or the compressor lu"e oil an& !or the engine 4ac-et water@ %n this 3 stage compressor the !ee& gas inlet pressure is normall) 2@$Cw@g@ an& out let pressure is a"out '66 psig@ 3!ter 2n& stage some gases change into liBui& (con&ensate)A this liBui& or con&ensate is pumpe& to the re!iner) !or !arther processing into Butan =ropane an& 8HG (8uwait Hatural Gasoline) pro&ucts@ ,hese ")-pro&ucts are then store& in special 1=G tan- within the re!iner) area "e!ore the) are e#porte& the 1=G tan-s are &esigne& to maintain the pro&ucts in their liBui& !orm !or long perio& o! time@

2. Proc#++ '&o0 Rout#

CRU -roduction f&o07 Flow tan-s 1p !lare line 3'C valve Vessel C-161 *uction "ottle 1st stage compressor +ischarge "ottle (-161 cooler Vessel C-162 *uction "ottle 2n& stage compressor +ischarge "ottle (-162 cooler Vessel C-163 *uction "ottleA 3r& stage compressor +ischarge "ottle G-161 (-163 cooler Vessel C-16 G-162 3$

2-1.

-101 -u(-+7

%t pumps the liBui& !rom C163 through ( 163 to C16 @ +ischarge pressure is appro#imatel) 966 psig@ G161 has a circulating line connecte& !rom the pump &ischarge line "ac- to vessel C163@ ,he circulating liBui& passes through a small hole 95' C in an ori!ice plate !itte& in the circulating line@ ,he CR> will not shut&own when G161 stops@ But i! not restarte& soonA units will shut&own on (high level C163)@ 3n auto &ump is !itte& on each suction o! G161 pump i! G161 stops an& C163 level reaches a certain high pointA auto &ump will open &umping e#tra liBui& to main tan!illing line through N8C valve@ ,his is to avoi& high-level shut&own@ ,he chec- valve !itte& on G161 &ischarge line is to stop the gas in (163 !rom going "ac- to C163 when G161 is not running@ 2-2. ?102 Pu(-7

%t !unction is also same as G-161 pump@ But it pumps out con&ensate !rom C-16 to con&ensate pipeline s)stem@ ,he &ischarge pressure is appro#imatel) 1666psig Hote0

(. C- GM'A-3 Engine 5es"ri*tion

,he Cooper-Bessemer G.73-; is a stro-e c)cle NVC t)pe engine using gas as !uel@ ; nos@ power c)lin&ers are arrange& in 2 "an-s at an angle o! 3' &egree "etween the centerline o! the 2 "an-s@ ,hus the name V t)pe "eing given@ Facing the !l)wheel en& the power c)lin&ers are &esignate& le!t "an- an& right "anan& is num"ere& 11A R1 starting !rom the en& opposite to the !l)wheel@ ,he engine rotation is cloc-wise !acing the !l)wheel@ ,he engine is rate& at 2666 /= at 2$6 R=.@ nos compressor c)lin&ersA 2 on either si&e o! the engine are &riven ") connecting ro&s &irect !rom the engine cran-sha!t@ ,he engine5compressor unit (8969) is &esigne& to compress < ..CF5&a) o! tan- vapors in 3 stages to $<$ psi@ ,he Buantit) o! con&ensate pro&uce& !rom <..CF5&a) o! tan- vapor varies consi&era"l) with the Bualit) o! the vaporsA "ut a !air average woul& "e $66B"ls5&a)@ (ach c)lin&er hea& is eBuippe& with a gas ignition valveA starting air valveA in&icator coc- an& two spar- plugs@ ,wo camsha!tsA one !or each c)lin&er "an- are chain &riven !rom the cran-sha!t@ Cam !ollowers operate the gas in4ection valves through push ro&s an& roc-er arms@ Roc-er arm pins are lu"ricate& ") a special !ee& !rom engine lu"e-oil s)stem@ =istons are internall) coole& ") a continuous spra) o! oil through a &rille& passage in each connecting ro&@

3'

3-1. D#finition %f C, CB0 G0 .0 70 30 ;0

*)A-= En$in#7

*tan&s !or Cooper Bessemer *tan&s !or gas engine *tan&s !or integral engine (i@e@ engine an& compressor "uilt together into one unit)@ *tan&s !or "ore an& stro-e si2e( i@e@ 1;C "ore # 26C stro-e *tan&s !or t)pes o! scavenger (i@e@ air "lower t)pe)@ *tan&s !or ; c)lin&ers engine@

(-#. Po7er C/$in er o*erating *rin"i*$e? %t provi&es in the essential power !orce reBuire& to &rive the engine ") "urning in the correct ratio o! !uel air mi#ture@ ,he c)lin&er has gas in4ection valveA two spar- plugsA air inta-e ports an& gas e#haust ports@ ,he !uel gas in4ecte& into the c)lin&er hea& at the proper time an& is mi#e& with the suppl) o! !resh air that has 4ust "een a&mitte&@ *ince the two ports(inta-e an& e#haust) are close&A the gas :air mi#ture is compresse& an& the pressure insi&e the c)lin&er is increase&@ ,his is calle& the NCompression stro-eC@ 3s the piston moves !urther towar& the c)lin&er hea&A the compression o! the !uel gas-air mi#ture continuous until reaches near top &ea& center (,+C) where it is ignite& ") the twin spar- plugsA a!ter which the piston is !orce& "ac- to the cran- en& as the com"ustion charge e#pan&s@ ,his is the N power stro-eC@ 3s the piston approaches the en& o! this power stro-eA "ottom &ea& en&(B+C) the e#haust ports are uncovere& again to push out the "urnt gases as mentione& a"ove completing the c)cle@ 3-3. Lu2# %i& S5+t#(7 ,he s)stem lu"ricating the engine supplies lu"e oil to all internal moving part accept power c)lin&erA air "lower an& compressor c)lin&ers@ ,he power c)lin&er linear an& compressor c)lin&er are lu"ricate& ") mechanical !orceA !ee& lu"ricators an& seBuential &istri"ution s)stem@ (,arpon lu"ricator s)stem)@ ,he lu"ricating oil is store& an& collecte& in the un&er groun& tan- an& the engine cran- case sump@ ,he engine lu"ricating s)stem in pressure& ") 3u#@ 1u"e oil pumpA pre lu"e oil pump an& main lu"e oil pump &uring engine running@ : Pr# &u2# oi& -u(-7 Be!ore the start up lu"e oil is supplie& to all parts o! the engine ") pre lu"e oil pumpA which is air &riven@ ,his pump will give 3-$ psi pressure to the s)stem "e!ore start up@

39

: *in# &u2# oi& -u(-7 %t is a rotar) gear t)peL sel! lu"ricate& pump an& chin &riven !rom the engine gas@ %t is mounte& on the opposite en& o! ht !l)wheel@ Relie! valve set at 9$ psig protects the pump an& s)stem against e#cessive pressure@ ,he lu"e oil is pumpe& !rom the engine sump through a thermostat to the oil cooler (!in !an)@ 3!ter the cooler lu"e oil passes through !ilterA an& strainer to the main lu"e oil hea&er@ /ea&er in the engine "ase@ Form the galler) lu"e oil is supplie& to all lu"rication point accepts power c)lin&erA air "lower an& compressor c)lin&er@ : T"#r(o+t!t 0!&&7 3ccor&ing to the temperature it allows oil to ") pass or "e coole& ") the coolerA an& so automaticall) regulates the temperature@ : 'in f!n7 3 serous o! lu"eA through which the lu"e oil an& water passP@ 3 !an "lower air over the tu"e an& cools the lu"e oil@ ,he cooler consists o! two sections@ One section is !or cooling the waterA an& the other section is !or cooling the lu"e oil@ ,he !an is &riven ") electric motor@ %! vi"ration occurs "ecause o! a "ro-en "la&eA vi"ration switch will stop the !in !an@ Rest "utton must "e presse& "e!ore restarting@ : Po0#r c5&ind#r &u2ric!tor ICH 107 ,he power c)lin&ers are lu"ricate& !rom !lange t)pe lu"ricator@ 3 common sha!t &riven ") the engine actuates the lu"ricator@ 1u"e oil %C/ 6 settings0 =ressure 1ow pressure trip ,emp *hut&own Co(-r#++or c5&ind#r &u2# oi& ( EC-140)7 Compressor c)lin&ers are lu"ricate& ") G(C '6@ 3n& the normal pressure is 166-126 psi@ ,he low pressure set at 6 psi@ %! either the power or compressor lu"ricator reservoirs are !on& to "e empt)A &on not restart the unitA "ecause in this case plungers will "e air loc-e& an& reBuire maintenance &ept@ to &isconnect an& prime each plunger an& lu"ricating point@ 36-3$ psig 1$ psig 1'6-196 F 26$ F

3-1. 'u#& $!+ +5+t#(7

3;

Fuel gas suppl) to the CR> is !rom engine gas scru""er at 13$ pos@ the !isher << regulating valve is re&uces !uel gas pressure 2 6 psi an& the sensing line is connecte& with !ilter outlet@ ,his !ilter has an auto &ump@ : /#++#& C-10B7 ,his vessel is a scru""er to ensure no liBui& is allows into the engine@ %! liBui& !rom that will &ump with the normal &rain to a pit@ %t has a relie! valve set at <6 psi@ : 'u#& $!+ -&u$ .!&.#7 ,his valve is use& to shut&own the engine manuall) or emergenc) case@ : 'u#& +"ut off .!&.#7 %t shuts o!! gas suppl) an& vents the !uel gas !rom the engine &uring normal an& emergenc) shut&own@ ((*+)@ +uring start upA when ignition in&icator comes on at F,-$6 panelA instrument air is applie& to the &iaphragm o! the valve to open the gas port an& close the vent port o! the valve@ : 'u#& contro& .!&.#7 ,his is the main control valve that regulates the !uel gas pressure to the engine@ %n other wor&s it is the valveA which controls the spee& o! the engine increase or &ecrease@ %t is remotel) an& manuall) controlle& !rom the F,-$6panel@ +uring start-up the !uel gas control valve is at the minimum open position (set to regulate to the light up pressure o! 16-12 psi !uel gas)@ %n or&er to run the engine at minimum spee& o! 1'$ R=.@ : !+ in@#ction .!&.#+7

,he) are operate& ") cam-!ollowers through push ro&s an& roc-er arms@ 3 "urnt out gas in4ection valve will result in heav) smo-e an& &etonation o! the engine@

3-5. I$nition +5+t#(7

,he purpose o! ignition s)stem is to !urnish is spar- in the com"ustion cham"er o! the c)lin&er to the !ire the air5 !uel mi#ture at the proper point in the stro-e seBuence to maintain smooth engine !iring@ %n each c)lin&er has two spar- plugs !ire& simultaneousl) to provi&e continuous an& rela) a"le ignition@ ,win spar- plugs in each power c)lin&er hea& provi&e source o! ignition at all loa&s an& spee& to the engine@ ,win spar- means a s)stem in which the two spar- plugs !ire at the same time@ %n the twin spar- s)stemA i! one o! the plugs !ail the other plug will !ire@ ,he purpose o! the twin spar- is to permit more e!!icient com"ustion an& improve relia"ilit) o! the s)stem though "ase-up ignition@ U&tr!+onic 11-CP/-i$nition +5+t#(7 ,his new s)stem consists o! an ultrasonic generator unitA the ultrasonic unit provi&es a&eBuate starting out put at an engine spee& 36-$6 R=. an& ensures !ree operating 3<

&uring running perio&@ ,his ignition s)stem operate& &uring start upA the engine is cran-e& !or 9 secon& !or purging seBuence@ 3!ter this perio& a rela) on F,-$6 panel is energi2e& an& sen&s out a 2 volt +C signal to the ultrasonic C=V via a reall) "o#@ ,he coils step up the primar) voltage !rom low to high tensione& charge the sparplugs !or a 2 secon& perio&@ 7hen the ignition on in&icator light is on the F,-$6 panel &uring start upA the !ollowing events ta-e place0 ,he rela) "o# is energi2e& an& the ignition switch insi&e is open to remove groun&ing o! the ignitions s)stem@ ,he !uel shut o!! valve is signale& to open to in&icate the ignition !iring seBuence@ ,he ignition C=V is programme& with the engine !iring seBuence logic &erive& !rom 3'6 "ar holes &rille& along the perimeters e&ge o! the !l)wheelA each hole representing one &egree@ Four magnetic pic--ups are !i#e& opposite the rotating si&e o! the !l)wheel an& at opposite the rotating si&e o! the !l)wheel an& at a &istance o! 6@1$C air gap !rom the rotating path o! the !l)wheel to o"tain optimum sensing o! pluses@ (ach pic- up has its own separator !unctionA as &escri"e& "elow@

=ro"e 1- transmits rotational signals to F,-$6 panel !or spee& in&uction on tachometers an& !or over spee& protection@ =ro"e 2- signals altronic ignition control unit to initiate !iring seBuence through altronci C=>@ =ro"e 3- sen&s ignition timing signal to the altronic C=V ") measuring revolution o! the !l)wheel to in&icate which power c)lin&er is rea&) an& in the !iring line@ =ro"e - transmits signal to F,-$6 panel spee& carsA as a "ac- up !or spee& in&ication an& !or over spee& trip rela)

1.
T"# co(-r#++or7

!+ Co(-r#++or

3 reciprocating compressor is positive &isplacement eBuipment an& an integral part o! a CB engineA sharing the same cran-sha!t@ ,he cran-sha!t transmits the pro&uce& energ) !rom the power pistons to the compressor pistons@ ,he compressor c)lin&ers arrange& hori2ontall) an& connecte& in such a wa) that the piston movement is perpen&icular to the cran-sha!t@ %n this wa) the cran-sha!t converts the rotar) motion into reciprocating movement@ Co(-r#++or o-#r!tion7 ,he 1st stage has two c)lin&ersA hori2ontall) oppose&@ ,he inlet gas is &rawn !rom C-161 at 2@$Cw@gA which is connecte& to the tan- vapor ha&er@ithe1st stage compressor the gas an& &ischarges at appro#imatel) $; psig into vessel C-162@ ,he pressure &epen&s on engine spee& an& num"er o! unloa&ers screwe& in or out@

,he gas is &rawn !rom C-162 at appro#imatel) $$ psig into the 2 n& stage compressor an& compresse& up to 1< psig@ ,he 2n& stage has onl) one c)lin&er@ ,he gas is &ischarge& into vessel C-16 @ ,his 3r& stage also has onl) one c)lin&er@

5.%-#r!tin$ Proc#dur#+
CRU Pr# St!rt-u- C"#c6 Li+t7 *eparator area0 *eparator plant pro&uction not less than '6A666 B"ls5&a) *econ& stage separate pressure '6 psi@ CR> process s)stem0 1@3'C suction valve to C-161 open@ C161 vessel &raine& an& &rain shut Gas rec)cle valve 'C !rom 3r& stage compressor &ischarge valve open@ Four unloa&ers out 3ll vent valves are shut C162 manual &rains shut an& auto &ump set !or correct operation C1635C16 auto water &ump set !or correct operation C163516 e#tra &umps an& set !or correct operation Open the suction valves an& G1615G162 Valve on circulating line !rom G162 &ischarge to C16 open %solating valve on transit line to re!iner) open C16 =RV >5s an& +5* valves open an& ")-pass shut Quic- &rain >5* valve open *uction an& &ischarge "ottle &rains are shut Cru&e oil cooling s)stem0 ( 161 cru&e oil outlet valve is set to give appro#imital)1266 F outlet temperature@ Open manual &rain to chec- !or cooler tu"es lea-@ ( 162 cru&e oil outlet valve is !ull) open@ Open manual &rain@ (163 cru&e oil outlet valve is !ull) open@ Open manual &rain automatic temperature controller >5* an& +5* valve openA an& set at <66 F@

,he pressure &rop o! the cru&e oil across the cller inlet to outlet shou& not e#cee&s 2@$ psi@ 3s this puts unnecessar) loa& on the pumps@ ,he trimming valve controls@ ,his &oes not appl) to CR>Fs where hot oil s)stem is use& !or cooling@ *cavenge air s)stem0 *an& "lower switche& on 7ater an& mercur) manometers are service a"le@

'u#& +5+t#( Valve on engine gas scru""ers is open Gas valve >5 stream !isher << (Big Eo) open =ressure &own stream o! (!isher <<C regulator is 6 psi) C16< &raine& o! an) liBui& Fuel gas plug valve open Governor gas valve is shut position@ DCS Contro& Roo(7 =ress CR> R(*(, push"utton at the operator console@ 3t the +C* chec- an& ensure the !ollowing0 C-163 ? C-16 level controllers set points are correctl) set 1ean gas pressure controller =%C-$2$ put the set point at $$6psi Compensating gas pressure controller =%C : $29 !or &r) tanan& =%C-661 !or wet tan- set points are set at 2@;C 7G@ 1= hea&er "utter!l) valve set to control at 3@;C 7G@ %T-.0 Pane$? 3t F,-$6 control panel turn N3C8-R(*(,C -no" to R(*(, position an& chec- the !ollowing@ >nit shut&own start permissive@ Class B shut&own start permissive *tart air pressure start permissive Fuel gas pressure start permissive +C* start permissive

HO,(0 Class B shut&own consists o! the !ollowing points 1ow lu"e oil pressure shut&own Eac-et water low-pressure shut&own =ower c)lin&er low !low shut&own Compressor c)lin&er low !low shut&own@ =ut *,O= 5 R>H switch on stating panel on R>H position@

St!rt-u- Proc#dur# of CRU7

1@ =ress N3>,O *,3R,C "utton@ =re lu"e oil pump start Class B shut&owns are overri&&en (")-passe&) !or 1;6 sec@ *eBuence progress light comes OH <6 sec a!ter oil pressure reaches $ psi cran- permissive comes OH 2@ N Cran-case OH C *tarting motor cran-s the engine !or 9 sec(purge time)

3@ N %GH%,%OH OH C %gnition coils charge spar- plugs !or 2 sec perio& an& ignition in&ication comes OH

@ N F>(1 OH C Fuel shut o!! valve opens Fuel control valve allows 16 to 12 psi gas !low to the engine to attain minimum spee& o! 1'$ R=.@ 1= Buic- vent valve close automaticall) 3t <6 R=. spee& starter motor au#iliar) an& pre lu"e oil pumps stops Class B shut&own overri&e in&icators are cleare& $@ N 73RH >= OH C@ 7arn up timer is energi2e& !or 1;6 sec (ngine remains running on i&eal spee& 1'$ R=. &uring this perio& 7hen lu"e oil temperature reaches 116 &egree F N3CC(1 =(R.%**%V(C light comes OH@ '@ N >H%, R(3+O ,O 1O3+ OHC@ ,he engine is now rea&) to increase spee& an& !or loa&ing up 3!ter unit rea&) to loa& comes OH normall) close the starter motor isolating valve@ 9@ N1O3+%HG >=C@ %ncrease the engine spee& to 226 R=. using the raise push"utton *lowl) close the 'C ")pass valve !rom thir& stage !illing =ut unloa&ers in as reBuire& an& watch C-161 pressure 7hen liBui& appears in C-163A prime the G-161 pump an& *tart the G-161 pump 7hen liBui& appears in C-16 A prime the G-162 pump an& *tart the G-162 pump .anuall) stro-e C-162 auto &ump valve an& C-163 an& C-16 water &ump valves to ensure the) are in wor-ing or&er@ Chec- the controllers status on the +C* an& ensure that C-163A C-16 levels an& C-16 pressure controls are O8@

?Tro!9$e )hooting Of CR=

C%CDITI%C 1. C-101 Pr#++ur# &o0. (L#++ t"#n 0.<D) .) P%SSIA,LE 'AULTS 1@ Butter valve or compensating valve not wor-ing properl)@ 2@ =ro&uction is less C%RRECTI/E ACTI%C 1@ ,a-e one or more un loa&ers out@

2@ Report to 3

then "e!ore@

3@ *witch is !ault)@

instrument &epartment@ (For chec-ing !ault no 2?3)

1@ 1ower (-161 temperature@ 2@ Report to maintenance &epartment@ 1@ Raise (-161 temperature@

2. 2nd +t!$# co(-r#++or "i$" di+c"!r$# t#(-#r!tur#.

1@ (-161 outlet temperature is too high@ 2@ Compressor suction or &ischarge valves or lea-ing@

3. LiEuid &#.#& in C-102.

1@ (-161 outlet temperature is too low@

2@ 3uto &ump is not wor-ing properl)@

1. Lo0 &iEuid &#.#& in C103. 1@ 3uto water &ump is stuc- open@ 2@ C-163 1CV is not wor-ing properl)@ $@ C-163 1CV is not wor-ing properl) or *witch is !ault)@ '@ G-162 is not pumping@

2@ Chec- auto &ump valve &rain the C162@

1@ *hut auto water &ump upstream valve@ 2@ Report to instrument &epartment@ 1@ Report to instrument &epartment to checthe 1CV ? switch@ 2@ Report to maintenance to checthe prime the pump@ 1@ Report to maintenance &epartment@ C-16 pressure controller put on manual@ Chec- C-163 outlet temperature@ %t must "e a"ove ;66 F@ Report to instrument &epartment@

5. Hi$" &iEuid &#.#& in C-103 .

4. Hi$" Pr#++ur# in C-103.

1@ 3r& stage compressor

suction valves are lea-ing@

<. Hi$" Pr#++ur# in C-101.

1@3utomatic pressure controller is not wor-ing properl)@

2@ C-16 pressure control valve !ro2en@ 3@ 1ean gas line to /p gas s)stem is !ro2en@

=. -101 -u(- i+ U9S (not -u(-in$) !nd (or# cond#n+!t# i+ n##d#d.

Bro-en pump impeller@

Open C-163 &rain to pit@ *hut G-161 suction valve@ Raise (-162 temperature watching 3r& stage compressor &ischarge

temperature not e#cee&e& 2'66F@ Report to maintenance &epartment@ Report to electrician@

*heare& coupling@

B. -102 (otor !(-+ !r# too "i$".

10. -1019 -102 -u(c!-!cit5 d#cr#!+#d.

(lectric motor is >5*@ 3mpere meter is !ault)@ G-162 motor is overloa&e&@ *uction hea& or level low@ /igh &ischarge pressure@ 1ow suction pressure@ %mpeller &amage&@ 3ir loc- in the water s)stem *urge tanlevel is low@ Full !low !ilter is ver) &irt)@ (ngine sump level is low@

(lectrician to chec- the ampere meter@ ,a-e one or more un loa&ers out@ 1@ Chec- C-163 5 C-16 levels an& a&4ust i! necessar)@ 2@ Chec- the C-163 5 C16 1CVFs &own stream valves@ 3@ *top pump report to maintenance@ 1@ Open "lee& points@ 2@ Fill up surge tan-@

11. )!t#r -r#++ur# i+ &o0.

1@ 2@

12. Lu2# oi& -r#++ur# i+ &o0.

1@ 2@

13. Lu2# oi& or 0!t#r out&#t t#(-#r!tur# i+ "i$".

1@ Fin !an stopper@ 2@ Fin !an on low spee&@ 3@ ,hermostat is not operating correctl)@ 1@ 1u"ricator reservoir is empt)@ 2@ *ha!t &rive is sheare&@ 3@ *hut&own switch is !ault)@

1@ Report to maintenance &epartment to clean !ilter@ 2@ Fill up to normal level manuall) i! !loat is >5*@ 1@ Call electrician an& restart !an@ 2@ Change to high spee&@ 3@ Report to maintenance &epartment@ 1@ +onFt start the unitA plungers are chec-e& an& reBuire maintenance@ 2@ Report to maintenance $

11. Co(-r#++or c5&ind#r &u2# oi& -r#++ur# &o0.

3@

15. En$in# i+ d#ton!tin$.

1@ 1ow scavenges air pressure@ 2@ 3 "urnt gas in4ection valve@

1@

2@

14. Po0#r c5&ind#r t#(-#r!tur# i+ &o0.

1@ *par- plug is !ault)@

1@

2@ Gas valve is not wor-ing properl)@ 3@ %gnition C=> ma) not "e giving output to the spar- plug or particular wire is loose@ 1@ Fuel gas valve is not wor-ing properl)@ 2@ *pee& sensor !ault)@ 1@ +uring g start up i! an) proce&ures are not complete& an in complete seBuence trip is generate&@ 1@ 7el&ing woris going insi&e the G@C@ 2@ >V is !ault)@

2@

&epartment@ /an& prime the s)stemA s)stem to test !ail sa!e shut&own switch@ ,a-e un loa&ers out an& report to maintenance &epartment@ *top the unit an& report to maintenance &epartment@ Report to maintenance &epartment to checthe gas valve@ Report to auto electrician@ to

3@ Report %nstrument &epartment@

1<. En$in# o.#r +-##d.

1=. Inco(-&#t# +#Eu#nc#.

1@ Report to instrument &epartment to Chec- the !uel gas valveA an& spee& sensor@ 1@ Report to instrument &epartment@

1B. U/ d#t#ctor #n$in# 9 -u(- !ctu!t#d.

1@ *top the >V &etectors suppl)@ 7hen wel&ing is going insi&e the G@C@ 2@ Report to instrument &epartment@

'

20. En$in# .i2r!tion Hi$".

1@ *witch can "e !ault)@ 2@ 3n) &amages insi&e the engine@

1@ Report to instrument &epartment@ 2@ Report to maintenance +ept@

1. Intro !"tion Of R!ston T!r9ine TA-1.00

,he Ruston mar- ,3 1$66 gas tur"ine is use& to &rive the main cru&e oil pumps@ %t operates on an open c)cle@ ,he gas tur"ine has a power rating o! 12'6 Brea- hours power@ ,he tur"ine has the a&vantage o! "eing a"le to run !or long perio&sA with little maintenance cost@ %t is having a long service li!e can "e o"taine& ") re&ucing num"er o! starts an& ") not e#cee&ing the recommen&e& gas temperatures@ ,he gas tur"ine pro&uces continuous !low o! compresse& air !rom the air compressorA continuous com"ustion within the com"ustion cham"er an& continuous power &eliver) !rom the tur"ine section@ %n GCD1 has two transit pumps are &riven ") gas tur"ine !or &ispatching the cru&e oil@ Both tur"ines are operating with &i!!erent control s)stems@ One is *ervo oil control s)stem an& other one is eBuippe& with 7oo& 7or& e#cel 2$6 =1C control s)stem (programma"le logic control)@ ,he pump sets is compose& o! main pump an& Booster pump@ 7hich are arrange& in series with each other@

1-1. %-#r!tin$ c5c&#7

3s the air passes to the 13 stages compressor is &riven ") starter motor@ ,he moving "la&es increase the pressure an& the velocit) o! the airA whiles the starter "la&es convert some o! the increase& velocit) into !urther increase o! pressure@ ,he compresse& air leaves the compressor at 1<3 C an& at '1 =si@ ,he high-pressure air!lows through the cross over &uct it enters the com"ustion cham"er@ 7hen the main "urner is on the heat o! energ) will "e pro&uce& ") com"ustion@ ,he !orce o! this hot stream o! gas 9$ 6 C at '6 psi is use& to &rive the compressor tur"ine an& power tur"ine "e!ore "eing release& to atmosphere through the e#haust &uct@ ,he temperature at the power tur"ine &rops to a"out $$16 C at 2 temperature a!ter the power tur"ine &rops to $66 C at 1 @9 psi@ ,@.a# ? inter-&uct temperatures@ 12%nter &uct temp0 ; thermo couples !itte& aroun& the inter-&uct@ %tFs D 2 on the Cam"ri&ge in&icator@ ,@ .a# ,emp0 %t is o"taine& ") the !ollowing com"ination0 =si an& the

3verage inter &uct temp R (compressor outlet temp- compressor inlet temp)S ,@.a#

(#ample0 comp@ %nlet temp S 1;6 C Comp@ Outlet temp S 1<36 C 3verage inter-&uct temp S $$16 C ,@ .a# S $$1 R (1<3-1;) S 92'6 C ,@ .a# shoul& not "e more than 9926 CA loa& must "e re&uce&@

#. T!r9ine Main Parts

Tur2in# *!in P!rt+7 3ir !ilter .esh screen !ilters Compressor inlet casing 3ir compressor 13 stages Crosse over &uct com"ustion cham"er ((l"ow t)pe) %gnition s)stem .ain "urner Compressor tur"ine %nter me&iate-&uct =ower tur"ine Re&uction gear (#haust *tarter motor Blow-o!! valve Over spee& trip Governor Control unit@ Air fi&t#r7 %t is a sel!-cleaning t)pe an& &esign to clean the air "e!ore entering the air compressor@ ,he screen is rotate& through a "ath o! viscosene oil@ ,he 3C motor is &riven an& turns !or ; secon& ever) 12 minutes@ *#+" +cr##n fi&t#r7 3 mesh screen is !itte& "etween the inlet air &ucting an& the compressor air inlet casing to prevent an) soli& material !rom entering the compressor@ Co(-r#++or in&#t c!+in$7 %t is !orming the connection "etween the air inlet &ucting an& the 13 stages compressor entr)@ Air co(-r#++or 13 +t!$#+7 ,he 13-stage compressor is connecte& to the air !ilter ") &ucting@ %t is an a#ial !low t)pe compressor@ ,he compression is ration o! 01@ ,he air enters the compressor at atmospheric pressure an& temperature an& leaves at '1 psi at a temperature o! 1<36 C the spee& range is "etween ;$66 to 1166 R=. &epen&ing on loa&@ ,he 13-stage compressor is !irst starting ") a starter motor an& the air outlet passes through a &i!!user@ %t re&uces a velocit) o! air an& increase the pressure@

Cro++o.#r duct7 %t trans!ers the air !rom the outlet o! the compressor to the com"ustion cham"er@ Fle#i"le "ellows are !itte& to allow !or e#pansion with out causing an) &amage@ Co(2u+tion c"!(2#r- E&2o0 t5-#7 %t consists o! an outer casingA inner !lame tu"e an& a &i!!user cone@ ,he incoming air !rom air compressor is &ivi&e& into three streams@ =rimar) air!low through the &i!!user to sta"ili2es the !lame@ *econ&ar) air is controlle& ") vanes to give an even temperature Cooling air passes "etween the !lame tu"e an& the outer casing to cool the internal walls@ ,he normal pressureA temperature is ('6 psi 5 9$ 6 C)

I$nition +5+t#(7 %t consists o! small "urner an& a spar- plug@ ,he spar- plug is supplie& with high-tension current !rom ignition coil ($666 volts)@ ,his solenoi& valve is to control the !uel gas !low to small "urners its suppl) the pressure at (2-3 psig)@ *!in 2urn#r7 %t is a roun& tu"e !itte& with a no22le with holes in an& screwe& into the com"ustion cham"erA to allow gas to pass into the com"ustion cham"er through the no22les@ ,he main "urner gas pressure is usuall) 6 to '6 psig &epen&ing on loa&@ Ho22les partl) "loc-e& cause hot spots@ Co(-r#++or tur2in#7 %t &rives the 13-stage compressor &irectl) through a gar&en sha!t each stage consist o! ;3 rotor "la&es an& 9' starter "la&es@ /ot gas !rom com"ustion cham"er !low into rotor "la&es that ma-es tur"ine spin an& &riving the 13-stage compressor at the same time@ Int#r-(#di!t# duct7 (%nter-&uct) ,his consists o! outer casing an& inner cone@ %t is !itte& "etween the compressor tur"ine an& the power tur"ine@ ,he hot gasses !lows along the annulus !orme& "etween the cone an& the outer casing into the power tur"ine@ ,he normal pressure an& temperature is (2 psi 5 $$16C)@ Po0#r tur2in#7 %t has <9 rotor "la&es an& <2 stator "la&es on each stage@ %t is connecte& to the re&uction gear ") a gar&en sha!t@ =ower tur"ine spee& is '666R=.A re&uce to 1$66R=. ") the re&uction gear to &rive the main cru&e oil pump through the output sha!t@ R#duction $#!r7 %t is !itte& "etween the power tur"ine an& the output sha!t@ ,he gears are lu"ricate& !rom the main lu"ricating oil s)stem@ +rives the main lu"e oil pumpA governor an& over spee& trip@ ,he re&uction gear"o# re&uces the spee& o! power tur"ine to output sha!t as !low !or tur"ine ,3-1$66 -'A'66 to 'A'66 R=.@ E3"!u+t7 ,here are two e#haust &uctsA which release the "urnt gases to atmosphere@ ,he normal e#haust pressure an& temperature is (1 @9 psia 5 $66 C)@ St!rt#r (otor7 %t is connecte& to the &irectl) 13-stage compressor air compressor ") a starting &og (clutch)@ ,he starter motor &rives the air compressor &uring the starting seBuence at a"out 2$66 to 3666 R=.@ *tarter motor is stoppe& when compressor outlet pressure (=2 pressure reaches ' =isa) an& compressor spee& is ( $66R=.)@ 3t GC D 1 the starter motor is starte& ") air ta-en !rom CR> start air vessel@

<

,&o0-off .!&.#+7 ,wo "low-o!! valves are !itte& on cross over &uct@ ,he) are alwa)s shut when tur"ine is turning on normal spee&@ ,he small airline is ta-en !rom the cross over &uct to !le#i"le &iaphragm to close or open the "low-o!! valves@ 7hen openA the) allow the some o! the outlet air compressor to go to atmosphere@ ,he two micro switches are operate&0 when spee& is e#cee&e& the selecte& set spee& ") 6 to '6 R=.@ .icro switches will "e energi2e& an& sen& a signal to air ma#seal valve to vent the air "low o!! valves will open@ 7hen the spee& &rops to with in 6 R=. o! the set spee& air ma#seal valve will stop venting an& "low o!! valves will close@ ,he "low-o!! valve are opene& when ever an) o! the !ollowing con&ition accrue0 - +uring starting0 one "low-o!! valve is hel& open ") a spring@ 3!ter the main "urner is light an& compressor outlet pressure rises to $-psia pressures will !orce the "low-o!! valve to close@ ,his is to prevent a compressor surge an& possi"le &amage@ - Blow-o!! valve without spring is close& as soon as the 13-stage compressor is turning@ 1arge loa& re&uction0 "oth "low-o!! valves are opene& when loa& is re&uce& su&&enl)@ ,his is carrie& out ") signal !rom the governor (two micro switches) to air vessel valve to vent the airline on the &iaphragm "low-o!! valves@ ,o open the "lowo!! valvesA an& vent the air !rom the crossover &uct@ ,he &ropping o! compressor pressure will re&uce tur"ine spee&A an& prevent over spee& trip %.#r +-##d tri-7 Gears &rive it !rom output sha!t@ ,he over spee& trip will happen i! the loa& &ecreases so much an& spee& reaches the over spee& set '266R=.@ ,he un"alance& ring will over come the !orces o! the spring an& moves to &riving sha!tA the trip leaver han&le moves &own wor&s causing the servo oil to spill@ ,he loss o! servo oil will close the !uel gas shut-o!! valveA tur"ine stops@ 3lso the mechanical air valve opens an& went the hol&ing air pressure !rom the "low-o!! valves to open@ ,his is occurre& when the micro switches !aile& to operate@ o.#rnor7 ,he governor !uel valve regulates the gas suppl) to the main "urner to control the tur"ine spee&@ Governor spee& motor0 %t is a small +C motorA use& to increase or &ecrease the tur"ine spee&@ %t is operate& ") han& switch in control unit panel@ %t is gear mechanical which increase an& &ecrease the spee& spring !orces to regulate the spee& as reBuire@ *pee& limit switches0 ,wo micro switches limit the output sha!t spee&@ ,he) open to &e-energi2e the governor spee&er motor when the minimum or ma#imum spee& limits are reache&@ Contro& unit7 ,he control unit controls the operation o! the tur"ine &uring starting c)cle@ (lectrical section0 ,he control unit contains ; series o! switches operate& ") cames on the han& wheel spin&le@ ,hese switches control the electric circuits necessar) !or starting the tur"ine@

$6

3. *!in S5+t#(+ %f Tur2in# TA-1500

,his inclu&es the !ollowing *)stems 1u"e Oil *)stem Fuel Gas *)stem *ervo Oil *)stem *tarting 3ir *)stem

3-1. Lu2# oi& +5+t#(7

1u"ricating oil is supplie& to the s)stem ") the three pumps .ain lu"e oil pumpA +@C au#iliar) lu"e oil pump@ 3n& 3@C au#@ 1u"e oil pump@ ,he normal lu"e oil pressure is (26 psi) it is controlle& ") relie! valve@ ,he lu"e oil t)pe is ,/B ';@ ,he lu"e oil is to suppl) an& lu"ricating the 13-stage compressor "earingA compressor tur"ine "earingsA power tur"ine "earingsA main cru&e oil pumps "earings an& gear"o#@ ,he operating control an& sa!et) &evices in using servo oil s)stem@ .ain lu"e oil pump0 %tFs supplies to the oil lu"ricating can servo s)stems &uring normal running o! the tur"ine@ ,he main lu"e oil pump &riven ") the gear"o#@ ,he $ psig HRV opens to allow oil to ") pass the main pumpA when the +C 3u#@ 1u"e oil pump is running@ +C 3u#@ 1u"e oil pump0 %t is &riven ") an electric motor it &ischarges the oil into the suction line o! the main lu"e oil pump through the $-psi HRV to ensure that the main pump is alwa)s prime& on start-up@ ,he 3u# pump has "uilt in relie! valve set at ;6 psig@ %t runs a!ter an) shut&own an& han& wheel on (Run) positionA onl) !or 36 minutes@ 3C 3u# lu"e oil pump0 %t runs when the han& wheel on au#@ On position@ %t runs an& stops ") pressure switch (2; psi)@ 7hen the pressure in the cross over &uct is less than 2; psiA the 3C lu"es oil pump will continuous running@ %! it is more than 2; psi it will stop@ Hote0 %n case o! power !ailureA 3C pumps an& lu"e oil cooler will not startsA onl) +C pump will not continuous running@

$1

3-2. 'u#&

!+ S5+t#(7

1ean gas supplies to the tur"ine !rom engine gas scru""er@ ,he engine gas scru""er inlet =RV controls the pressure at 19$ psig@ 3n& the outlet =RV controls the pressure to the engine at 12$ psig@ - Hormal !uel gas pressure is ( 6-'6psig) a!ter governor@ - 1ow !uel gas pressure shut&own is ;6psi@ Be!ore starting the tur"ine open the &rain ") pass valve manuall) to prevent liBui&s entering the com"ustion cham"er@ (ngine gas scru""er0 ,his scru""er is to ensure no liBui& is allowe& into the tur"ine@ 3n auto &ump to line ;6 can &amp an) liBui& !orme& automaticall)@ +emister0 %t consists o! two cham"ers upper an& lower@ 3 !loat insi&e the lower cham"er shuts o!! the gas !low to stop the tur"ine i! there is a high level@ (ach cham"er has an auto &ump route& to sump tan-@ From the &emister gas outletA a small suppl) line is ta-en to the igniter through a re&ucer an& a solenoi& valve@ Governor gas valve0 %t is connecte& into the main gas line to the "urner an& acts as a throttle valve to control the !uel suppl) to the "urner@ %t is !ull) open at the "eginning o! the starting seBuence@ Fuel shut o!! valve0 %t is locate& near the main "urner an& opene& ") servo oil pressure when the au#@ 1u"e oil pump is !irst starte&@ %t is !itte& near the main "urner to ensure a Buic- shut &own o! the tur"ineA shoul& an) o! the sa!et) &evices operate@ .anual shut o!! valve0 ,his valve can "e shut to stop the tur"ine in case o! an emergenc)@ %t shoul& "e -ept shut when the tur"ine is not running to prevent gas lea-ing into the com"ustion cham"er@

$2

3-3. S#r.o %i& S5+t#(7

,he servo oil s)stem is use& in operating the sa!et) &evices o! the tur"ine@ %t is ta-en !rom main lu"e oil suppl) 4ust "e!ore the pressuring valveA which -eeps servo pressure a"out '6 psig@ ,he servo oil suppl) is &ivi&e& into the !ollowing points@ Governor Control unit 1oa& an& start limiters ,wo !uel shut o!! valves 1ow servo oil pressure shut &own switch 36 psig *olenoi& servo valve trip (ma# seal valve) 1ow lu"e oil pressure shut&own switch (13psig) Over spee& trip ('A266 R=.) %t consists o! the !ollowing parts@ 1- Filter0 cleans the servo oil 2- Restrictors0 ,he) ensure Buic- &rop in servo pressure when an) o! the sa!et) &evice operates@ ,he relie! valve set at '6 psig an& it opene& to the sump@ 3- .a# seal servo release valve (solenoi& operate&)0 %t is !itte& in the servo oil line an& is use& ") electricall) operate& sa!et) &evices to shut &own the tur"ine ") spilling the servo oil pressure@ ,he solenoi& is &e-energi2e& to open the valve@

3-1. St!rtin$ !ir +5+t#(7

,he s)stem consists o! the !ollowing@ *tarter motor Re&ucer *olenoi& valve +iaphragm valve '6 psig pressure switch an& 1$ secon&s timer@ *tarter motor0 ,he starter motor is turne& ") air supplie& !rom the CR> starting compressor vessel@ 7hen the starter is turne&A its teeth an& rotor &ogs engage to connect the starter motor with the 13-stage air compressor@

$3

Re&ucer0 %t re&uces the gas pressure to <6psig !or the &iaphragm valve@ *olenoi& valve0 ,his solenoi& is energi2e& to open the valve ") a signal !rom a cam switchA when the han& wheel is move& to starter onA an& allows staring air to open &iaphragm valve@ +iaphragm valve0 +iaphragm valve is to regulate the pressure suppl)@ %t is opene& ") air or gas suppl) through T N small pipe ta-en !rom the inlet to s)stem@ 3n& re&uce& to <6psig ") re&ucer to solenoi& valve to open the &iaphragm valve@ '6-psig pressure switches an& 1$ secon&s timer0 %t is to prevent the han& wheel "eing move to the ignition on position until the tur"ine is completel) purge& with air@ ,his is &one when the pressure reaches '6 psig in the &own stream o! the &iaphragm "e!ore the starter motorA a T N small pip is suppl)ing the '6 psig switch to energi2e it A an& the '6 psig switch will energi2e& 1$ secon&s timer rela) to &ela) "e!ore (2n& inter loc-) is !ree@

1. Tr!n+it Pu(- Unit

Introduction
%n GCD 1 has two transit pump sets per &ispatching the cru&e oil to 3hma&i tan- !orm@ 3 pump set is pump house& o! main pump an& Booster pumpA which are arrange& in series with each other@ ,he num"er o! pumps in commission &epen&s upon the amount o! cru&e oil to "e &ispatch an& the pressure in the transit line@ ,he transit pumps are &riven ") a gas tur"ine@ ,he oil !lows ") gravit) !rom the main tan- to the inlet o! the Booster pump (at a pressure o! 3-$ psig &epen&ing on &r) tan- oil level) where its pressure is increase& ") the centri!ugal !orceA it then passes through to the inlet o! main pump where its pressure is !urther increase& to a high pressure enough to !orce it into the transit line@ 1-1. ,oo+t#r -u(-+7 ,he "ooster pump have to re&uction gear "o#esA the !irst one is !itte& "etween the main pump outlet an& the "ooster pump to re&uce the output sha!t spee& !rom '666 R=. to 1 66 R=.A an& the secon& one is !itte& on the "ooster pump to re&uce the output sha!t spee& 1 66R=. to 1666R=. at "ooster pump@ ,he gear"o# lu"rication is ta-en !rom the main lu"e oil s)stem@ Booster pump &escription0 .a#imum range *uction pressure +ischarge pressure 1ow gear oil pressure /igh lu"e oil temp
T!2&# 1

3"out 1666 R=. 3-$ psig normal 3$- 6 psig normal 1$ psig shut&own 1$66 F

1-2. *!in -u(-7 %t is ta-ing suction pressure !rom "ooster pump at 3$- 6 psi an& it is giving &ischarge pressure to transit line@ .inimum spee& .a#imum spee& Over spee& trip *uction pressure .a#imum casing pressure Casing temp *hut&own 66 R=. $966 R=. '266 R=. 3$- 6 psig normal $66 psig 1$66 F

5. Tur2in# Pr#-St!rt C"#c6 Li+t

=re-start chec-list0 I Control room0 - Chec- the &r) tan- level in normal (12 !t)@ - Reset the tur"ine on emergenc) shut&own panel@ - Chec- the engine gas scru""er outlet pressure control valve set at 136 psig@ I .ain plant area0 - Chec- the &r) tan- suction valve is to "e opene& - Chec- the engine gas scru""er isolating valve are opene& - Chec- the main starting air valve to tur"ine is opene&@ - Chec- the main !uel gas suppl) valve to tur"ine is opene&@ I (lectrical su"-station room0 - *witch "atter) charger selector switch !rom auto to manual position@ - Chec- 3C lu"e oil pump switch is on auto@ - Chec- lu"e oil cooler switch is on auto@ - *tart the ventilation !an@ I ,ur"ine room0 - Chec- the screen !ilter is running (clean) - Chec- the lu"e oil level in tur"ine room - Chec- !uel pressure is &emister in 126 psig an& &rain manuall) (chec- all isolating valves to auto &umps are opene&)@ - Open insolating !uel valve upstream o! main "urner@ - Open isolating !uel valve o! small "urner - Open isolating starting air valve@ I Control unit an& rela) panel0 - *witch (on) 3C an& +C isolatorFs switches@ - *witch Cam"ri&ge in&icator is on position@(Ho@ 2 inter-&uct temp)@ - Re&uce governor spee&s to minimum set spee&@ - Control han& wheel on (O!!) position@

$$

Reset emergenc) shut&own push "utton on rela) control panel@

I =ump room0 - Chec- suction valve to "ooster pump is open - Chec- suction pressure is 3-$ psig - Chec- an& open main cru&e pump &ischarge valve T N open@ - =rime main cru&e oil pump - Chec- all valves to CR> in an& out are opene& an& ") pass is close& (col& s)stem onl))@ - Chec- cru&e oil pump circulating valve is close&@ - Replace ol& chart with new chart o! cru&e oil &ispatch@

4. St!rt U- Proc#dur#+
'-1@ *ervo Oil Operate& Control *)stem *tart up proce&ure0
1@ R(*(, Fail *a!e =anelA (URea&) to RunU light light comes OH) 1@ 3u#@ On0 1i!t han& wheel catch an& move wheel !rom O!! to 3u#@ =ump on position@ 3C an& +C 3u#@ 1u"e oil pumps will start an& re& in&ication light will shows on the controller@ 7ait !or lu"e oil pressure to "uil& up to 26 psig (!irst interloc- with&raws ") te&&engton pressure switch when lu"e oil pressure reaches 13 psig) *ervo oil pressure will "e '6-;6 psi@

2@ *tarter On0 .ove the han& wheel to V*tart positionF@ (lectric signal !rom han& wheel to starting air solenoi& valve to passes <6-psig air pressure !rom re&ucer to &iaphragm valve !orce to open@ +iaphragm valve will pass starting air o! <6 psig to starter motor@ *tarter moves will "ecome on an& &rive the air compressor an& 13-stage compressor tur"ine at 2$66-3666 R=.@

+o not attempt to start the tur"ine i! the compressor &oes not reach 1;66 R=. on the starter@ 3@ U%GH%,(R OHU .ove /an& wheel to U%GH%,(R OHU position@ Chec- that the %gniter is lit@ 2 volts signal !rom han& wheel to coil to suppl) $ 8V to spar- plug@

$'

7hen the %gniter is litA move /an& wheel to U.3%H B>RH(R OHU@ Control %nter &uct ,emperature "elow $9$ WC@ 2@ .ove /an& wheel to U*,3R,U =osition@ *tarter .otor stops at $666 rpm@ 3@C@ 3u# 1u"e Oil will stop i! Crossover +uct pressure is a"ove 36 =sig@

3@ .ove /an& wheel to UR>HU =osition@ +C 3u# 1u"e Oil pump will stop@

*et =ump rate to suit reBuirement ")0 a@ 3&4usting ,ur"ine *pee& to .inimum possi"le@ "@ 7i&e open +ischarge Valve to ma#imum possi"le@

'-1@ 7oo&war& Control *)stem *tart up proce&ure0

,his s)stem is operating ") (#cel 2$6 =1C (=rogramma"le 1ogic Control *)stem)@ =G%-166 Operator %nter!ace *tationA call UOV(RV%(7U screen &ispla)@ (,ouch the *creen +ispla) to clear out *creen *aver 3ctive)@ From UOV(RV%(7U +ispla)A select U.3%H .(H>U &ispla)@ From the U.3%H .(H>U +ispla)A select U*,3R, =(R.U o"4ect to &ispla) start =ermissive *creen@ From the U*,3R, =(R.%**%V(U &ispla)e& *creenA veri!) the !ollowing =ermissive are satis!ie&0 Re-start ,imer ($ .ins@) complete& GG re!erence at 1ower 1imit (3A;66 rpm) =, Re!erence at 1ower 1imit (3A;66 rpm) Ho *hut&owns 3ctive Ho 1ight-o!! (Flame) +etecte& G*-3 Valve at .inimum position ($G) .o&e *et (1ocal5Remote) *tart =ermissive !rom +C* - O8 2@ From U*,3R, =(R.%**%V(U &ispla)A select UH(K,U to &ispla) U*,3R, *(Q>(HC(U &ispla)@ 3@ From the ,ur"ine 1ocal Control =anel (1OC=)A veri!) UR(3+O ,O *,3R,U Green light is OH@ @ From the ,ur"ine 1ocal Control =anel (1OC=)A press *tart =ush"utton an& U.3*,(R R>H R(13OU will energi2e the *tart seBuence as !ollows0

$9

*tart-up Overall *eBuence ,imer (7atch&og ,imer) o! 126 secon&s is energi2e&@ 3u#iliar) 3C5+C 1u"e Oil =umps will start an& 1ow 1u"e Oil =ressure *hut&own signal is ")passe& !or 16 *econ&s@ *tarter .otor is energi2e& to engage an& rotate the tur"ine 13th *tage 3ir Compressor@ *tarter .otor ,imer is activate& !or 1$ *econ&s count &own@ Note: If the Turbine fails to reach above 700 RPM of GG Speed within the 15 Secs period, the Start up se!uence is aborted"

"@7hen GG *pee& reaches a"ove 966 R=.A the !ollowing will happen0

Ventilation an& Filter Fan start@ 1u"e Oil Cooler Fan *tarts@

c@7hen GG *pee& reaches 1A9$6 R=.A the =ilot %gnition *)stem is energi2e& an& the =ilot comes OH@ 3 1$ *econ& %gnition ,imer is energi2e& !or =ilot !lame con!irmation@ &@7hen the =ilot Flame is &etecte&A %gnition ,imer is &e-energi2e& an& the GG 3cceleration ,imer o! 36 *econ&s is starte& an& the !ollowing ta-e place0

.a#seal 2-7a) *hut-o!! Valve in the !uel gas line is open@ 7oo&war& Governor Fuel Valve is energi2e&@ Ramp *tart 1imiter ? (G, 1imiter are energi2e&@ GG *pee& acceleration is controlle& not to e#cee& G =er *econ&

@ e@7hen GG *pee& reaches A$66 R=. (or 9@$ =si Cross-Over +uct =ressure)A the !ollowing ta-e place0

3cceleration ,imer is &e-energi2e& (time& out) ,he =ower ,ur"ine starts to "rea-awa)@ *tarter .otor stops@

!@7hen the =, *pee& reaches a"ove 3A;66 R=.A =, Control +ela) ,imer o! $ *econ&s is energi2e& !or U*eBuence CompleteU eventsA ie0

Overall 7atch&og ,imer is &e-energi2e& (time& out)@ (G, Control =oint is switche& !rom *tartup Value Control (12<2 WF) to Hormal Value Control (1 $ WF)@

$;

(G, *prea& *et point is switche& !rom *tartup Value ($66 WF) to Hormal Value (1 6 WF)@ Vi"ration .onitoring *)stem (Bentle) Heva&a) is re-activate& (normall) at GG *pee& a"ove $666 rpm)@ 3u#iliar) 3C 1u"e Oil =ump is switche& UOFFU@ Note: #$ %ube &il Pu'p will stop when %ube &il Pressure in the S(ste' is above 15 1) Psi*"

*eBuence Complete Green 1ight comes OH at 1OC=@

<. A&!r( A +"utdo0n +#ttin$+7

,ur"ine si&e@
+escription ,ur"ine high ,@.a# ,ur"ine high ,@.a# 1ow lu"e oil pressure 1ow lu"e oil pressure /igh lu"e oil temp /igh lu"e oil temp 1ow servo oil pressure 1ow !uel pressure 1ow starting air pressure 1ow "atter) voltage Over-spee& trip
T!2&# 2

*etting 9<66C ;166 C 1$ psig 13 psig 1$66 F 1'$6 F 36 psig ;6 psig 6 psig 1; volts 'A266 R.=

3ction 3larm *hut&own 3larm *hut&own 3larm *hut&own *hut&own *hut&own Ho start *hut&own *hut&own

=ump >nit *i&e0

.ine pump !ormal &rive en& .ine pump !ormal !ree en& Booster pump 4ournal &rive en& Booster pump 4ournal !ree en& .aine pump casing temp .aine pump high &ischarge pressure Booster pump low suction pressure Gear"o# oil low pressure 1;66F 1;66 F 1;66 F 1;66 F 19$ 6F $6 psig 2@2 psig 1 psig *hut&own *hut&own *hut&own *hut&own *hut&own *hut&own *hut&own *hut&own

$<

%nstruments air low pressure Cru&e pump lu"e oil low pressure
T!2&# 3

$6 psig 16 psig

*hut&own *hut&own

Di+tri2ut#d Contro& S5+t#(

1. Introduction %f DCS7
%t is a process control s)stem that is controlle& ") a networ- o! small computers -nown as Nno&esC or controlling !iles@ 3 large process plantA li-e a G@CFs@ it ma) have as man) as eight or more areas to &istri"ute control@ (ach area no&e can have 32 control or monitoring loops that can also communicate with each other an& e#change &ate@ ,he communication "etween no&es is ma&e possi"le through special line& -nown as NBusC or N+ataC highwa)@ Hormall) two highwa)s are provi&e&A one as "ac- up in the event o! !ailure o! one@ ,he +C* is there!ore the most e!!ective an& sa!er control s)stem availa"le in the in&ustr) to&a)@ ,his s)stem is "etter than having a single large computer controlling man) loops in a process plant@ ,he control ") a single computer in a process plant can "e ris-) "ecause i! it !ails the whole plant also !ailsA an& this is 4ust li-e putting all )our eggs in one "as-et an& loose them all@ ,he +C* s)stem there!ore avoi&s this t)pe o! pro"lem@ 1-1. Pur-o+# A function of D.C.S7 %t provi&es intelligent control an& on line monitoring !unction o! process plants at a remote centrali2e& plant@ %t !unctions as an operator wor-station !or &ispla) an& access to all plant parameters inclu&ing graphic &ispla)A control elements an& alarms@ %t stores an& reports all necessar) plant &ata@ i@e@@ ,ren&ingA shi!t reportsA perio&ical logging o! cru&e an& gas pro&uction !iguresA &ata acBuisition con&ition monitoring o! process plant an& all main eBuipments@

2. Ro+#(ount DCS
,he control s)stem to "e supplie& ") FR* (Fisher Rosemount *)stem) is "ase& on the esta"lishe& an& proven R*3 &istri"ute& control s)stem an& its associate& technologies@ ,his will "e an integrate& s)stem comprising o! stan&ar& R*3 eBuipment@ ,he primar) operational o"4ectives o! the complete s)stem are as !ollows@ i,o provi&e plant wi&e monitoring an& alarming ") !ast &ata acBuisition ii,o ensure comprehensiveA relia"le an& secure automatic an& remote manual control@ '6

iiiivvvi-

,o ena"le the s)stematic an& comprehensi"le &ispla) o! plant con&itions an& ma4or operating parameters to the operators@ ,o provi&e a means o! recor&ing an& storing currant or calculate& &ata !or su"seBuent retrieval or anal)sis@ ,o provi&e means o! reporting@ ,o provi&e a soun& plat!orm !or a&vance& control implementation@

2-1. Ro+#(ount S5+t#( d#+cri-tion7

,he R*3 s)stem consists o! the !ollowing main &evices inter-connecte& via a peerwa)@ - .,CC0 multi-tu"e comman& console 2 noFs@ - Control !ile 2-3 noFs@ - /%30 highwa) inter!ace a&apter % no@ ,hese main stations are !urther connecte& with separate groups o! &evices that ma-e up the total Rosemount R*3 s)stem@ ,he &evices are connecte& un&er each station one is !ollows0 I .,CC0 =rinter /ar& &is ,ape &rive CR, catho&e ra) tu"e 8e) "oar& I Control !ile0 3nalog !le# term Contact !le# term 3nalog marshalling panel Contact marshalling panel@ 3ll the &evices are lin-e& via a N=eerwa)C witch is a &ata transmission ca"le or "etter -nown with other s)stem as N&ata /ighwa)C@ ,here are normall) two peer wa)s !or ever) GC s)stem@ One operates as the main an& the other as a stan& ")@ Failure o! one peerwa) will cause all in!ormation to "e sent over the stan& ") one automaticall)@

2-2. RS-3 "!rd0!r# d#+cri-tion+7

3nalog marshalling panel0 3ll !iel& signals li-e 1,A =,A ,,A 1OA =OA ,OA etc are connecte& to this panel@ %t is !actions are to &irect an& commutate these messages receive& to analog !le# term@ %t has "oth input an& output channels@ *ignals receive& here are analog t)pe@

'1

+igital marshalling panel0 %t has the same !unction as the analog marshalling panel@ ,he onl) &i!!erence is the t)pe o! signals receive&@ %t mainl) han&les &igital signals o! status con&ition such as shut&own an& alarm or control signal to energi2e or &e-energi2e *ovFs (6V5116V3C)@ %t is receive& "oth &igital input an& output signals@ Control !ile0 ,his is the heart o! the Rosemount s)stem all &evices an line &epen&s on it to pass them in!ormation@ %t is an electronic car& locate& in cage with control an& commutation section "uilt insi&e it@ One control !ile normall) has ; car&s with power suppl) "oar&@ 3n& each car& has << noFs o! controller &evices which control the process plant an& trans!ers in!ormation to other &evices@ ,he control !ile is the place where the process control schemes an& logics are "uilt@ %nstrument engineers create the control schemes reBuire& an& put them into the control !ile !or operation use@ 3 simple e#ample o! this is when the operator wants to change the set point o! a control loop@ ,he valve o! change& memor) is store& into controller memor) an& compare& with the actual process value input@ ,he control !ile then process an& communicate out put signals to !iel& &evices via !iel& "uses an& analog or &igital .arshalling panels@

Control !ile is all is all responsi"le !or running0 3ll o! the con!igure& programs inclu&ing process valves &etails an& graphic &ispla)s@ ,he &ata "ase management program that -eeps all o! the various s)stem &ata"ases in or&ers@ ,he s)stem management program that monitors are health an& con&ition o! the Rosemount s)stem@

.,CC0 ,his is the operator inter!ace@ %t provi&es the inter!ace "etween process sensors or actuator an& the operator wo- station@ 7hen operator ma-es change on process plantA i@e@@ Changing set point or switching controller in manual5auto mo&e@ ,hese in!ormation are han&le& through .,CC@ .,CC also connects the operator wor-stationL printerA !lopp) &riveA har& &is- an& tape &rive with the control !ile an& process plant via the peerwa)@ .,CC has electronic cor&s to han&le all in!ormation that is passe& through it@ %t also temporall) stores process &ata@ =eerwa)0

'2

,his is a coa#ial ca"le that passes communication messages "etween .,CC an& control !ile@ ,he in!ormation are transmitte& at a spee& o! 1 million "its per secon&@ ,he transmission is in pulse t)pe signals@ Flopp) &is-0 %t stores all in!ormation o! process plant an& Rosemount s)stem &etails in B%, !orm@ %t has limite& capacit)@ ,ape &rive0 %t also stores all in!ormation o! process plant an& s)stem &etails "ut with high capacit) memor)@ /ar& &is-0 ,his is the main storage "an- !or all &ata o! process plant an& s)stem &etails@ %t stores Con!igure& graphics an& other &etails such as tagsA tren&sA alarm pointsA scale range an& son on@ 3lso stores s)stem &etails such as control !iles in!ormationA analog !le# term &etails num"er o! peer wa)s connecte& an& con!iguration &ata@ 3ll this in!ormation is also store& in a !orm o! "it@ =ower "ac- up unit0 ,he R*-3 s)stem is provi&e& with power "ac- up unit@ %t generates 36 Volts +C power suppl) to all electronic car&s locate& in .,CCA control !iles an& !le# term &uring power !ailure@ ,he &uration o! suppl) to the electronic car&s is "etween 36 secon& to $ minute ma#imum@ ,he purpose !or this "ac- up suppl) is to allow all shut&own an& alarms con&itions an& last process parameters to "e store& an& save& in the har& &is-@ ,he power "ac- up unit is provi&e& with long li!e "atteries witch ma) last !or 2 )ears@ 7hen the "atter) li!e is near its en&A alarm will "e given on the operator wor-station an& on the "ac- up unit itsel!@ Re& !ault light comes on@ Operator shoul& "e aware o! power "ac- up capa"ilities at this s)stem an& what e!!ect a power !ailure or surge will have on their process plant@ Co(-on#nt+ of contro& fi&#7 3nalog !le# term Contact !le# term Controllers Co-or&inate processor H@V memor) car&s =ower suppl) car& =eerwa) "u!!er car& Control process car&0 Control processor car& is the C/(3R,C which co-or&inates with analog an& contact !le#term !or process in!ormation@ =re&e!ine& !le#i"le control "loc-s resi&e in the controllerA which integrates input an& output "loc-s@ ,otall) 12' control "loc-s resi&es in each controller@ .a#imum -!le#

'3

term can "e connecte& to each controller an& !le#term can "e analog contact or =1C@ ; controllers can "e connecte& in each control !ile@ Co-or&inate processor car&0 ,his car& is responsi"le !or trans!er o! in!ormation "etween controller car& an& HV memor) car& an& =eerwa) "u!!er car&@ ,his in!ormation trans!er "etween one controller to other is ta-ing place through this car&@ ,wo car&s are provi&e& in the s)stem one is "ac- up to other@ *witch is provi&e& to &isa"le the car&@ Re& in&ication is provi&e& !or !ailure o! car&@ HV memor) car&0 HV memor) car& hol&s all user con!iguration &etails@ %t hol&s s)stem con!iguration &etails inter communication ta-es place "etween controller an& HV memor) car& continuousl)@ ,he in!ormation is "ac-e& up lithium "atter)@ =ower suppl) car&0 ,he s)stem reBuires 12VA $V suppl) !or all control !ile car&s@ ,hese are generate& ") power suppl) car&@ Hormall) two power suppl) car&s e#ist@ One is "ac- up to other@ ,hese car&s can "e remove& in energi2e& con&ition@ Re& in&ication is provi&e& !or !ailure o! car&@ =eerwa) "u!!er car&0 =eerwa) "u!!er car& "asicall) use& to communicate in!ormation "etween no&e &evices@ Hormall) two peerwa) "u!!er car&s are installe& in the control !ile@ =eerwa) ca"le is connecte& to peerwa) car&s "etween no&es through peerwa) tap@ %n!ormation trans!er in peerwa) ca"le is 1 million "its per secon&@

2-2. Contro& ,&oc6 D#t!i&+

1$ 3nalog inputs can "e lin-e& in each control "loc-@ 3nalog inputs are lin-e& !rom either input "loc- or an) control "loc-s to inputs &esignate& as N3 to OC@ 1' +igital inputs can "e lin-e& in each control "loc-@ +igital input are lin-e& !rom either input "loc-s or an) control "loc- to inputs &esignate& as NX a to X oC@ 1' +igital outputs are availa"le an& &esignate& Na to pC %nput Bloc-s0 ,he !unctions o! these "loc-s are 3ssign tag names to incoming signals !rom the !iel& Con&itioning 5 Filtering o! output signals !rom ,hermocouples an& Ori!ice plates@ '

3ssign an& a&4ust alarms to process varia"les 3llow Communication with *.3R, !iel& instruments (,ransmitters an& =1CFs)@

'&o0
'&uid f&o07 *ince most liBui&s are consi&ere& to "e incompressi"le there is a &e!inite relationship "etween the Buantit) o! liBui& !lowing in a con&uit an& the velocit) o! !low@ ,his relationship is e#presse&0

@ A AB6
7here QS Capacit) in cu"ic !eet per secon&@ 3S 3rea o! con&uit in sBuare !eet VS Velocit) o! !low in !eet per secon&@ Pi-# 'riction7 Friction in pipe will var) with pipe si2eA capacit)A lengthA an& viscosit)@ ,a"les !or calculating the !riction through a piping s)stem are availa"le in the h)&raulic institute stan&ar&sL pump manu!actures literatureA an& man) han&"oo-s@ Pi-# &in# f&o0 contro&7 =ipeline h)&raulics0 %n or&er to positivel) control pipeline operation an& internal con&itionsA the wa) liBui&s "ehave with in pipe line s)stem (liBui& h)&raulics principles) must "e "asicall) e#plaine& +e!inition o! h)&raulics0 /)&raulics is the stu&) o! !lui&s in motion an& !lui&s at rest@ %n pipe line operationsA it repairs to the movement o! liBui&s through a pipe line@ *tea&)-state h)&raulics repairs to the state where at an) points along the pipeline pressure an& !low rate are constant over time@ ,ransient h)&raulics repairs to the state where the pressure an& !low rate an& at an) point can changeA instantaneousl)A with time (such as 4ust a!ter a pump is starte& or a valve is close&)@

'$

+ensit)0 +ensit) (or mass &ensit)) is &e!ine& as the mass o! liBui&(or other su"stance) per unit volume(8g5m3)@ 7eight &ensit) (speci!ic weight) is &e!ine& as the weight o! a liBui& per unit volumeA it is relate& to mass &ensit)@ %t is the pro&uct o! mass &ensit) an& the acceleration &ue to gravit)@ (EE-01 ) 7eight &ensit) S mass 8g I acceleration &ue to gravit) (g) S 8g5m3 >nit volume(m3 ) 3n increase in pressure will cause a &ecrease in volume an&A there !oreA an increase in &ensit) (ver) smallA usuall) negligi"le)@ 3n increase in temperature results in an increase in volume an& a correspon&ing &ecrease in &ensit)@

*peci!ic gravit)0 *peci!ic gravit) is &imensionless num"erL which is a ratio o! the &ensit) o! a liBui& to the &ensit) o! waterA at '66 F@ (EE-02)7 *peci!ic gravit) S +ensit) o! an) liBui& (X '66 F) +ensit) o! water (X '66 F) 3=% gravit)0 3=% gravit) is an ar"itrar) scale &evice ") the 3merican =etroleum institute to e#pen& the gravit) scale !or cru&e oil an& petroleum pro&ucts@ 7ith this scaleA gravit) is measure& in &egrees 3=%@ (EE-03)7 3=% gravit) (3=%) S 1 1@$ 6 *peci!ic gravit) X '6 F 131@$

3=% gravit) is inversel) proportional to speci!ic gravit)A as speci!ic gravit) increasesA 3=% gravit) &ecreases an& vise versa@ ,he 3=% gravit) water is 16 3=% gravit) measurement is ma&e with a h)&rometerA which con!ormsA to an 3*,. slan&ere&@

Viscosit)0 Viscosit) is a measure o! !lui&s internal &istance to !low or its internal !riction@ Viscosit) can "e e#presse& in two wa)sA a"solute viscosit)( centipoises ) an& -inematics viscosit)(centisto-es )@

(EE-01)7 8inematics viscosit) S a"solute viscosit) +ensit) (mass)

''

,he viscosit) o! a liBui& is ver) &epen&ent upon its temperature@ 3s the temperature o! petroleum !lui& increases the viscosit) &ecreases an vice versa@

Re)nol&s num"er0 ,he Re)nol&s num"er (Re) is a &imension less num"er use& to &etermine the t)pe o! liBui& !low (laminarA tur"ulent or critical) occurring insi&e a pipeline@ %t is calculate& as !ollows@ (EE05)7 Re S 221 I Q Q S !low rate in "arrels per hour(B=/) &Iv & S pipe insi&e &iameter in inches(in) v S !lui& -inematics viscosit) in centisto-es(cs) 1aminar !low occurs when Re Y 2666 ,ur"ulent !low occurs when Re Z 666 Critical or transitional !low occurs !or 2666 Y Re Y 666@ Friction loss0 ,he energ) lost when !lui& particles in motion ru" against each other an& the pipe wall is calle& !riction loss@ 3 pressure &rop in the &irection o! !low can see this !riction loss Friction loss &epen&s on the !ollowing !actors0 (!lui& gravit)A !lui& viscosit)A !low rate o! the !lui&A internal pipe &iameterA pipe lengthA internal roughness o! the pipeA losses through !ittings such as valves an& meters)

Con.#rtion f!ctor+7
Volume 1 1itre 1 1itre 1 Barrel 1 Barrel 1>*G =ressure0 1 B3R S 6@22 %.=(R%31 G311OH* S 6@2' >@* G311OH* S 2 >@* G311OH* S 3$ %.=(R%31 G311OH* S 3@9;' 1itres@ S 1 @$63; =*%G@

S!&t in crud# !n!&5+i+7

Cru&e oil !rom the reservoir is pro&uce&A containing var)ing amount o! water@ ,he volume o! water pro&uce& along with the cru&e oil ma) contain as low as traces o! water an& some times as high as $6G or more@ ,his water contains var)ing Buantities o! salts@ *o&iumA magnesiumA an& calcium are most common cautious o! the salts@ Chlori&esA sulphites an& car"onates are the t)pical anions associate& with the captious@ ,he composition an& concentration o! such salts &epen&s upon the nature o! geological !ormations !rom which the oil steams@ 7ater containing salts in the cru&e is un&er sirea"le as it causes corrosion in the process eBuipment an& !oul heat e#changers etc@@ ,here!ore a limit has "een !i#e& on the amount o! salt content@ '9

%n 8OC ma#imum permissi"le salt in the cru&e &ispatch lines !rom GCFs is 16@6 =,B(poun&s per thousan& "arrels)@ S!&t cont#nt of 0!t#r in crud#7 ,he amount o! salt content o! pro&uce& water in cru&e can "e !oun& out as shown in the !ollowing e#amples@

(#@ %! pro&uce& oil contains %G cut o! salt water an& the salt content o! the salt water is '6A666 ==.@ 7hat is the salt content in =,B[ .etho& 10 '6A666 # 6@3$ # 1 5 166 S 216 =,B Hote0 1==. S 6@3$ =,B@ .etho& 20 '6A666 5 2@;$9 # 1 5 166 S 216 =,B@ Hote0 1 =,B S 2@;$9 ==.@ ") %! wet cru&e is &eh)&rate& to a ma#imum acta"le level o! 6@1G@ what will "e thesalt content o! the remaining water in treate& cru&e@ 3ns0 '6A666 # 6@3$ # 6@1 5 166 S 21 =,B@

C) consi&ering the ma#imum limit o! salt content o! 8uwaiti cru&esA the a"ove result o! 21 =,B still shows that the &esalte& cru&e is !ar !rom the acta"le limit i@e $=,B@ ,his means that the cru&e nee&s !urther &esalting process an& this can onl) "e achive& ") a&&ing &ilution water to wash out the remaining salt@ ,he e!!ect o! wash water is shown in the !ollowing e#amples@ %! G &ilution water o! ;A 666 ==. salinit) is a&&e& to this same cru&eA then what will "e the !inal salt content o! the remaining water in &eh)&rate& cru&e@ =ro&uce& water cut \\\\\@ 1G *alt in water cut\\\\\\\ '6A666 ==. +ilution water a&&\\\\\\ G *alt in &ilution water\\\\\ ;A 666==. Cru&e &eh)&rate& to\\\\\ 6@1G 3ns0 ,otal salt o! water in cru&e S '6A666 R ;@666 5 2@;$9 # $ 5 166 S 1A1<6=,B@ But the cru&e is &eh)&rate& to 6@1GA there!ore the salt content in it is

';

1A1<6 # 6@1 5 166 S 1@1< =,B@ Generall) the amount o! wash water nee&e& in &esalting process is 3 to ;G o! treate& cru&e an& this &epen&s on B@*?7 content o! the treate& cru&e *alt content o! the pro&uce& !ormation water *alt content o! the wash water Hum"er o! the treating stages .i#ing metho&@ Con.#r+ion f!ctor+ for conc#ntr!tion of +!&t+ in crud# oi&+7 %n# ,!rr#& F 12 U.S *$9&it#r (*$91) 6@3$ 2@ ;$ '@66 $@66 .g5liter is eBuivalent to gms 5 -illoliter .g5liter can "e converte& to parts per million (ppm) ") &ivi&ing .g5l ") the speci!ic gravit) o! the oil@ =pm is also eBuivalent to gms5metric ton@ API RA/ITG %' CRUDE %IL (IP-1409=2)7 3=% is a scale to &etermine the gravit) o! cru&e oil as recommen&e& ") 3merican =etroleum %nstitute@ 3=% gravit) is e#presse& in &egrees an& ma) "e converte& to speci!ic gravit)A ") using the !ollowing !ormula@ 3=% gravit) (+egrees X '66 F S 1 1@$ *p@gravit) at '66 F 3=% gravit) is an important in!ormation relate& to the Bualit) o! cru&e oil@ =nits for eB*ression of 7ater ana$/sis res!$t? 1. P!rt+ P#r *i&&ion (PP*) %t is most commonl) use& unit !or reporting water anal)sis &ata@ %t is measure o! portion o! weightA eBuivalent to a unit weight o! &issolve& su"stance per million unit weights in solution@ 2. *i&&i$r!( P#r Lit#r (*$9&)7 131@$ !&&on+. Pound+91000 ,2&+(PT,). 1@66

'<

%t e#presses a weight :volume relationship over the temperature range !oun& in most la"oratories@ %t is in&epen&ent o! the speci!ic gravit) 3 low concentration o! &issolve& material less then 9666-==. .g5l are su"stantiall) eBual to ==.@ ,he relation ship "etween the two unitsA ") &e!inition is ==. S (.g5l) 5 (*p@gr@) (Or) .g5l S (==.)@ (*p@Gr@) For water with a speci!ic gravit) o! near oneA .g5l an& ==.A !or all practical purposes are interchangea"le@

96