PDOC 3phase Separator Operation Manual

5/24/2018 PDOC 3phase Separator Operation Manual

1/20

OPERATION AND MAINTENANCE

MANUAL FOR

1st& 2ndSTAGE 3 PHASE SEPARATOR

Petrodar Order No. 11!"#$311!!132$M%!1$!2!

E'()*ent Ta+ No. 1,- 2,- 3,- ,$/3!1

LEPS Do0 No. LEPS$2!!#1!!"$O&M

H(+e(+ Do0 No. PDOC$232!#$,D$MEC$!#"

Issue and Revision Record

016-03-

09Submitted for Approval LEPS LEPS

Re

No.Date Des0r()t(on

Pre)ared45

S'))(er

Re(e6ed45

S'))(er

A))roed45 HDC

O6ner Petrodar peratin! "ompan#Limited

EPCC Contra0tor $i!lei! Petroleum Services% Inv& "o& Ltd&

S'))(er 7 S'4$Contra0tor LA'SEL EPS (ec)nolo!ies PteLtd

INDE8

1.! SAFET9

Do0'*ent No LEPS$2!!#1!!"$O&M

etrodar Operating CompanyMoleeta F F Oil Development

roject


2/20

1&1 Safet# *)en Enterin! t)e separator

1&+ Safet# *)en fillin! t)e vessel *it) il1&3 Safet# *)en Empt#in! t)e ,essel

2.! E%UIPMENT DESCRIPTION

+&1 Internals+&+ eir plates+&3 .affle+&/ ,orte .reaer +&2 e-sandin! Line and 4o55les+&6 $eatin! "oil

3.! START$UP PREPARATION

3&1 ,essel and Internals3&+ Pipe ors3&3 Instruments3&/ Electricit#

.! START$UP PROCEDURE

/&1 illin! *it) "rude/&+ Ad7ustment of Interface Level/&3 il Level

".! NORMAL OPERATION

2&1 4ormal peratin! and 8aintenance Instructions

.! S9MPTOMS OF FAULT9 SEPARATOR OPERATION

#.! SHUT DO:N PROCEDURE;Nor*a and E*er+en05 *ill be modified to meet site re;uirements

In an# case> if several safet# rules !overn t)e same application> t)e most constrainin! ones

*ill be applied

1.1 Saet5 6?en enter(n+ t?e se)arator

)en enterin! t)e separator t)e safet# rules applicable to process vessel s)ould be

follo*ed& As eample some of t)ese rules are listed )ere under

Aut)ori5ation permit to enter t)e vessel s)ould be delivered b# t)e relevant

aut)orit#

All vessel flan!es connected *it) process lines s)ould be blinded

,essel must be free of oil> *ater !as or dirt

An eplosivit# test must be carried out in all accessible parts of t)e vessel internal

Internal temperature must be acceptable

4atural or mec)anical ventilation s)ould be sufficient to permit *or inside t)e

vessel *it)out ris

Etc

1.2 Saet5 6?en enter(n+ t?e esse 6(t? o(

In order to avoid t)e information of eplosive miture> t)e vessel s)ould be totall#

pur!ed from air before c)ar!in! *it) )#drocarbons

()is pur!in! can be done usin! nitro!en or ot)er inert !as *)ic) is not )armful if

released to atmosp)ere

1.3 Saet5 6?en e*)t5(n+ t?e esse

In order to avoid formation of eplosive atmosp)ere *)en empt#in! t)e vessel > it is

absolutel# imperative to replace pumped put product b# inert !as?e& 4itro!en@ or

*ater under lo* pressure?B12psi!@



6/20

Special care *ill be taen also to avoid an# vacuum in eac) vessel compartment

durin! pumpin! out&

2.! E%UIPMENT DESCRIPTION

2.1 Internas

Separators are )ori5ontall# mounted on a sid& ()e separator is divided in to t*o

compartments be a *eir plate& i&e t)e *ater side and t)e oil side& Internals consist of

*eir plate> baffles> vorte breaer and diverter& Internals are of SS316 and are bolted

to t)e vessel *it) fittin!s *)ic) are SA216


7/20

2." Desand(n+ L(ne and noes

Inlet crude mi brin!s *it) it sand particles> *)ic) !et settles in t)e vessel& esandin!needs to be done to remove t)e accumulated sand in t)e vessel& re;uenc# of

desandin! operation depends on t)e sand content in a !iven crude mi& e-sandin!

*ater is circulated t)rou!) t)e desandin! line and it is spra#ed on t)e accumulated

sand at t)e bottom of t)e vessel t)rou!) t)e spra# no55les> *)ic) are fitted to t)e

desandin! pipes& esandin! line is of SS316 8aterial

2. Heat(n+ Co(

In order to maintain a temperature of 20 de!rees " in t)e separator at all times> even*)ile it is not in operation> )ot oil is circulated t)rou!) t)e )eatin! coils& Inlet )ot oil

temperature is +20C"

3.! START > UP PREPARATION

D IMPORTANT NOTE BEFORE STARTING AN9 OPERATION- PLEASEREFER TO CHAPTER 1.!. SAFET9.

3.1 ,esse and Internas

Ensure t)e condition of t)e pressure vessel and t)e internals&

")ec t)e maimum allo*able *orin! pressure and t)e operatin! temperature>

*)ic) are mared on t)e name plate of t)e vessel&

3.2 P()e :or@s

Ensure all pipe *or is correctl# installed

3.3 Instr'*ents

")ec all instruments for correct function

")ec all relief=safet# s#stem for correct operation

")ec all control valves and associate s#stem for correct function includin!

failureF modes&

3. Ee0tr(0(t5

All electrical part s)ould be carefull# c)eced G *irin! of all elements s)ould be c)eced

as *ell as t)eir satisfactor# connection> Eart)lin! circuit s)ould be c)eced



8/20

.! START UP PROCEDURE

(See chapter 1.0 SAFETY)

.1 C?ar+(n+ 6(t? H5dro0ar4on

IMPORTANT NOTE

Beore 0?ar+(n+ 6(t? ?5dro0ar4on- t?e esse s?o'd 4e 0o*)ete5 ree o a(r. T?(s

)'r+e s?o'd 4e done 6(t? n(tro+en or an5 ot?er (nsert +as not ?ar*' to t?e

at*os)?ere. C?e0@ t?at a aes. Dra(ns ents sa*)e are 0osed and t?e(r 0a)s are

(nstaed. :?en t?e ee o o( (s 4et6een t?e o6 ee and ?(+? ee- t?en reset t?e

o6 and ?(+? aar* o t?e (ntera0e 45 )ress(n+ t?e reset )'s? 4'tton on t?e 0ontro

)ane.

.2 Ad'st*ent o Intera0e Lee

ollo* t)e development of t)e interface level b# usin! t)e level !au!e on t)e

standpipe& )en t)e set supper level is reac)ed> t)e control valves opens in

accordance *it) t)e controller si!nal and allo*s produce *ater to flo* out of vessel&

()e preferred settin!s at desi!n production rates for irst Sta!e Separator are as

follo*s

Interface Li;uid Level IL$$

IL$

ILL

ILLL



9/20

Preferred settin! for Second Sta!e Separator is

Interface Li;uid Level IL$$

IL$

ILL

ILLL

"ontrol valves operation taen place suc) t)at t)e interface la#er sta#s bet*een IL$ and ILL

additional lo* level and )i!) level cut offs are provided bet*een IL$ and ILL&

")ec alarm and trip circuit for )i!) and lo* levels b# stimulatin! abnormal level conditions&

.3 O( Lee

il levels are maintained on t)e basis of follo*in! oil level settin!s&

()e preferred settin!s at desi!ned production rates are as follo*s

Li;uid Level in Separator L$$

L$

LL

LLL

Preferred settin!s for +nd sta!e are

Li;uid Level in Separator L$$

L$

LL

LLL

Levels are controlled bet*een L$ and LL& Additional cut offs are provided at L$$ and

LLL&

")ec alarm and trip circuits for )i!) and lo* level b# stimulatin! abnormal level

condition&

".! NORMAL OPERATION

".1 Nor*a O)erat(on and Ma(ntenan0es Instr'0t(ons?See ")apter 1&0 SAE(HF@



10/20

".1.1 O)erat(on Data S?eet

If re;uired a dail# operatin! data s)eet *ill be issued& ()is data s)eetallo*s all essential parameters t)at allo* operation and control of t)e

plant&

".1.2 Pre)arat(on or t?e Ins)e0t(on o t?e ,esse

)en a vessel inspection is foreseen> t)e follo*in! recommendation

s)ould be applied

Stop t)e plant

")ec t)at t)ere is no volta!e on t)e Po*er unit

rain t)e vessel accordin! to ")apter 9&+

Isolate t)e vessel b# placin! blind flan!es on all t)e inlet and outlet

no55les&

pen bot) man)oles and top vent of vessel&

,ent t)e vessel *it) lo* pressure steam if available ?Lo*er t)an 3

bar@ for +/ )ours&

"onnect a stripped cable to an eart)lin! pad or to vessel *all> t)en

connect it to t)e electrode& 4o spar or presence of current s)ould be

detected&

"lean t)e internal *alls of vessel *it) pressuri5ed *ater> )ot if

available&

.efore enterin! t)e vessel ensure t)at t)e temperature )as dropped

sufficientl# to allo* entr# and t)at an# )armful or flammable !as )as

been pur!ed&

".1.3 Ma(ntenan0e and tro'4e > s?oot(n+

()e separator until offers )i!) operatin! reliabilit# because all parts of t)e units

vessel and internal ?baffles> *eir> etc @ pipin! etcstatic elements &It trouble on t)e

treatin! operations occurs> t)en refer to c)apter :&0

All items of e;uipments ?Instruments> vessels> po*er units> pipin! etc@ s)ould be ept

in !ood condition and clean ?free of rust@ t)e# s)ould be c)eced re!ularl# for !ood

operation and sealin!&

If a part or e;uipment appears to be fault# or out of order> t)en refer to t)e trouble G

s)ootin! !uide in t)e manufacturerJs manuals



11/20

It is recommended t)at *)en t)e vessel is opened or maintenances internal

distribution and collection pipe *or to!et)er *it) t)e electrode s !rids and t)e vessel

s)ell are inspected for si!ns of erosion and=or corrosion&

".1. Po6er and 0ontro Pane

E;uipment on t)e control panel suc) as rela#s> contactors> voltmeter> ammeter and

pus) buttons *ill be c)eced and maintained re!ularl#&

.! S9MPTOMS OF FAULT9 SEPARATOR OPERATION

NOTE .efore ad7ustment in t)e plant> c)ec t)at operatin! conditions are inconformit# *it) re;uired specifications&

FAULT PRIMAR9 CAUSE SECONDAR9 CAUSE REMED91 $i!) oil ppm in

produce *ateroutlet

A Ineffective separation

B Level settin! of

interface level noteffective

a. "ontrol valve defective

4. "onnection fault at L(

0. ault in "S si!nals

Leaa!e t)rou!) .afflePlated

$i!)er production ratesover t)e desi!n rates

Reduce productionto desi!n limits

Lo* operatin!temperature

$i!) viscosit#

2 $i!) *ater ppm inoil outlet

A Leaa!e t)rou!) *eirplates

a. .olts on *eirloose=!aset notdefective

")ec and ti!)ten

B Level settin! ofinterface level noteffective

a. "ontrol valve defective

4. "onnection fault at L(

0. ault in "S si!nals

Leaa!e t)rou!) .affleplates

$i!)er production overt)e desi!n rates

Reduce productionto desi!n limits

Lo* operatin!temperature

$i!) viscosit#3 Sand content )i!) A Sand accumulation too a. "arr# out



12/20

in outlet *ater )i!) desandin!operation

B a. 4o outflo* in

outflo* lines4o !as content 4. Kse inert !as

0.

" Improperfunctionin! ofvorte meter

C a.

4.

Improperfunctionin! of Pmeter

A

B

#.! SHUT DO:N PROCEDURE ;NORMAL AND EMERGENC9 debris> bloca!es etc&> ensure t)e# arefree of tar build-up etc&

3@ ")ec all items s)o* no si!ns of dama!e from erosion> sur!es etc&>c)ec *eirs and sound&

/@ ")ec all boltin! is ti!)t and fitted *it) second nut ?loc nut@&

2@ "arr# out re-certification inspection of pressure vessels in accordance*it) manufacturerJs instructions=statuar# re;uirements&

If it is necessar# to remove t)e internals from t)e vessels follo* t)e reversedprocedures outlined in section 3&3&

12.2.1 ,esseAs re;uired b# pressure vessel code> carr# out periodic re-certificationre;uirements&")ec for

"racin! of attac)ment *elds to s)ells

Erosion of vessel s)ells at areas around inlet=outlet no55les "orrosion around drain connections and instrumentation connections

"lo!!in!> plu!!in! of instrumentation connections

Pittin! or scuffin! of an# !aseted faces

Al*a#s use !asets *)en re-main! no55le=man*a# flan!e connections&


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PDOC 3phase Separator Operation Manual

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