INTRODUCTION
Contents
Description
Page
1.0 INTRODUCTION 2 2.0 OBJECTIVE 3 3.0 DEFINITIONS 4 4.0 REFERENCES 42
1.0
INTRODUCTION
This information contained in this manual is intended as an aid to the operation of EOR facilities installed in the following platform:
Sumandak Selatan Integrated Platform (SUPG-B) Samarang Oil Production Platform SMP-B Samarang Drilling Platform SMDP-B Samarang Jacket Platform SMJT-E
It is provided for the guidance and instruction of the platform operators and other personnel concerned with the design intent of the platform and thus will help to ensure the safety and the proper operation of the platform.
Samarang Redevelopment Phase 2 EOR project will be undertaken to extend Samarang field life and is anticipated to increase recoverable reserves by as much as 78 mmstb from 17 mmstb to 95 mmstb within 2026. If implemented and executed as recommended, the field will achieve a state of zero continuous venting within 2015, and result in a remaining oil production rate of 6,000 bopd at 2026. Recovery factors from the field will increase from the pre-FDP forecast of 41%, to 51% in 2026.
Phase 2 EOR Detail Design work for identified wells consists of infill, water and gas injection facilities (Gravity Assisted Simultaneous Water and Gas - GASWAG). The work involves platform upgrading at existing Sumandak platform SUPG-B, tie-in on existing Samarang platforms (SMP-B / SMDP-B and SMJT-E), and infill drilling on two existing drilling platforms SMDP-B and SMJT-E. Samarang will be utilizing Sumandak SUPG-B water injection (WI) facilities, with 2 new booster pumps installed in series with the existing water injection pumps to meet Samarang water injection pressure. Whereas, for the gas compression facility, there are originally 3 gas compressor trains installed on SUPG-B. However, compressor train A has been removed due to the reduction in export gas amount and SUPG-B is currently operating on 2X100% mode. A new 2 stages compressor train will be installed in place of the existing compressor, as the existing one has limited pressure to meet the required injection pressure in Samarang.
A new 6” flexible pipeline (~13.5 km) is required to export the gas injection from SUPG-B to SMP-B. The gas will be further routed to SMDP-B via bridge link piping and the remaining gas will be routed to SMJT-E via new 4” flexible pipeline (~2.3 km). For water injection, a new 6” flexible pipeline (~13.5 km) will be installed from SUPG-B to SMP-B. And new 4” flexible pipeline (~2.3 km) will be installed to transfer water injection from SMP-B to SMJT-E.
Safety Procedures and Operating Procedure bulletins issued by the Owner must be considered in conjunction with these guidelines and incorporated into actual procedures to be implemented. Of particular significance are:
i. Structure of the supervisory management in the operating organization and line of communication within.
ii. Experience of Owner’s operator.
iii. Liaison between Owner’s operator and field representatives of equipment manufacturers during initial start-up.
iv. Detailed operating guidelines for vendor package equipment.
The manual is divided into six sections. Each section provides information such as system description, equipment design data, detailed operating sequences and instructions, and equipment / valve location tables, to facilitate proper and safe operation of the facilities.
Relevant diagrams are also provided to enhance the understanding of instructions and the operation of Sumandak Selatan Integrated Platform (SUPG-B).
Although the manual contains inherent safe operating practices, it is intended to supplement, but not replace, other relevant Carigali approved safety and operating procedures. This manual must be read in conjunction with other relevant Carigali approved safety and operating procedures, including, but not limited to, the following:
1. Carigali Operating Procedure Bulletins.
2. SUPG-B Emergency Response Procedures Manual(s) and related documentation. 3. Carigali’s approved Vendor/Manufacturer Operating Procedures.
4. Carigali Operations key as-built Drawings (contained within the Blue Books). 5. Carigali HSEMS Manual.
6. Electrical Standing Instructions.
Where applicable, within the operation procedures included in Section 3 and Section 4, for more specific references refer to the Operating Procedure Bulletins and/or to Vendors' / Manufacturers' Operating Procedures.
Units of measurement generally conform to the System International (SI) units, followed by the equivalent Imperial units in parentheses e.g. 10 m (32.91 ft).
2. 0 OBJECTIVE
The objective of this document to define the scope of work required to re-instate the system and make it ready for Non Hydrocarbon (Water Injection System) and Hydrocarbon (Gas Injection System) introduction. The whole scope of work to be completed in 3 phases;
a) Reinstatement b) System start-up
4
3.0 DEFINITIONS
COMPANY : PETRONAS CARIGALI SDN BHD (PCSB) CONTRACTOR : PETRA RESOURCES SDN BHD
VENDOR : Party who supplies and manufactures equipment/ materials or services specified
and ordered by CONTRACTOR
SUBCONTRACTOR : Party who providing subcontracting packages or services specified and
ordered by CONTRACTOR
4.0 REFERENCES:
PSD-EOR-CO-013-REVB for Start Up, Shut Down and Operating Manual
Attachment List
ATTACHMENT 1.0 : Flowchart for Water Injection Black Start
ATTACHMENT 1.1 : Prepare EOR Water Injection Facilities for Black Start-Up ATTACHMENT 1.2 : USD System
ATTACHMENT 2.0 : Flowchart for Gas Injection Black Start
ATTACHMENT 2.1 : Prepare EOR Gas Injection Facilities for Black Start-Up
ATTACHMENT 2.2 : Pressurization of Sumandak and Samarang Gas Injection Facility to 7400 kPag
ATTACHMENT 2.3 : Start-Up Gas Turbine for Gas Injection Compressor ATTACHMENT 2.4 : Shutdown of EOR Gas Compression
1.0
Flowchart for Water Injection Black Start
THIS FLOWCHART IS FOR FIRST BLACK START UP ONLY, NOT DESIGNATED FOR POST ABANDON PLATFORM STARTUP.
Prior to introduction of Non Hydrocarbon, PASR and shall be conducted which include pre startup check in order to ensure Platform readiness for RFSU.
STEP NO. PROCEDURE INSTRUCTION PROCEDURE ACTIVITY DRAWING REFERENCE CHECK (/) ONCE TASK IS COMPLETED 1 Power Supply from 6.6kV SG‐7510 (Existing) 09‐SUPG‐B‐E‐ 10001‐1 2 Vacuum Circuit Breaker (VCB 204)(Existing) 09‐SUPG‐B‐E‐ 10001‐1 3 Vacuum Circuit Unit (VCU‐214 & 220 spare), 1000KW VCU 214 and 1000KW VCU 220 (Existing) 09‐SUPG‐B‐E‐ 10001‐1 4 Ensure that all for DMC WI Mechanical (Off Skid + relevant skids) System and checksheets and records are complete and signoff 1.0 5 Prepare PASR
6
6 Prepare and CEM Simulation Test 1.1 09‐SUPG‐B‐I‐ 10001‐01‐1 7 Prepare for SAT P‐4085A/B system 1.1 09‐SUPG‐B‐B‐ 10139‐1‐3 8 Prepare and Start P‐4085A/B 1.2 09‐SUPG‐B‐B‐ 10139‐1‐3 9 Prepare and USD Test 1.3 09‐SUPG‐B‐I‐ 10001‐01‐1 10 Prepare and Endurance Test Pump A/B 2 x 72 hours 1.2 09‐SUPG‐B‐B‐ 10139‐1‐3 11 Prepare for Dumping at SMP‐B 1.2 09‐SMP‐B‐P‐0031‐1 12 Prepare for Dumping at SMJT‐E 1.2 09‐SMP‐E‐P‐0022‐ 1‐3 13 Stop P‐4085A/B Pump after endurance test 1.2 09‐SUPG‐B‐B‐ 10139‐1‐3 14 Prepare and restart P‐4085A/B 1.2 09‐SUPG‐B‐B‐ 10139‐1‐3 15 Prepare for Scaling Inhibitor / Fine Stabilizer Injection at SMJT‐E 1.2 09‐SMP‐E‐P‐0022‐ 1‐3 16 Prepare for Water Injection to Wellhead SMJT‐E (SM 74) 1.2 09‐SMP‐E‐P‐0001‐ 1‐3‐4 17 Prepare ESD Test (with GI system) 1.2 09‐SUPG‐B‐I‐ 10001‐01‐118 Prepare for Scaling Inhibitor / Fine Stabilizer Injection at SMDP‐B 1.2 09‐SMDP‐B‐P‐ 0014‐3‐WT 19 Prepare for Water Injection to Wellhead SMDP‐B (SM 50) 1.2 09‐SMDP‐B‐P‐ 0001‐3‐WT
1.1
Prepare EOR Water Injection Facilities for Black Start-Up
STEP
NO. ACTION
CHECK ONCE TASK IS COMPLETED
1. Confirm water injection pipeline from SUPG-B to SMP-B is ready for operation.
2. Confirm water injection pipeline from SMP-B to SMJT-E is ready for operation.
3. Confirm communication with Samarang via VSF radio/telephone.
4.
Confirm water injection facility at SMP-B, SMDP-B and SMJT-E ready to receive water injection export from SUPG-B.
5. Ensure that all water injection facility PSVs are online (inlet isolation valves car seal open)
6.
Check that check valve VCH-1111/1112 and restriction orifice RO-4086A/B on pump minimum recycle line are installed correctly.
7. Ensure that all instrumentations are commissioned and online.
8
8.
Ensure chemical injection system on SUPG-B has been filled with the related chemicals – clay stabilizer and scale inhibitor are ready for operation.
9.
Flush pipes between water injection pump (P-4080A/B/C) discharge line to water injection booster pump (P-4805A/B) suction to remove any construction debris prior to "black start-up" of water injection booster pump. Route the flushed water to overboard via water injection booster pump suction drain valve VBA-1187 / 1188 and VBA-1191 / 1192. Close the drain valves once flushing is completed.
10.
Flush water injection booster pump (P-4805A/B) discharge line to water injection export SDV to remove any construction debris prior to “black start-up” of water injection booster pump. Route the flushed water to overboard via water injection booster pump discharge drain valve VBA-1189 / 1190 and VBA-1193 / 1194. Close the drain valves once flushing is completed.
11.
Check water injection booster pump suction strainer to remove any construction debris prior to “black start-up” of water injection booster pump.
12.
Set water injection booster pump discharge pressure controller 4085 @ 21060 kPag by MCP. Place PICA-4085 in MANUAL mode and check PCV-PICA-4085 is fully closed. Open bypass valves VBA-1004 & VGL-1001 for pressure equalization. Close VBA-1004 & VGL-1001 once the pressure reaches 21060 kPag.
13. Set water injection booster pump recycle flow controller FIC-4087A/B @ 74 m³/hr in AUTO mode.
14.
Apply start-up override for the following instrumentation trip: Water injection booster pump suction pressure low low PZALL-4085A/B (LL set @ 2260 kPag)
Water injection booster pump discharge flow low low FZALL-4087A/B (LL set @ 70 m3/h)
The start-up override bypasses a process value to allow time for the value to reach a state that does not initiate a trip. The start-up override is cleared automatically when pressure/flow restored above low low set point.
15. Ensure water injection pump P-4080A/B/C is running and water injection supply header at 8000 kPag (PICA-4081).
16.
Ensure SUPG-B water injection header pressure controller PIC-0908 is at 1200 psig (8274 kPag) in AUTO mode. This is to ensure stable suction pressure for water injection booster pump operation.
17.
Ensure SMP-B water injection dump valve HCV-4060 is 50% open prior to starting water injection booster pump at SUPG-B. HCV-4060 to be regulated to desired pressure once water injection arrives at SMP-B. During this procedure, ensure VB-2111 and VB-2112 (guard filter inlet isolation valves) is in close position. This is for flushing pipeline purposes before introducing water injection into guard filter.
18.
Ensure SMDP-B water injection dump valve HCV-4089 is 50% open prior to introducing water injection at Riser Guard. HCV-4089 to be regulated to desired pressure once water injection arrives at SMDP-B. During this procedure, ensure DBB-3009 & DBB-3010 is in closed position.
19. Ensure water quality at water injection supply header meets required water injection quality.
20. Ensure all spectacle blinds and valves LC/LO/NC as per P&ID.
21. Line up the valves as shown in the checklist below.
1.1.2 P‐4085A Valve Status Checklist (Water Injection Black Start‐up)
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Preparation Operation P O
VBA-1001 Discharge header of existing water
injection pump LO LO
VBA-1141 P-4085A suction isolation valve Open Open XV-4085A P-4085A suction ON/OFF valve Open Open XV-4086A P-4085A discharge ON/OFF valve Open Open VBA-1002 P-4085A discharge isolation valve Open Open VBA-1187 /
1188 P-4085A suction drain valves Open Close
VBA-1189 /
1190 P-4085A discharge drain valves Open Close VBA-1142 P-4085B suction isolation valve Close Open XV-4085B P-4085B suction ON/OFF valve Close Close XV-4086B P-4085B discharge ON/OFF valve Close Close VBA-1003 P-4085B discharge isolation valve Close Open VBA-1191 /
1192 P-4085B suction drain valves Close Close VBA-1193 /
1194 P-4085B discharge drain valves Close Close VBA-1195 /
1196 PCV-4085 inlet isolation valves Open Open VBA-1197 /
1198 PCV-4085 outlet isolation valves Open Open VBA-1004 /
VGL-1001 PCV-4085 bypass valves Open Close
1.1.3 P‐4085B Valve Status Checklist (Water Injection Black Start‐up)
Tag No. Location/Description
Valve Position Check
VBA-1001 Discharge header of existing water
injection pump LO LO
VBA-1141 P-4085A suction isolation valve Close Open XV-4085A P-4085A suction ON/OFF valve Close Open XV-4086A P-4085A discharge ON/OFF valve Close Open VBA-1002 P-4085A discharge isolation valve Close Open VBA-1187 /
1188 P-4085A suction drain valves Close Close VBA-1189 /
1190 P-4085A discharge drain valves Close Close VBA-1142 P-4085B suction isolation valve Open Open XV-4085B P-4085B suction ON/OFF valve Open Close XV-4086B P-4085B discharge ON/OFF valve Open Close VBA-1003 P-4085B discharge isolation valve Open Open VBA-1191 /
1192 P-4085B suction drain valves Open Close
VBA-1193 /
1194 P-4085B discharge drain valves Open Close VBA-1195 /
1196 PCV-4085 inlet isolation valves Open Open VBA-1197 /
1198 PCV-4085 outlet isolation valves Open Open VBA-1004 /
VGL-1001 PCV-4085 bypass valves Close Close
Water Injection Launcher L‐4086 at SUPG‐B
Tag No. Location/Description
Valve Position Check
Preparation Operation P O
XV-4089 Launcher bypass XV Open Open
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1011 XV-4087
/ 4088 Launcher outlet XV Close Close
VGL-1014 /
VBA-1014
Launcher kicker line valves Close Close
VBA-1008 Launcher balance line valve Close Close
VBA-1005 / 1006 / 1007 / 1010
Launcher drain valves Close Close
VBA-1015 /
VGL-1002
Launcher vent valves Close Close
Water Injection Receiver R‐4060 at SMP‐B
Tag No. Location/Description
Valve Position Check
Preparation Operation P O
VB-2025 Incoming water injection supply from
SUPG-B Open Open
VB-2026
/ 2027 Receiver inlet isolation valves Close Close VB-2013
/ 2061 Receiver outlet isolation valves Close Close
VB-2030 Receiver bypass valve Open Open
VB-2028 / VO-2014
Receiver bypass pressure equalization
valves Close Close
/ VO-2015 VB-2036
/ VO-2012
Receiver vent valves Close Close
VB-2031 Receiver balance line valve Close Close VB-2037
/ 2038 / 2039
Receiver drain valves Close Close
VB-2105
/ 2106 PSV-4060A inlet isolation valves LO LO VB-2107
/ 2108 PSV-4060B inlet isolation valves LC LC VB-2109
/ 2110
Water injection header dump line isolation valves
Open (Note
1) Open
VB-2084 Water injection header low point drain Close Close
Notes:
1. HCV-4060 (downstream of VB-2109/2110) is 50%-70% open before introduction into guard filter during commissioning or black start.
Water Injection Guard Filter F‐4065 at SMP‐B Tag No. Location/Description
Valve Position Check
Preparation Operation P O
VB-2111
/ 2112 Filter inlet isolation valves
Close (Note
1) Open
VB-2044 Filter bypass valve Close Close
VB-2113
/ 2114 Filter outlet isolation valves Open Open VB-2041
/ 2042 Filter drain valves Close Close
VB-2115 / 2116
Water injection supply to SMDP-B
14
VB-2117 / 2118
Water injection supply to SMJT-E
isolation valves Open Open
Notes:
1. To be open after complete water injection dumping. Estimated 1 hour of dumping duration before opening the valves (for reducing filter clogging due to debris and off spec water).
Water Injection Launcher L‐4070 at SMP‐B
Tag No. Location/Description
Valve Position Check
Preparation Operation P O
VB-2094 Water injection to SMJT-E Open Open
VB-2052 Launcher bypass valve Open Open
VB-2048
/ 2049 Launcher outlet valves Close Close
VO-2016 / VB-2066
Launcher kicker valves Close Close
VB-2047 Launcher balance valve Close Close
VB-2046 / 2050 /
2051
Launcher drain valves Close Close
VO-2017 / VB-2093
Launcher vent valves Close Close
Water Injection Manifold / Flowline at SMDP‐B Tag No. Location/Description
Valve Position Check
DBB-3009 Water injection to injection well Close (Note 1) Open DBB-3010 Water injection to injection well Close (Note 1) Open VB-3015 /
3016
Water injection dump line isolation
valves Open (Note 2) Open
Notes:
1. To be open once the water injection meets quality.
2. Set opening of HCV-4089 (downstream of VB-3015/3016) at 50%-70%.
Water Injection Wellhead SM‐50 at SMDP‐B
Tag No. Location/Description Valve Position Check
Preparation Operation P O
SSV-5051 Surface safety valve Close Open
SCSSV-5051 Surface controlled subsurface safety valve Close Open
FCV-5051 Injection choke valve Close Open
- Wing valve Close Open
- Master valve Close Open
Water Injection Wellhead SM‐49 at SMDP‐B Tag No. Location/Description
Valve Position Check
Preparation Operation P O
SSV-4951 Surface safety valve Close Open
16
FCV-4951 Injection choke valve Close Open
- Wing valve Close Open
- Master valve Close Open
Water Injection Receiver R‐4084 / Manifold at SMJT‐E
Tag No. Location/Description
Valve Position Check
Preparation Operation P O
VB-4019 Incoming water injection supply from
SMP-B Open Open
VB-4046
/ 4047 To water injection wellhead SM-48 Close (Note 1) Open
DBB-4026
Water injection header dump line DBB
valves Open (Note 2) Open
VB-4017
/ 4018 Receiver inlet isolation valves Close Close VB-4033
/ VO-4022
Receiver outlet isolation valves Close Close
VB-4020 Receiver bypass valve Open Open
VB-4027 / VO-4026
Receiver vent valves Close Close
VB-4023 Receiver balance line valve Close Close VB-4024
/ 4028 / 4031
Receiver drain valves Close Close
Notes:
2. Set opening of HCV-4084 (downstream of DBB-4026) at 50%-70%. Reduce the opening once quality is met.
Water Injection Wellhead SM‐74 at SMJT‐E
Tag No. Location/Description Valve Position Check
Preparati on
Operation P O
SSV-7451 Surface safety valve Close Open
SCSSV-7451
Surface controlled Subsurface safety valve
Close Open
FCV-7451 Injection choke valve Close Open
STEP
NO. ACTION
CHECK ONCE TASK IS COMPLETED
1. Prior to starting water injection booster pump P-4085A, ensure Sumandak Water Injection Facilities are prepared.
2. Ensure communication between 2 platforms, Sumandak & Samarang, are established.
3. Perform line flushing at SMP-B, SMDP-B and SMJT-E.
4. Start water injection booster pump P-4085A
5. Check the water is recycling via pump minimum line via recycle pump flow control valve
6. Ensure pump discharge flow is about 74 m³/hr via flow measurement at FIC-4087A to prevent pump damage
7.
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Observe recycle water temperature via temperature measure at TIA-4087A on pump recycle line. Temperature should not exceed 60°C. To reduce the temperature, consider gradually open PCV-4085 bypass valves VBA-1004 & VGL-1001. Close the valves once the temperature is manageable.
8. Check pressure differential across pump suction strainer via PDA-4085A.
9. Once pump discharge flow is stabilized at about 74 m³/hr, open PCV-4085 gradually by 5 – 10% opening.
10. Set water injection booster pump discharge pressure controller PICA-4085 in AUTO mode once FCV-4087A is fully closed.
11. Remove all inhibited trips once the water injection booster pump discharge pressure and flow has stabilized.
12. Start injecting clay stabilizer and scale inhibitor into SUPG-B water injection export header
13.
Monitor pressure at the following location:
Water injection booster pump discharge pressure at 21060 kPag (PICA-4085)
Water injection export header to SMP-B at SUPG-B (PIA-4092) Water injection incoming header from SUPG-B at SMP-B (PI-4060) Differential pressure at SMP-B water injection guard filter F-4065 Water injection export header to SMJT-E at SMP-B (PI-4070) Water injection supply header at SMDP-B (PI-4090)
Water injection incoming header from SMP-B at SMJT-E (PI-4086)
14.
Prior to injecting to wellhead, perform the SLOPE Test.
NOTE: Ensure the water injection guard filter is online before performing the SLOPE Test.
15
SMJT-E is achieved, water injection to individual wellhead can proceed.
16.
Water injection to individual wellhead shall be done one wellhead at a time and follows the following sequence:
a) Open well SCSSV, manual master valve, manual wing valve and followed by SSV from WHCP unit.
b) Manually open injection choke valve at minimum opening and gradually increase as per requirement to introduce water injection into the well.
STEP NO. ACTION CHECK ONCE TASK
IS COMPLETED
1. Start-up after USD/PSD/ESD requires operator attendance at the platform
2. Reason for USD/PSD/ESD has been identified and any correction implemented and conditions cleared.
3.
Ensure all wellhead water injection choke valves and water injection dump valves are closed and confirm pressure in water injection header.
4.
Water injection dump valves shall be open 50% to prevent water hammering during start-up of water injection booster pump and shall be gradually reduce once water injection quality is met.
5. Confirm pressure in water injection header.
20
6.
Apply start-up override for the following instrumentation trip:
Water injection booster pump suction pressure low low PZALL-4085A/B
Water injection booster pump discharge flow low low FZALL-4087A/B
The start-up override bypasses a process value to allow time for the value to reach a state that does not initiate a trip. The start-up override is cleared automatically when pressure/flow restored above low low set point.
7. Follow steps mentioned in section 1.2
STEP NO. ACTION CHECK ONCE TASK IS
COMPLETED
1.
Monitor pressure at water injection supply header. Open water injection dump valve as necessary to divert the flow overboard.
2.
Slowly reduce water injection supply flow by means of gradually closing wellhead water injection choke valve one by one.
3.
Once all wellhead water injection choke valves are closed, place water injection booster pump discharge pressure controller PICA-4085 in MANUAL mode. Close 4085 gradually by 5% to 10%. By closing of PCV-4085 gradually, the water injection flow will be diverted to pump suction via minimum pump recycle line through FCV-4087A.
4. Close well SSV followed by SCSSV from WHCP unit.
1.4 Shutdown EOR Water Injection Facilities
5. Stop the clay stabilizer and scale inhibitor injection into water injection export header at SUPG-B.
6. Monitor water injection booster pump discharge flow via FIC-4087A
7. Stop the water injection booster pump P-4085A once PCV-4085 is fully closed.
1.5 Instrument Set Points
Water Injection Booster Pump at SUPG‐B
Tag No. Location/Description Set Point
PZALL-4085A P-4085A suction pressure low low 2260 kPag
PIAL-4086A P-4085A suction pressure low 3765 kPag
PIAH-4087A P-4085A discharge pressure high 22180 kPag FZALL-4087A P-4085A discharge flow low low 70 m3/h
FICL-4087A P-4085A discharge flow low 74 m3/h
TIAH-4087A P-4085A discharge temperature high 60°C PZALL-4085B P-4085B suction pressure low low 2260 kPag
PIAL-4086B P-4085B suction pressure low 3765 kPag
PIAH-4087B P-4085B discharge pressure high 22180 kPag FZALL-4087B P-4085B discharge flow low low 70 m3/h
22
TIAH-4087B P-4085B discharge temperature high 60°C
PICAH-4085 Water Injection Booster Pump discharge header
pressure high 22000 kPag
PICAL-4085 Water Injection Booster Pump discharge header
pressure low 10450 kPag
Water Injection Launcher at SUPG‐B
Tag No. Location/Description Set Point
PIAH-4092 Water injection to SMP-B pressure high 22000 kPag PIAL-4092 Water injection to SMP-B pressure low 10450 kPag
Water Injection Receiver at SMP‐B
Tag No. Location/Description Set Point
PSV-4060 A/B Water injection to Water Injection Guard Filter
pressure safety valves 208 barg
Water Injection Guard Filter at SMP‐B
Tag No. Location/Description Set Point
PSV-4065 Water Injection Guard Filter pressure safety valve 208 barg PSV-4066 Water injection line to SMDP-B 208 barg
Water Injection Wellheads at SMDP‐B
Tag No. Location/Description Set Point
PEL-5053 Water injection flowline to wellhead 115.8 barg PEL-4953 Water injection flowline to wellhead 115.8 barg
Tag No. Location/Description Set Point PEL-7453 Water injection flowline to wellhead 115.8 barg
1.6 SMP-B/SMDP-B
The gas from SUPG-B to SMP-B will be further routed to SMDP-B via bridge link piping and injected into two new GI wellheads. Automatic flow control is provided at each gas injection wells.
Flow meter will be provided on the common line prior to SMP-B bridge linked to SMDP-B and gas injection export line to SMJT-E, to monitor total gas injection rate. Flow meter is also provided on the line to individual wells.
The EOR gas injection facilities at SMP-B consist of: Gas Injection Receiver (R-2940)
Item Specification
Design Pressure 28000 kPag (4060 psig)
Design Temperature 100°C (max) / -20 ºC (min)
Size (Major Barrel/Minor Barrel) Diameter: 200 mm / 150 mm Length: 1860 mm / 2420 mm Gas Injection Launcher (L-2950)
1 Item 2 Specification
3 Design Pressure 4 28000 kPag (4060 psig) 5 Design Temperature 6 65 °C (max) / -20 ºC (min) 7 Size (Major Barrel/Minor
Barrel)
8 Diameter: 150 mm / 100 mm 9 Length: 1830 mm / 1000 mm
1.6.1 SMJT-E
The remaining gas injection from SMP-B will be routed to SMJT-E. New 4” flexible GI pipeline will be installed to transfer injection gas from SMP-B to SMJT-E.
24
There is no additional equipment installed in SMJT-E for gas injection.The EOR gas injection facilities at SMJT-E consist of:
Gas Injection Receiver (R-2910)
10 Item 11 Specification
12 Design Pressure 13 28000 kPag (4060 psig) 14 Design Temperature 15 65 °C (max) / -20 ºC (min) 16 Size (Major Barrel/Minor
Barrel)
17 Diameter: 150 mm / 100 mm 18 Length: 2040 mm / 1690 mm
THIS FLOWCHART IS FOR FIRST BLACK START UP ONLY, NOT DESIGNATED FOR POST ABANDON PLATFORM STARTUP.
Prior to introduction of Hydrocarbon, PIR-04/PASR and shall be conducted which include pre startup check in order to ensure Platform readiness for RFSU.
STEP NO PROCEDURE INSTRUCTION PROCEDURE ACTIVITY DRAWING REFERENCE CHECK (/) ONCE TASK IS COMPLETED 1 Power Supply from 400V SG SB‐ 7710(Existing) 09‐SUPG‐B‐E‐4012‐1 2 Air Circuit Breaker (ACB 311)(Existing) 09‐SUPG‐B‐E‐4012‐1 3 Vacuum Circuit Unit (VCU‐214 & 220 spare), 1000KW VCU 214 and 1000KW VCU 220 (Existing) 09‐SUPG‐B‐E‐4012‐1 4 MCC‐7810 (Existing) 184KW 09‐SUPG‐B‐E‐4012‐1 5 230V AC UPS DB 7814B (Existing) 09‐SUPG‐B‐E‐4012‐1 6 IRP 7810 (Existing) 09‐SUPG‐B‐E‐4012‐1
2
.
0
Flowchart for Gas Injection Black Start
Formatted: Font: BoldFormatted: Font: (Default) Arial, Bold Formatted: Font: (Default) Arial, Bold Formatted: Font: (Default) Arial, Bold
26
7 Ensure that all for RFC GI Mechanical (Off Skid + relevant skids) System and checksheets and records are complete and signoff 2.0 8 Prepare PIR‐04 9 Prepare PASR 10 Prepare for CEM Simulation Test 2.0 09‐SUPG‐B‐I‐10001‐ 01‐1 11 Prepare for RFSU 12 Prepare and Pressurization Pipeline from SUPG‐B to SMJT‐E at 72 Barg (System Test) 2.1 09‐SUPG‐B‐B‐10119‐ 1‐3 13 Prepare for GTC Start Up 2.2 09‐SUPG‐B‐B‐10119‐ 1‐3 14 Prepare and GTC pressurize 117 Barg to SMJT‐E (System Test) 2.2 09‐SUPG‐B‐B‐10120‐ 1‐3 15 Start GTC Ramp Up Pressure to 234 Barg 2.2 09‐SUPG‐B‐B‐10120‐ 1‐3 16 Prepare for ESD Test 2.4 09‐SUPG‐B‐I‐10001‐ 01‐1 17 Prepare and Restart Up GTC and Injection to SMJT‐E SM 121 (72 Hours) 2.3 09‐SMJT‐E‐P‐0019‐1‐ 118 Prepare for Gas Injection into SM 37 & SM 47 at SMDP‐b 2.3 09‐SMDP‐B‐P‐0009‐ 1‐3‐WT STEP NO. ACTION CHECK ONCE TASK IS COMPLETED
1. Confirm gas injection pipeline to SMP-B is ready for operation
2. Confirm gas injection facility at SMP-B, SMDP-B and SMJT-E ready to receive gas injection export from SUPG-B
3. Confirm communication with Samarang via VSF radio/telephone
4.
Check the following utility is ready for operation:
Fuel Gas @ 1860-3450 kPag Instrument Air @ HOLD kPag Power supply
5. Ensure that all gas injection facility PSVs are online (inlet isolation valves car seal open)
6. Ensure all check valves and restriction orifices are installed correctly
7. Ensure that all instrumentations are commissioned and online
2
.
1
Prepare EOR
Gas
Injection Facilities for Black
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Formatted: Font: (Default) Arial, Bold Formatted: Font: (Default) Arial, Bold Formatted: Font: (Default) Arial, Bold
28
8.
Ensure gas injection facility piping at SUPG-B, SMP-B, SMDP-B and SMJT-E is already purged and ready prior to hydrocarbon entry. The piping shall be purged and pressurized to 690 kPag with nitrogen.
9.
Ensure gas injection compressor package pre start-up checklist and action item required as stated in Vendor Manual (see vendor doc TPIM 1010) has been completed and complied with.
10. Verify gas injection compressor casings have been drained.
11.
Set gas injection compressor backpressure controller PICA-2430 @ 23000 kPag and place it in MANUAL mode. Set the controller output to ensure PCV-2430 is fully open.
12.
Set 1st stage compressor suction scrubber level controller LICA-2415 on gap control (LCV open @ 650 mm and LCV close @ 400 mm). Place the controller in AUTO mode.
13.
Set 2nd stage compressor suction scrubber level controller LICA-2416 on gap control (LCV open @ 650 mm and LCV close @ 400 mm). Place the controller in AUTO mode.
14. Close all gas injection choke valves via SMQ-A
15.
Apply start-up override for the following instrumentation trip:
1st stage GI compressor scrubber liquid level low low LZALL-2415 1st stage GI compressor suction pressure low low PZALL-2426 1st stage GI compressor suction flow low low FZALL-2425 1st stage GI compressor discharge pressure low low PZAHH-2425 2nd stage GI compressor scrubber liquid level low low LZALL-2416 2nd stage GI compressor suction pressure low low PZALL-2446
2nd stage GI compressor suction flow low low FZALL-2445 2nd stage GI compressor discharge pressure low low PZAHH-2445 SUPG-B gas injection export header pressure low low PZALL-2932A/B/C
SMP-B gas injection incoming header pressure low PEL-2940 SMP-B gas injection export header pressure low PEL-2950 SMJT-E gas injection incoming header pressure low PEL-2910
The start-up override bypasses a process value to allow time for the value to reach a state that does not initiate a trip. The start-up override is cleared automatically when pressure/flow restored above low low set point.
16. Line up the valves as shown in the checklist below.
Gas Injection Preparation Valve Status Checklist Downstream of Gas/Glycol Heat Exchanger at SUPG-B
Tag No. Location/Description
Valve Position Check
Prepare Operation P O
VDBB-1032 Gas supply tie-in DBB LO LO
VDBB-1033 PSV-2230B inlet DBB LC LC VDBB-1034 PSV-2230A inlet DBB LO LO VBA-1019 PSV-2230B outlet valve LO LO
VBA-1017 PSV-2230A outlet valve LO LO
1st Stage Gas Injection Compressor Suction Scrubber V-2415 at SUPG-B
Tag No. Location/Description Valve Position Check
Formatted: Font: (Default) Arial, 11 pt, Bold, English (Malaysia) Formatted: Font: (Default) Arial, 11 pt, Bold, English (Malaysia)
30
Prepare Operation P O
VBA-1059 Suction scrubber inlet isolation valve Open Open
SDV-2415 Suction scrubber inlet SDV Close Open
SDV-2416 Suction scrubber inlet bypass SDV Close Close
VBA-1175 / 1176
PSV-2415A inlet isolation valves LO LO
VBA-1177 /
1178
PSV-2415B inlet isolation valves LC LC
VBA-1077 PSV-2415A outlet isolation valve LO LO
VBA-1145 PSV-2415B outlet isolation valve LO LO
VBA-1079 Suction scrubber vent valve LC LC
VGL-1008 Suction scrubber vent valve NC NC
VBA-1068 /
1069
Suction scrubber drain valves NC NC
VBA-1070 Suction scrubber instrument drain valve NC NC
SDV-2417 Suction scrubber outlet SDV Close Open
VBA-1071 /
1126
LCV-2415 inlet isolation valves Open Open
VBA-1127 /
1122
Tag No. Location/Description
Valve Position Check
Prepare Operation P O VBA-1124 / VGL-1015 LCV-2415 bypass valves NC NC
1st Stage Gas Injection Compressor K-2425 & After Cooler E-2435 at SUPG-B
Tag No. Location/Description
Valve Position Check
Preparation Operation P O
XV-2426 Hot gas compressor bypass
valve Open Close
VDBB-1090 PSV-2425A inlet DBB LO LO
VDBB-1091 PSV-2425B inlet DBB LC LC
VBA-1084 PSV-2425A outlet isolation
valve LO LO
VBA-1087 PSV-2425B outlet isolation
valve LO LO
VBA-1083 Compressor vent valve LC LC
VGL-1009 Compressor vent valve NC NC
VBA-1081 / 1082 After cooler drain valves NC NC
XV-2427 Cold gas compressor bypass
valve (HOLD) Open Close
2nd Stage Gas Injection Compressor Suction Scrubber V-2416 at SUPG-B
32
Preparation Operation P O
VBA-1183 / 1184 PSV-2416A inlet isolation
valves LO LO
VBA-1185 / 1186 PSV-2416B inlet isolation
valves LC LC
VBA-1037 PSV-2416A outlet isolation
valve LO LO
VBA-1035 PSV-2416B outlet isolation
valve LO LO
VBA-1104 Suction scrubber vent valve LC LC
VGL-1010 Suction scrubber vent valve NC NC
VBA-1041 / 1042 Suction scrubber drain valves NC NC
VBA-1043 Suction scrubber instrument
drain valve NC NC
SDV-2420 Suction scrubber liquid outlet
SDV Close Open
VBA-1040 / 1128 LCV-2416 inlet isolation valves Open Open
VBA-1129 / 1150 LCV-2416 outlet isolation
valves Open Open
VBA-1125 /
VGL-1016 LCV-2416 bypass valves NC NC
2nd Stage Gas Injection Compressor K-2426 & After Cooler E-2436 at SUPG-B
Tag No. Location/Description
Valve Position Check
Preparation Operation P O
XV-2445 Hot gas compressor bypass
valve Open Close
VDBB-1050 PSV-2426A inlet DBB LO LO
VDBB-1051 PSV-2426B inlet DBB LO LO
VBA-1051 PSV-2426A outlet isolation
valve LO LO
VBA-1053 PSV-2426B outlet isolation
valve LO LO
VBA-1144 PSV-2426C outlet isolation
valve LO LO
VBA-1110 Compressor vent valve LC LC
VGL-1011 Compressor vent valve NC NC
VBA-1057 / 1056 After cooler drain valves NC NC
XV-2446 Cold gas compressor bypass
valve (HOLD) Open Close
Gas Injection Compression Discharge Header at SUPG-B
Tag No. Location/Description
Valve Position Check Preparation Operation P O SDV-2435 Compressor discharge header SDV Close Open
V BA-1155
/1203SDV-2436
Pipeline pressurisation manual valvesCompressor discharge header bypass SDV
Open
Close
X
V-2428VBA-1202 Manual blowdown XV to LP flare Close Close
VBA-1136 XV-2428 VBA-1202 outlet isolation
valve LO LO
BDV-2427 Compression discharge header BDV loseOpen Close
VBA-1094 BDV-2428 outlet isolation valve LO LO
VBA-1090 Compression discharge header isolation valve
Open Open
Gas Injection Launcher L-2930 and Compressor Seal Gas Supply at SUPG-B
34
Preparation Operation P O
XV-2932 Launcher bypass XV Open Open
SDV-2930 Gas injection line SDV to SMP-B Open Open
XV-2930
/ 2931 Launcher outlet XV Close Close
VGL-1094 /
VBA-1074
Launcher kicker line valves Close Close
VBA-1033 Launcher balance line valve Close Close
VBA-1020 / 1095 / 1034 / 1096 / 1032
Launcher drain valves Close Close
VBA-1027 / 1098 / 1026
Launcher purging line valves Close Close
VBA-1021 /
1022
Launcher manual depressurization line
valves Close Close
BDV-2931 Gas injection export header BDV Close Close
VBA-1030 BDV-2931 outlet isolation valve LO LO
VBA-1102 BDV-2931 outlet line bleed valve NC NC
SDV-2932
Gas supply to gas injection turbine
compressor seal gas system Open Open
1123 / 1153 VBA-1092 /
1155
PCV-2937 outlet isolation valves Open Open
VBA-1181 /
1182
PSV-2930A inlet isolation valves LO LO
VBA-1151 PSV-2930A outlet isolation valve LO LO
VBA-1179 /
VBA-1181
PSV-2930B inlet isolation valves LC LC
VBA-1152 PSV-2930B outlet isolation valve LO LO
VBA-1029 /
1149
Gas injection export pipeline blowdown Close Close
Gas Injection Compressor Turbine at SUPG-B
Tag No. Location/Description
Valve Position Check Preparation Operation P O
VBA-1120 Compressor turbine utility air
supply valve Open Open
VBA-1205 / 1206 Compressor turbine instrument air
supply valve Open Open
VB-24204A Compressor turbine potable water
supply valve Open Open
VBA-1210 Engine air inlet duct drain valve Open Open
VBA-1207 Lube oil tank drain valve NC NC
36
VBA-1121 Drip pan oil drain valve NC NC
VBA-1209 Engine exhaust collector and
combustor drain valve NC NC
VBA-1174 Seal gas filter drain valve Close Close VB-59305 /
VBA-1204 Compressor turbine N2 supply LC LC
VBA-1212 TC fuel gas filter inlet Open Open
VBA-1211 TC fuel gas filter inlet drain line NC NC VBA-1213 TC fuel gas filter drain point NC NC VBA-1214 TC fuel gas filter depressurisation
line LO LO
VBA-1216 Potable water supply to high
pressure water mist skid Open Open
Gas Injection Receiver at SMP-B
Tag No. Location/Description
Valve Position Check Preparation Operation P O
ABV-2940 Incoming gas injection supply from
SUPG-B Open Open
VB-2001 /
2002 Receiver inlet isolation valves Close Close VBO-2010 /
VB-2087 Receiver outlet isolation valves Close Close
VB-2007 Receiver bypass valve Open Open
VB-2005 / VO-2009
Receiver bypass pressure equalization
valves Close Close
VB-2009 /
2008 Receiver vent valves Close Close
VB-2101 /
2102 Receiver purging line valves Close Close VB-2003 /
2010 / 2011 Receiver drain valves Close Close
VB-2100 / 2099
Future pipeline pressurization line
isolation valves Close Close
VB-2085 VCH-2001 bypass valve Close Close
BDV-2941 Gas injection incoming header BDV Close Close VB-2012 BDV-2941 outlet isolation valve LO LO
DBB-2004 Gas injection to launcher L-2950 DBB
valves Open Open
DBB-2005 Gas injection to SMDP-B gas injection
38
Gas Injection Launcher at SMP-B
Tag No. Location/Description
Valve Position Check Preparation Operation P O
VB-2091 VC-2002 bypass valve Close Close
VB-2014 Launcher bypass valve Open Open
VB-2020
/ 2021 Launcher outlet isolation valves Close Close VB-2024
/ 2023 Header vent valves Close Close
ABV-2950 Gas injection supply to SMJT-E
Open (Note
1) Open
Notes:
1. Ensure valve is open after ABV-2910 at SMJT-E is fully open during preparation line up.
Gas Injection Manifold at SMDP-B
Tag No. Location/Description
Valve Position Check Preparation Operation P O
ABV-2942 Gas injection supply from SMP-B Open Open
DBB-3021 Flowline connection for SM-47 Open Open
DBB-3022 Flowline connection for SM-61 Open Open
VB-3007 /
3008 Gas injection manifold drain valves Close Close
Tag No. Location/Description
Valve Position Check Preparation Operation P O VB-3003 /
3004 Flowline vent valves Close Close
SSV-6151 Surface safety valve Close Open
SCSSV-6151 Surface controlled subsurface safety valve Close Open
Gas Injection Flowline Wellhead SM-47 at SMDP-B
Tag No. Location/Description Valve Position Check
Preparation Operation P O VB-3005 /
3006 Flowline vent valves Close Close
SSV-4751 Surface safety valve Close Open
40
Gas Injection Receiver at SMJT-E
Tag No. Location/Description Valve Position Check
Preparation Operation P O ABV-2910 Gas injection supply from SMP-B Open Open
VB-4001 /
4002 Receiver inlet isolation valves Close Close VB-4042 /
4043
Future pipeline pressurization line isolation
valves Close Close
VB-4003 Receiver bypass valve Open Open
VB- 4029 Header vent valves Close Close
Gas Injection Manifold at SMJT-E (Error! Reference source not found.33)
Tag No. Location/Description Valve Position Check
Prepare Operation P O VB-4044 /
4045 Flowline connection for SM-7448 Open Open
VB-4013 /
4014 Gas injection manifold drain valves Close Close
Gas Injection Manifold Wellhead at SMJT-E
Tag No. Location/Description Valve Position Check
Prepare Operation P O VB-40438 /
40439 Flowline vent valves Close Close
SSV-121104851 Surface safety valve Close Open
2.2
Pre
ssurization of Sumandak and Samarang Gas Injection Facility to 7400 kPag
STEP NO. ACTION CHECK ONCE TASK IS COMPLETED 1.Line up the following valves at respective platform for pipeline pressurization:
(The table focuses on the valves involved in pressurization.)
Downstream of Glycol Heat Exchanger E‐2230 (SUPG‐B) Tag No. Location/Description
Valve Position Pressurization Operation
VDBB-1032
Gas supply tie-in DBB
LO LO VDBB-1033 PSV-2230B inlet DBB LC LC VDBB-1034 PSV-2230A inlet DBB LO LO
Formatted: Font: (Default) Arial, Bold Formatted: Font: Bold, English (Malaysia)
42
VBA-1017 PSV-2230A outlet valve LO LO
VBA-1019 PSV-2230B outlet valve LO LO
1st stage Gas Injection Compressor Suction Scrubber V‐2415 (SUPG‐B) Tag No. Location/Description
Valve Position Pressurization Operation VBA-1059 Suction scrubber inlet isolation valve Close Open VBA-1155 Pressurization bypass line isolation
valve Open LC Gas Injection Compression Discharge Header (SUPG‐B) Tag No. Location/Description
Valve Position Pressurization Operation VBA-1203 Pressurization bypass line isolation
valve Open LC
VBA-1090 Compression discharge header
isolation valve Open Open
Gas Injection Launcher (SUPG‐B)
Tag No. Location/Description
Valve Position Pressurization Operation PCV-2430 Launcher pressure control valve Open Open
VCH-1003 Launcher check valve Open Open
SDV-2930 Gas injection line SDV to SMP-B Open Open BDV-2931 Gas injection export header BDV Open Open
VBA-1030 BDV-2931 outlet isolation valve LO LO
Gas Injection Receiver (SMP‐B)
Tag No. Location/Description
Valve Position Pressurization Operation ABV-2940 Incoming gas injection supply from
SUPG-B Open Open
VB-2005/VO-2009
Receiver bypass pressure
equalization valves Open Close
VCH-2001 Receiver check valve Open Open
BDV-2941 Gas injection receiver BDV Close Close
DBB-2004 Gas injection to launcher L-2950 Open Open DBB-2005 Gas injection to SMDP-B injection
manifold via bridge Open Open
Gas Injection Export (SMP‐B)
Tag No. Location/Description
Valve Position Pressurization Operation
VC-2002 Export check valve Open Open
VB-2014 Launcher bypass valve Open Open
VB-2024/23 Header vent valves Close Close
ABV-2950 Gas injection supply to SMJT-E Open Open
Gas Injection Manifold (SMDP‐B)
44
Pressurization Operation ABV-2942 Gas injection supply from SMP-B Open Open
DBB-3021 Connection to SM-47 Close Open
DBB-3022 Connection to SM-61 Close Open
VB-3007/08 Manifold drain valves Close Close
Gas Injection Receiver (SMJT‐E)
Tag No. Location/Description
Valve Position Pressurization Operation ABV-2910 Gas injection supply from SMP-B Open Open VB-4001/02 Receiver inlet isolation valves Close Close VB-4050/51 Future pipeline pressurization line
isolation valves Close Close
Gas Injection Manifold (SMJT‐E) Tag No. Location/Description Valve Position Pressurization Operation
VB-4044/45 Connection to SM-74 Close Open
VB-4013/14 Manifold drain valves Close Close
(Continue from step no.1) STEP NO. ACTION CHECK ONCE TASK IS COMPLETED 2.
Pressurize the pipeline in 4 stages (each stage accounts for 25% of 7400 kPag): 1850, 3700, 5550, and 7400 kPag. Control the inlet pressure using PCV-2430 in MANUAL mode by setting the control valve to the pressure at each stage. Close VBA-1155 and 1203 to isolate the bypass line at each stage.
Formatted: Font: Bold, English (Malaysia)
3.
The expected pressure profile is shown in the figure below. A certain time should be reserved for stabilization of pressure and leakage detection upon completion of pressurizing at each stage. Dedicated personnel will be assigned to perform testing (to detect leakage) and remediation at the main valves during pressurization.
4.
Be reminded that the pressure is taken from design value, at discharge of 2nd stage GI compressor. Value may vary during actual pressurization.
5.
Close VBA-1155 and VBA-1203 (LC) when the pressure in the pipeline reaches 74 barg (or the current export pressure). This is to prevent backflow during compressor startup and cause Glycol Contactor C-2220 to overpressure.
6. Open 1 st
stage compressor suction scrubber inlet bypass SDV-2416 to start pressurization of gas injection facility to 7400 kPag
7.
46
backpressure controller PICA-2430 in AUTO mode (set point: i. 117.0 barg and ii. 234.4 barg). Due to control action, the pressure control valve PCV-2430 will close.
8. Start cooler fan for 1st stage gas injection compressor after cooler E-2435 and 2nd stage gas injection compressor after cooler E-2436
9.
Line up the following valves for operation prior to compressor start-up:
•1st Stage Gas Injection Compressor Suction Scrubber Inlet SDV-2415 •1st Stage Gas Injection Compressor Suction Scrubber Inlet Bypass SDV-2416 •Compressor Discharge Header SDV-2435
•Pipeline pressurisation manual valves VBA-1155 / 1203
Refer to 2.0 for the valve position during operation.
NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for detailed sequencing of the valves.
2.3 Start-Up Gas Turbine for Gas Injection Compressor
STEPNO. ACTION
CHECK ONCE TASK IS COMPLETED
NOTE: Refer vendor doc. title Turbomachinery Package Installation Guideline: Compressor and Mechanical Drive Units, doc no. TPIM 1010 for further details
1. Check that fuel gas supply is adequately available for the gas injection compressor turbine driver.
2. Ensure adequate process gas supply is available from glycol
contactor for compressor start up.
NOTE : A restart may be initiated one minute after the turbine engine speed drops to 15 percent. In case of a malfunction shutdown, do not attempt another restart until the cause of the malfunction has been determined and the condition has been corrected. After three attempted starts have been unsuccessful, additional troubleshooting
Formatted: Font: Bold, English (Malaysia)
may be required.
3.
Select Maintenance display screen and select onscreen FAIL TO LOAD SHUTDOWN ENABLE button. Verify [Fail to Load Enabled] highlights.
4. Select Unit Valves display screen and select onscreen Seal System Auto button. Verify [Auto] highlights for Seal System Status. 5. From Unit Valves display screen, select onscreen Yard Valves Auto
button and verify [Auto] highlights for Yard Valves System Status. 6. Select HPC Surge Control display screen and select onscreen Auto
button. Verify [Auto] is highlighted for ANTI-SURGE CONTROL.
7. Select LPC Surge Control display screen and select onscreen Auto button. Verify [Auto] is highlighted for ANTI-SURGE CONTROL.
8. Verify Operation display screen is selected to monitor package during start.
9. Press START Switch (S1010) or select Operation display screen onscreen START button.
a. STARTING Light (DS1014) begins flashing and [Starting] is highlighted on Operation display screen. Enclosure vent fan is energized. Backup lube oil pump is tested for operation and pre/post pump starts pre-lubrication cycle. The control system begins a fuel system check. Start system is energized.
b. After pre-lube cycle is complete, engine cranking begins.
c. After starter has cranked engine to 15 percent speed, purge timer provides a preselected period of exhaust system purging via engine air flow. [Purge Crank] is highlighted on Operation display screen.
d. After purge cycle is completed, fuel is admitted into combustor chamber where it is mixed with compressed air and ignited. [Ignition] is highlighted on
e. Operation display screen. Light off occurs within next few
seconds and combustion begins.
f. The engine continues to accelerate and engine temperature increases to 400°F (204°C). [Light Off] is highlighted on Operation display screen, fuel ramp is activated, and ignition is
de-48
energized. ENGINE HOURS/START COUNTER Meter (M210) registers a successful start.
g. Engine speed increases to starter dropout speed. Engine-driven lube oil pump pressure increases and pre/post lube oil pump stops. Start system is de-energized and starter clutch overruns. Engine speed increases to idle speed. ENGINE HOURS/START COUNTER Meter (M210) begins to log engine operating hours. STARTING Light is extinguished and [Running] is highlighted on Operation display screen.
h. If engine speed remains at idle speed, manually increase engine speed by pressing INCREASE Switch (S1054) until [Ready to Load] is highlighted on Operation display screen.
NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant
Functional Specification, doc. no. 3Y041-149007 for detailed sequencing of the
valves.
NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant
Functional Specification, doc. no. 3Y041-149007 for detailed sequencing of the
valves.
2.3
.1 Start-Up Gas Turbine for Gas Injection CompressorSTEP
NO. ACTION
CHECK ONCE TASK IS COMPLETED 1. Confirm that gas injection compressor is in stable operation
2.
Monitor flow, pressure and temperature at the following location: 1st stage GI compressor suction pressure (PIA-2425) via GI compressor TCP
1st stage GI compressor discharge pressure (PIA-2426) via GI
Formatted: Font: Bold, English (Malaysia)
compressor TCP
1st stage GI compressor discharge temperature (TIA-2426) via GI compressor TCP
2nd stage GI compressor suction pressure (PIA-2445) via GI compressor TCP
2nd stage GI compressor discharge pressure (PIA-2448) via GI compressor TCP
2nd stage GI compressor discharge temperature (TIA-2446) via GI compressor TCP
2nd stage GI compressor after cooler outlet temperature (TIA-2457) GI injection export header flow (FQI-2435)
3.
With closed PCV-2430 due controller action, 2nd stage GI compressor discharge pressure is expected to build up to 23000 kPag. Upon reaching this pressure, PCV-2430 will start to open to pressurize the pipeline further from 74 barg to reach required operating landing pressure at SMP-B and SMJT-E depending on GI injection well consumption.
4.
Once required pressure at gas injection manifold at SMP-B and SMJT-E is achieved, gas injection to individual wellhead can proceed.
5.
Gas injection to individual wellhead shall be done one wellhead at a time and follows the following sequence:
a. Ensure the header valves are fully open.
b. Ensure the master and wing valves are fully open. c. Open well SCSSV and followed by SSV from WHCP unit. d. Open injection choke valve to introduce gas injection into the well
50
NOTE: Refer vendor doc. title Turbomachinery Package Installation Guideline: Compressor and Mechanical Drive Unit, doc no. TPIM 1010 for further details
This subsection describes the shutdown procedures for the turbine package. There are four types of shutdown procedures; normal stop, pressurized fast stop, emergency stop, and control system stop.
Once the turbine is shutdown, operator at SMG-A to stop gas injection at SMDP-B and SMJT-E as necessary by closing the wellhead gas injection choke valves. Close injector well SSV followed by SCSSV from well control-o-maticWHCP unit.
2.4.1
NORMAL STOP
NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for more details.
This subsection describes the procedures to initiate a normal stop from the control console. A normal stop shutdown sequence includes a cooldown period, which allows the engine to run with no load for a preset period before the engine is stopped.
1. Press NORMAL STOP Switch (S1011) or select Operation display screen onscreen STOP button. The following events occur:
a. COOLDOWN Light (DS1013) illuminates, surge control valve is opened, and [Cooldown] highlights on Operation display screen.
b. Engine slows to idle speed and continues to run for a preset cooldown cycle.
NOTE : Engine may be restarted during cooldown cycle by pressing ACKNOWLEDGE Switch, RESET Switch, and then START Switch or by selecting Operation display screen onscreen RESET and START buttons.
c. After preset cooldown cycle, fuel system valves close, combustion ceases, and engine begins to decelerate. COOLDOWN Light (DS1013) extinguishes and [Cooldown] indication reverts to normal video.
d. When engine speed decreases below 25%, Slow Roll Time counts down under TIME REMAINING on Operation display screen.
NOTE : The Variable Frequency Drive (VFD) commands the starter motor to a speed of ~2 to 3.5% NGP. As the engine speed continues to slow from 25%, the overrunning clutch continues to overrun until the engine speed matches the starter speed. The clutch engages and the starter maintains the commanded speed until the slow roll timer times out.
e. After preset slow roll cycle, start motor is de-energized. STOPPING Light (DS1011) illuminates, and [Stopping] highlights on Operation display screen.
f. Gas compressors suction valves and discharge valves close and vent valves remains closed to maintain pressure in gas compressors and process piping for a preselected pressurization hold time period.
g. [Running] indication reverts to normal video. ENGINE HOURS/START COUNTER Meter (M210) stops logging operating time.
h. After engine coasts to a stop and rundown timer expires, a preset post lubrication cycle will be initiated.
i. After preselected pressurization hold time period ends, vent valves open to depressurize compressors and process piping and seal system is de- energized.
2.4.2
PRESSURIZED FAST STOP
NOTE: Refer vendor doc. title Unit-Control Balance of Plant Functional Specification, doc no. 3Y041-149008 for further details
A pressurized fast stop causes the unit to stop with the compressors pressurized, and vent valves and blowdown valves remain closed. To initiate a pressurized fast stop, press the customer-furnished FAST STOP (REMOTE) Switch (S513). The following events occur:
1. Compressor suction valves close, discharge valves close, vent valves, and blowdown valves remain closed to maintain pressure in gas compressors and process piping for a preselected pressurization hold time period.
2. Engine shuts down immediately with no cooldown cycle. Slow roll cycle is bypassed, STOPPING Light (DS1011) illuminates, and [Stopping] highlights on Operation display screen.
3. ENGINE HOURS/START COUNTER Meter (M210) stops logging operating time.
4. After engine coasts to a stop and rundown timer expires, a preset post lubrication cycle will be initiated.
5. After pre-selected pressurization hold time period ends, vent valves and blowdown valves open to depressurize compressors and process piping and seal system is de-energized.
2.4.2
EMERGENCY STOP
NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for more details.
An emergency stop does not include a cool down period, which allows the engine to run with no load for a preset period before the engine is stopped. The emergency stop shutdown should only be used when plant conditions require an immediate shutdown.
52
An emergency stop prevents package operation until the emergency stop shutdown is acknowledged and reset by pressing the local ACKNOWLEDGE and RESET switches and the backup relay system is reset.
NOTE : In the following procedures, display screen indications that highlight in (reverse video) are shown in brackets [ ].
To initiate an emergency stop, press either the EMERGENCY STOP Switch (S1012) located on the turbine control panel or the EMERGENCY STOP Switch (S312) located on the enclosure twin control station. The following events occur:
1. Pressurized hold sequence is bypassed. Compressor suction valves close, discharge valves close, and vent valves open.
2. Engine shuts down immediately with no cool down cycle. Slow roll cycle is bypassed, STOPPING Light (DS1011) illuminates, and [Stopping] highlights on Operation display screen.
3. ENGINE HOURS/START COUNTER Meter (M210) stops logging operating time.
4. After engine coasts to a stop and rundown timer expires, a preset post lubrication cycle will be initiated.
2.4.3
CONTROL SYSTEM STOP
NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for more details.
There are two types of control system stops; cool down stop and fast stop. If an unsafe operating condition is detected by the control system, the control system will initiate a shutdown. Depending upon the severity of the shutdown, the control system will initiate either a cool down stop or a fast stop. If the control system stop was initiated due to a condition that is self-correcting, the engine can be restarted after the condition returns to normal. If the control system stop was initiated due to a condition that is not self-correcting, contact maintenance personnel to perform corrective actions.
Cooldown Stop
If a cooldown stop has been initiated, the compressors are unloaded and the engine is shut down in the same manner as a normal stop. There are two types of cooldown stops; cooldown lockout and cooldown nonlockout.
Cooldown Nonlockout (CN) - Cooldown nonlockout shutdowns reduce engine speed to idle for a preset cooldown period before initiating a shutdown. Cooldown nonlockout shutdowns include operator initiated normal stops, operating conditions that reached a shutdown limit because maintenance was not performed, a momentary disruption that causes an out-of-limits condition, and operating conditions that exceed alarm levels but are not serious enough to cause any immediate damage. Cooldown nonlockout shutdowns can be reset after corrective action has been taken or operating conditions revert to normal using either the local or remote acknowledge and reset switches.
Cooldown Lockout (CL) - Cooldown lockout shutdowns reduce engine speed to idle for a preset cooldown period before initiating a shutdown. Cooldown lockout shutdowns typically result from a component failure and not because operating conditions have exceeded alarm or shutdown levels. Cooldown lockout shutdowns may not present immediate danger, but corrective action must be taken to avoid damage resulting from a component failure. Cooldown lockout shutdowns prevent package operation until the shutdown is acknowledged and reset using the local acknowledge and reset switches.
NOTE : Remote acknowledge and reset switches cannot acknowledge or reset cooldown lockout shutdowns.
Fast Stop
If a fast stop has been initiated, the compressors are unloaded and the engine is shut down in the same manner as an emergency stop. There are two types of fast stops; fast stop lockout and fast stop non lockout.
WARNING : When a fast stop shutdown has been initiated due to fire detection, the postlube oil pump will remain energized for a preset rundown period. After the preset rundown period expires, the postlube oil pump will be deenergized for 20 minutes. After the 20 minute time period expires, the postlube pump will cycle on and off for a preset postlube period. If unsafe conditions still exist, the operator must manually abort the post lube cycle by opening the facility contactors for the postlube and backup lube oil pumps.
Fast Stop Nonlockout (FN) - Fast stop nonlockout shutdowns initiate an immediate shutdown of the engine. Fast stop nonlockout shutdowns typically result from a disruption in operation due to abnormal operating conditions and may not require corrective action. Fast stop nonlockout shutdowns can be reset when operating conditions revert to normal using either the local or remote acknowledge and reset switches.
Fast Stop Lockout (FL) - Fast stop lockout shutdowns initiate an immediate shutdown of the engine. Fast stop lockout shutdowns prevent package operation until the shutdown is acknowledged and reset using the local acknowledge and reset switches. In addition to using the local acknowledge and reset switches, fast stop lockout shutdowns initiated due to a microprocessor failure, fire detection, backup overspeed, or pressing of emergency stop switch will require the backup relay system to be reset. Fast stop lockout shutdowns