Professional Documents
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Z-8000-BB-4076 - Water Injection System
Z-8000-BB-4076 - Water Injection System
Z-8000-BB-4076 - Water Injection System
Z1
C6
C5
C4
C3
C2
C1
B1
A1
Rev
20/01/2005
2/12/2004
19/12/2003
14/12/2001
9/3/2001
28/12/00
7/7/98
20/5/98
2/7/97
Date
Revised
Addition of 4th WI pump
4th WI pump study
Risk assessed
Revised onshore
Revised Offshore
Validated for Use
Issued for Review
Issued for Comment
Description
REVISION
RL
RL
RL
RL
RL
RL
CD
RL
DH
RL
DH
RL
AS
DH
By Check
Originated
CD
RL
PS
RL
By
Check
Validated
CD
RL
By
Check
Risk Assessed
Page 1 of 158
2.
INTRODUCTION
1.1
1.2
4
5
DESCRIPTION
2.1
2.2
2.3
7
8
10
11
11
11
13
15
18
18
19
22
26
28
30
34
36
38
39
39
40
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
3.
4.
Purpose of Equipment/System
List of Reference Documents
Summary of Equipment
Water Injection Deaeration Package Z-44101
Water Injection Pumps P-45001A/B/C
2.3.1 Water Injection Pumps P-45001A/B/C Drive Motors
2.3.2 Water Injection Pumps P-45001A/B/C Lube Oil System
4th Water Injection Pump Package
2.4.1 4th Water Injection Pump Gas Turbine
2.4.2 GT Combustion Air Intake System
2.4.3 GT Combustion Exhaust System
2.4.4 Gearbox
2.4.5 Water Injection Pump P-45001D
2.4.6 Lubricating Oil System
2.4.7 Gas Turbine Enclosure
2.4.8 Gas Turbine Local Control Room & LER
2.4.9 Gas Turbine Enclosure Fire Protection System
2.4.10 Wash Cart
Water Overboard Discharges, Monitoring & Reporting
Chemical Injection
Turret Water Injection, Swivel and Turret Valves
Water Injection Flexible Risers
Subsea Water Injection System
WI Wellheads (Tree, Choke, Master & Subsurface Valves)47
Well Injectivity Decline
Water Injection Subsea Flowlines
Water Injection Wells
50
50
51
53
3.1
3.2
3.3
3.4
3.5
3.6
53
54
55
56
59
60
61
4.1
4.2
4.3
4.4
4.5
4.6
4.7
61
62
63
64
67
73
73
Pre-Start Checks
De-Aerator Package Purge Procedure
De-Aerator Package Start-up
Water Injection Pumps P-45001A/B/C Start-up
Solar Gas Turbine & Water Injection Pump P-45001D Start-up
Exhaust Gas Purging
4th Water Injection Pump & Turbine Start-up from CCR
Page 2 of 158
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
5.
97
5.1
97
98
99
100
109
6.1
6.2
109
112
112
115
118
121
126
129
130
131
131
132
6.3
6.4
6.5
6.6
6.7
7.
75
77
83
85
86
86
86
89
90
91
91
92
94
95
95
95
95
96
5.2
5.3
6.
De-Aerator HIPS
Pumps P-45001A/B/C Alarms and Actions
6.2.1 Pump P-45001A Alarms & Actions
6.2.2 Pump P-45001B Alarms & Actions
6.2.3 Pump P-45001C Alarms & Actions
Pump P-45001D & Turbine Local & Remote Alarms
Pump P-45001D Alarms, Actions, Shutdowns & Resets
Pumps P-45001A/B/C Shutdowns
ESD Actions & Valve Closure Sequences
6.6.1 Yellow ESD Shutdown
6.6.2 Water Injection Pump Trip PSD
Design Parameters
FAULT FINDING
133
7.1
7.2
7.3
7.4
133
134
134
134
137
144
Page 3 of 158
1. INTRODUCTION
1.1
Purpose of Equipment/System
As Schiehallion oil is produced, the space once occupied (reservoir voidage)
is filled up by natural aquifers attached to the reservoirs, but not at a
sufficient rate to maintain the required reservoir pressure/voidage
replacement. Produced water and seawater is therefore injected from the
FPSO through subsea equipment to the wells to assist the natural drive. The
aquifers provide edge drive from the west on Schiehallion and the North and
West for Loyal. Water injection minimises loss of productivity and increases
Gas Oil Ratio (GOR). All produced water is normally re-injected into the
reservoirs. However, de-aerated seawater is used as make-up feed to the
water injection system to maintain production.
Three 13.8kV motor-driven water injection pumps each of capacity 630m 3/hr
pump water at high pressure (over 200 bar) to the subsea water injection
wells. They are fed with a combination of produced water and de-aerated
sea water, depending on well fluids BS&W, reservoir performance, process
separation and operational requirements. To cater for the requirements of
the future North West production centre water injection wells, a new Solar
Taurus 70 gas turbine-driven water injection pump has been installed of
capacity 930 m3/hr. The turbine burns fuel gas from production.
The water injection system receives filtered seawater from the seawater
distribution system and removes oxygen from this water to prevent
contamination of the reservoir. The water injection pumps serve to drive the
treated seawater and/or produced water into selected water injection wells.
Well fluids from the reservoirs contain entrained water that must be
separated out, treated and disposed of prior to the oil being stored in the
cargo tanks. If this produced water was not removed, the cargo would be
adulterated with water, cause possible corrosion in the FPSO storage tanks,
and be of unmarketable quality for export. Currently excess water is drained
off at Sullom Voe Terminal. Produced water production is expected to rise
and plateau at 217,000 bbl/day (1438m3/hr) in year 15 of production.
The produced water system can process 225,000bbl/day (1490m 3/hr) of
produced water from the separation trains, with the facility to upgrade to
270,000bbl/day (1790m 3/hr). Produced water is processed using
hydrocyclones to 25 ppmv oil-in-water and is then injected into the reservoir
with de-aerated seawater. Some may be discharged overboard if clean
enough do so and if it cannot be re-injected.
The water injection system total capacity has now been increased to
2820 m3/hr following the addition of the 4 th Water Injection Pump.
The volume of water required for water injection is greater than the volume
of produced water obtained from the production profile. A water injection
rate of 1.1 times total fluid production rate is required, so de-aerated sea
water is always used to supplement the produced water (the pumps are not
designed to pump produced water only).
Page 4 of 158
All water injection valving within the turret system is manually operated with
no associated automatic control.
Treated produced water is utilised for water injection into the reservoirs
under normal operations.
Two hydrocyclone trains reduce the free oil
content of the main flow of produced water; a separate hydrocyclone being
utilised for water from the test separator. Both streams of treated water are
then co-mingled, de-gassed, and fed to the water injection pumps.
When any produced water is discharged overboard, it is cleaner than current
legislation requires thus minimising pollution and maximising recovery of oil
back to the process system.
1.2
L-8000-GF-0104.00
L-1000-GP-0041.01
L-1000-GP-0041.02
L-1000-GP-0043.00
L-8000-GP-0044.00
L-8000-GP-0046.01
L-8000-GP-0046.02
L-8000-GP-0004.01
L-8000-GP-0076.03
Seawater Distribution
M-5031-MA -8007.00
M-5021-GP-8004.00
S-9000-NP-9203.02
S-9000-NP-9220.01
S-9000-NP-9221.01
S-9000-NP-9213
S-9000-NP-9215
S-9000-NP-9216
S-9000-NP-9224
S-9000-NP-9225
S-9000-NP-9226
L-8000-JC-0002.024
L-8000-JC-0002.037
S-9000-GC-9200
Page 5 of 158
1.2
Z-8000-BB-4001
Z-8000-BB-4007
Z-8000-BB-4051
Methanol System
Z-8000-BB-4052
Z-8000-BB-4054
Z-8000-BB-4057
Z-8000-BB-4035
Z-8000-BB-4023
Z-8000-BB-4077
Z-8000-BB-4029
Flare Systems
Z-8000-BB-4012
Page 6 of 158
2.
2.1
DESCRIPTION
Summary of Equipment
The following table provides data on equipment in the water injection system:
Equipment
Water Injection
Deaerator Tower
V-44101
Water Injection
Stripping Gas Blowers
P-44201A/B
Stripping Gas
Exchanger
X-44201
Stripping Gas
De-oxidiser Vessel
V-44201
Start-up Heater
EEH-44201
13.8kV 5200kW Motordriven Water Injection
Pumps P-45001A/B/C
Gas Turbine-driven
Water Injection Pump
P-45001 D
Gear Box
Rating
Seawater Flow - 2250 m 3/hr
Operating Pressure - 5 barg
Height - 15m
Diameter - 3.1m increasing to 4.2m
5 barg inlet - 6.4 barg outlet
Motor rating 55 kW
356 mm OD x 5180 mm
Shell side - 5.7 barg
Tube side - 6.4 barg
1200 mm OD x 3000 mm
187 mm x 1780 mm
Power - 20 kW
Max capacity 750 m 3/hr (each)
Differential Pressure - 202 bar
(dependent on start-up DP or normal
running DP)
Capacity 3 x 33%
Normal Case (100% Speed) 930 m 3/hr
Overspeed Case (105% Speed) 1150
m3/ hr.
Differential pressure: 202 Bar
(Dependant on the start-up DP or
Normal Running DP)
Rated for 6910 KW
Input Speed 11051 RPM
Output Speed 3650 RPM
Can be run continuously 5% above the
rated speed.
6700-7800kW, depending on ambient
temperature
Tank Capacity: 100 litres
Operating Pressure: 6.9 barg
Operating Temperature: Ambient
Design Temperature: 93.3 C
Design Pressure: 9 barg
Size (DxL): 0.406m x 0.483m
Location
Package Z-44101
Fire Zone 201
(Port Aft)
Package Z-44101
Fire Zone 201
(Port Aft)
Package Z-44101
Fire Zone 201
(Port Aft)
Package Z-44101
Fire Zone 201
(Port Aft)
Package Z-44101
Fire Zone 201
(Port Aft)
Packages
Z-45001A/B/C
Fire Zone 251
(Starboard Aft)
Installed forward of the
aft Crane pedestal at
frame 40
(Palette 7)
Fire Zone 258
Palette 7
Palette 7
Palette 7
Note:
Information given in this document does not include details of the new
North-West drill centre.
Page 7 of 158
2.2
Page 8 of 158
The water passes down through the tower and mixes with a counter-current
flow of stripping gas (nitrogen) fed into the tower at a mid-vessel point, below
the packing column. The stripping gas absorbs oxygen contained in the
seawater and then passes through a demister in the top of V-44101 before
leaving the tower via a 6 line. Nitrogen is supplied to the deaerator tower at
a flow of approximately 4,900 kg/hr. As the nitrogen passes through the
tower packing, some of it is dissolved in the seawater and, therefore, there is
a requirement to add nitrogen to the system to maintain the required
stripping gas flowrate.
In addition, to achieve the required oxygen
concentration in the stripping gas, so as to maintain reactor efficiency, more
oxygen must be added. The required nitrogen and oxygen make-up is
achieved by using a combination of instrument air and nitrogen top-up lines.
Refer to P&ID L-8000-GP-0044.00.
Stripping gas is drawn off from V-44101 by the water injection stripping gas
blowers P-44201A/B, which are rotary lobe, positive displacement type
blowers. P-44201A/B are each fitted with their own single dedicated safety
relief valve (PSV-442003 and PSV-442006 respectively) which have a
setpoint of 10 barg and relieve to a safe location. P-44201A/B operate in
duty/standby mode with auto-start of the standby blower initiated by the low
flow alarm FAL-442008. P-44201A/B cannot be started until a normal
operating level (i.e. flow and level healthy) is established in V-44101.
On leaving the blowers, the stripping gas passes through the tube side of the
stripping gas exchanger X-44201 where it is pre-heated against stripping gas
returning from the stripping gas de-oxidiser vessel V-44201.
Stripping gas from X-44201 enters the de-oxidiser vessel V-44201. The
temperature of the gas entering V-44201 is controlled by TIC-442014. The
gas flows downwards into a de-oxidiser catalyst bed in which is embedded
the electric start-up heater EEH-44201. The catalyst is palladium pellets on
an aluminium oxide core supported on a perforated plate.
To create the catalytic effect in V-44201 which is required to purify the
nitrogen, methanol is added, as a fuel, to the stripping gas. This is injected
as a side stream into the main stripping gas flow at an entry point upstream
of the reactor V-44201. The catalyst within V-44201 needs to achieve a
threshold temperature before the required catalytic reaction can take place.
The catalyst bed is pre-heated by EEH-44201 to this threshold temperature
of 150C. Once this temperature is achieved then the power supply to the
start-up heater is shut-off as the resulting reaction within V-44201 is an
exothermic reaction during which temperatures of 240C to 260C may be
produced. Stripping gas leaving V-44201 is virtually oxygen-free (i.e. oxygen
content below 20 ppb).
Stripping gas from the bottom outlet of V-44201 passes through the shell
side of X-44201 and returns (via the restriction orifice RO-442022) to the
deaerator tower, forming a closed loop for the circulation of stripping gas.
The gas path through the shell side is protected by a single relief valve
PSV-442011 (set at 10 barg) which relieves to a safe location.
Some of the stripping gas in the tower is dissolved in the seawater.
Additionally, the stripping gas oxygen concentration may fall below that
required to maintain reactor efficiency. Nitrogen make up is supplied via
XV-441024 on the 2 feed line from the nitrogen distribution system.
PIC-441021 on the deaerator outlet line controls nitrogen top-up via
PCV-441023 or vents to safe location via PCV-441021.
Page 9 of 158
2.3
Page 10 of 158
However, even for low injection water demand at the wells, a significant flow
is required through the pump to reduce the system pressure and minimise
the peak pressure which may be obtained due to pressure surge/locked-in
pressure due to inadvertent wing valve closure. This is accomplished via a
high set point for the minimum flow FCVs. At full capacity, the system is set
up with four pumps operating. It is advantageous to inject as much water as
possible into the reservoir and therefore no standby or auto-start operating
mode is provided. The system can, however, be configured with any number
of pumps (1, 2 ,3 or 4) as running duty pumps.
2.3.1
2.3.2
Page 11 of 158
Page 12 of 158
The 4th water injection pump driver is a Taurus 70S gas turbine which
contains the following main components:
The gas turbine is mounted on a steel base frame. The accessory drive is
attached to the air inlet assembly and is driven by the gas turbines axial
compressor. This then supports and drives the lube oil pump and other
accessories, which are initially driven by the start system. The turbine speed
is directly related to the engine power level due to its two-shaft engine
configuration and is electronically adjusted. Air enters the air inlet and is
compressed by the 12-stage axial flow compressor. Pressurised air in the
annular combustion chamber is injected with fuel and the mixture is ignited
during the start cycle.
Figure 2 4th Water Injection Pump Package Looking to FPSO Port Side
Page 13 of 158
Start System
Fuel System
Electrical Control System
Lube Oil System
Engine drain system
Acoustic and Filtration Package
Page 14 of 158
Page 15 of 158
A manometric drain system is provided for the 4th stage vane separator and
the housing drains.
1st stage - Marine Vane Separator and Snow Hood
The function of the Marine Vane Separator is to reduce the quantity of
driving rain or heavy spray which may otherwise enter the intake under
adverse weather conditions. A snow hood is fitted prior to the 1st stage
separator to provide protection against driving snow.
The vane stage comprises stainless steel vanes held apart by spacers. The
high inertia of the water droplets causes them to be thrown out of the air
stream onto the vanes. The droplets collected on the vanes are then drained
down into the drain trough situated at the base of the vanes. Drain slots are
provided in the bottom of the separator for self-draining
Page 16 of 158
No drainage is required between the 2nd and 3rd stage filter. Drains are fed
into a drain trap, which allows drainage but prevents air being sucked into
the drain system by the provision of a water seal.
Intake Silencer and Transition
The intake silencer and transition provide acoustic attenuation for the
combustion intake to the gas turbine. The silencer comprises a series of
vertical splitters and a lined duct which reduces external noise levels. The
intake silencer can only be inspected internally during engine shut down and
via the personnel access panel in the gas turbine collector duct.
Intake Elbow & Flexible Intake Silencer
The intake elbow is lined for acoustic attenuation and turns the combustion
intake air through 90 degrees into the silencer. The system ensures an even
distribution of air at the inlet to the flexible intake silencer which directs clean
air into the turbine inlet. A weather seal and acoustic bolster is fitted around
the interface within the acoustic enclosure.
Page 17 of 158
2.4.3
2.4.4
Gearbox
A Renk gearbox is located between the turbine and the WI pump:
Rated Power: 6910 KW
Rated Speed:
Input: 11051 rpm
Output: 3650 rpm
Maximum Continuous Speed:
Input: 11604 rpm
Output: 3832 rpm
The gearbox can be run continuously 5% above the rated speed (overspeed
design case for the pump) and has a mechanical efficiency of 98.7%.
Measuring and control instruments include:
Oil enters the system on the suction side of the oil pump via a filler neck. The
oil system must be operating before the gearbox is started and once it is
stopped the oil pump must remain running until the unit has come to a
complete standstill. A separate auxiliary pump is available during start-up
and shutdown to ensure enough oil is supplied. This pump remains operating
until the gearbox has reached nominal speed or until it has come to a
complete standstill during shutdown.
Page 18 of 158
2.4.5
Page 19 of 158
250
PRES BARA
200
150
100
50
0
200
400
600
800
1000
1200
FLOWRATE M3/H
3833 RPM
3200 RPM
2250 RPM
3650 RPM
3000 RPM
TRIP-PRESSURE
3400 RPM
2750 RPM
N NEW
N OLD
QNEW = QOLD*
Page 20 of 158
N NEW
N OLD
HEADNEW = HEADOLD*
N NEW
POWERNEW = POWEROLD*
N
OLD
The minimum flow rate for the pump is 330m3/h. When the pump discharge
pressure exceeds 260barg, the pump will trip on high pressure.
Graph 2 below shows required power from the gas turbine as a function of
speed and flow rate. The turbine has a power limit of 6755 kW at 23 oC.
Note: If low ambient temperatures are experienced the power limit increases,
Sulzer have specified a maximum overspeed power limit as 8075 kW.
8000
7000
6000
KW
5000
4000
3000
2000
1000
0
200
400
600
800
1000
1200
FLOWRATE M3/H
3833 RPM
3400 RPM
3000 RPM
2250 RPM
3650 RPM
3200 RPM
2750 RPM
POWER LIMIT @ 20 Deg C
Page 21 of 158
Graph 3 below shows turbine power as function of air temperature. As the air
temperature drops, more water can be injected in the wintertime. The turbine
is designed for a maximum air temperature of 23 oC.
8500
KW
8000
7500
7000
6500
6000
-6
10
15
23
AIR TEMPERATURE oC
2.4.6
Page 22 of 158
The engine is below the starter dropout speed and the lube oil
pressure is at or below 25 psi.
The Pre/Post Lube Pump will not be annunciated as failed during steady
state engine running condition when the Lube oil pressure is less than the
Post Lube Low Pressure Shutdown Limit because the Engine Driven Pump
may be at fault.
Run protection for the engine is provided during steady state engine running.
This achieved by energising the pump/motor assembly at any time the lube
oil is below the lube oil low-pressure alarm limit. The pump runs for 30
seconds and is then de-energised. The following scenarios are possible:
If the lube oil pressure continues to fall below the allowable limit to
the shutdown limit, a Fast Stop Lockout engine shutdown is initiated
and the pump/motor BP 903 helps to protect the engine bearings
during shut down.
If the lube oil pressure continues to drop below the allowable low limit
but stabilises between this limit and the shutdown limit continuously
for 5 seconds again this initiates a Fast stop Non-lockout engine
shutdown and the pump aids bearing protection during shutdown.
If the lube oil pressure increases above the low pressure limit after 30
seconds or when pump/motor BP 903 is de-energised and the
pressure once again decreases, the pump/motor is energised again.
Page 23 of 158
1
2
3&4
5&6
7
8
9
10
11
Stud (8 off)
Filter Case Cover
Filter Case Spiral Gasket
Filter Element
Page 24 of 158
The main lube oil filter assembly FS901, located downstream from
Temperature Control Valve (TCV901/TCV01409D), is a non-bypass,
pedestal-type oil filter assembly containing replaceable filter elements. Lube
oil flow, as manually selected by positioning Lube Oil Filter Transfer Valve
(VT901), may be directed through either, or both, filters in the assembly. To
facilitate filter element replacement, each filter case cover includes a Bleed
Valve (VH902-1, VH902-2). A Drain Valve (VH902-3, VH902-4) is installed at
the bottom of each filter case. The two filters are interconnected by a line
with a Cross Feed Valve (VH903) which enables equalizing the pressure
within the cases during filter changeover and element replacement. The filter
case should be completely drained before replacing filter elements.
Bellows-type Differential Pressure Gauge PDI902/ PDG01418D is connected
in parallel with Main Lube Oil Filter Assembly Alarm Differential Pressure
Switch (S397-1/PDSHO1417D).
The gauge indicates the differential
pressure across the inlet and outlet of Main Lube Oil Filter Assembly
(FS901). Instrument Isolation Hand Valve (VI9011) is used to isolate the
differential pressure gage from the system for calibration, testing, or
replacement. After the first 1000 hours of engine operation and as
appropriate thereafter, the following should be performed in addition to
routine inspection items (shutting down engine prior to performing checks):
Replace lube oil and, if applicable, servo oil filter elements. Lube
oil and servo oil filter elements should be replaced when visible
contamination is present, when the differential pressure "pop-up"
indicators are popped, or when differential pressure limits are
exceeded. If none of these conditions occur, the filters should be
replaced at least annually.
Check the oil cooler for accumulation of foreign material that could
obstruct cooling airflow. Clean per manufacturers instructions.
Inspect all oil lines and oil system components for security and
condition.
Since the Main Lube Oil Filter Assembly is designed to operate using one
filter of Main Lube Oil Filter Assembly (FS901) at a time, filter service may be
performed during engine operation or during shutdown. It is preferred to shut
the unit down and have the post lube cycle completed prior to servicing. This
arrangement also permits the unit to be started while filter element
replacement is in progress.
Filter elements should be changed when the filter dp indicates a need for
service, whenever the oil is changed, or as annual maintenance. Increasing
dp will activate an alarm.
Page 25 of 158
7.
8.
2.4.7
Page 26 of 158
Page 27 of 158
2.4.8
Page 28 of 158
Page 29 of 158
2.4.9
Extinguishing agent
Type of system
Actuation method at the skid
Carbon dioxide
Total flooding
a) Electrical solenoid actuator/Pilot
nitrogen
b) Manual lever actuator
c) Refer also to electrical operating
instructions covering field devices and
the control system (Altair operating
manual 90398/L1327)
51 barg at 20 oC
45 kg capacity per cylinder
2 initial cylinders + 2 reserve cylinders
(each with a nitrogen Pilot cylinder)
258
The enclosure is fitted with seven personnel access doors. Visual indication
is provided locally, one on each side of enclosure. A CO 2 lockout switch is
provided each side of the enclosure should access to the enclosure be
necessary whilst the engine is running. The status of lockout is visually
indicated locally and in the CCR. Indications include:
CO2 fire protection system audible and visual alarms are installed on each
side of enclosure. The CO2 cabinet is fitted with extinguishant bottle rack
and associated process hardware, and is located adjacent to the Gas
Turbine Enclosure. All equipment is suitable for open deck duty in a marine,
offshore environment.
The fire & gas panel in the LER controls the
operation of the CO2 system.
Page 30 of 158
Page 31 of 158
Figure 4
Z-8000-BB-4076 Rev Z1 20 January 2005
4th Water Injection Pump Package Fire & Gas Detection System Cause & Effect Chart
Page 32 of 158
Figure 5
Z-8000-BB-4076 Rev Z1 20 January 2005
4th Water Injection Pump Enclosure showing Fire & Gas Detectors
Page 33 of 158
Page 34 of 158
Figure 6 4th Water Injection Pump Turbine Wash Cart (without PSV)
There are two separate skid edge connections; one for on-line cleaning and
the other for on-crank cleaning. Each connection is plumbed to the
respective manifold with the following components:
Inlet strainer
Shutoff solenoid
Triple cartridge filter
Three-way hand valve (on-crank only).
Page 35 of 158
2.5
o
o
stream
o
o
Page 36 of 158
Anti-foam injection
Calcium Nitrate injection
XXV441040
FCV441
001
XXV441002
Water
Injection
LIC211101
To LP Compressor
Suction Scrubber
V-34001
XV211
354
Hydrocyclones
V-41001A&B
Oil
from
wells
LCV211101
Minox Unit
LIC441
010
Oxygen
Scavenger
Injection
Fuel Gas
Water Injection
De-aerator Tower
V-44101
FIC441019
XV221
354
8
Recycle
Hydrocyclones
V-42001A&B
LCV221101
Produced
Water
Booster
Pumps
P-43001A/B/C
Oil-in-Water
Analyser
AL-430017
XV230
356
Injection Water
to
Subsea Wells
via Turret
Produced Water
Degasser V-43001
Flow Meter
FQI-430016
Produced Water
Filters
F-43001A/B
AI441018
oxygen
content
3 Overboard
Discharge
FCV441
019
Water Injection
Pumps
P-45001A/B/C/D
10
Overboard
Discharge
10 Overboard
Discharge
Hydrocyclone
V-40001
LCV230107
Reject oil to 2nd Stage
Separators
Z-8000-BB-4076 Rev Z1
20 January 2005
Biocide Injection
2 ppm (normal)
5 ppm (normal)
5 ppm (normal)
60 ppm (this will vary as the produced water
make increases)
Page 38 of 158
2.7
2.8
Layer 2: Spiralled steel layer to sustain the radial load generated by the
internal pressure.
The flexible risers and the flowline jumpers have essentially identical
construction, with an inner carcass of Grade 316L austenitic stainless steel,
which supports a pressure sheath of polyamide, or, for the WI risers, PE. The
inner layers are mechanically protected by a hydrogen sulphide-resistant
external wire armour layer, with polymer coating layers.
Page 39 of 158
Riser Group
Drill Centre
Riser/Flowline
Service
Schiehallion
Central
Schiehallion
Central
Production wells
Water injection
wells
Schiehallion
West &
Gas Disposal
Schiehallion
West
Production wells
Water injection
wells
Gas Disposal
Loyal
Production wells
Water injection
wells
Schiehallion
North
North West
Water injection
wells only
Production wells
Water injection
wells
Production line A
Production line B
Production line C
Production/Test
Gas Lift [1]
Water Injection
Umbilical
Production
Production/Test
Gas Lift [1]
Water Injection [2]
Umbilical [4]
Gas Disposal
Umbilical [4]
Spare Riser Base
Gas Lift
Production
Production/Test
Gas Lift
Water Injection [2]
Umbilical [3]
Water injection
Umbilical
Production
Gas Lift [5]
Water injection
Umbilical [6]
Loyal &
Schiehallion
North
North West
Riser
NB
(in)
9.5
9.5
9.5
7.5
9.5
n/a
9.5
7.5
7.5
5
9
9.5
7.5
7.5
9.5
n/a
9.5
11.5
-
Flowline
NB
length
(in)
(km)
10
2.65
10
2.65
10
2.65
8
2.65
8
2.90
12
2.65
n/a
2.630
10
4.30
8
4.30
6
4.75
10
4.80
n/a
2.989
8
9.30
n/a
5.009
10
8
6
10
n/a
10
n/a
10
8
10
-
5.90
5.90
5.90
4.90
4.920
2.40
2.313
6
2
2
2
2.9
[1]
[2]
[3]
[4]
[5]
[6]
Page 40 of 158
Injection rates to individual wells is controlled at each injection wellhead by ROVoperated chokes with flow control provided by shutting in components of the
system - either individual wells or one of the four injection pumps. For operation
of the first two injection wells, the pump minimum flow FCVs also serve to control
the pump flow. The design is aimed at infrequent adjustments to the water
injection rates; the rates being monitored using a venturi-type flowmeter which is
mounted at each wellhead, upstream of the injection choke.
Note:
Schiehallion Central
Schiehallion Central is located some 2.9 km South East of the FPSO. The eight
water injection trees are supplied individually from the 12 plastic-lined flowline
via two water injection manifolds M2 & M2A which are connected to the pipeline
FTA using 10 flexible jumpers. Each water injection tree is connected to the
manifold by a 6 flexible wellhead jumper.
Electro-hydraulic control functions and chemical supplies for the central manifold
and the production and water injection trees are provided by a control umbilical
from the FPSO. These services are distributed through the Controls Distribution
Trunking (CDT) which forms the upper section of the central manifold. The
water injection tree controls are supplied by two separate umbilicals, connected
to separate outlets on the CDT, each supplying an SCM on an injection tree,
each of which in turn controls another injection wellhead by direct hydraulic
control.
Schiehallion West
Schiehallion West is located 3.2 km to the South West of the FPSO and has five
water injection wells. The wells are connected to the FPSO by 10 & 12 plasticlined rigid flowlines. These flowlines are terminated by FTAs at both ends. The
water injection supply is provided from a 10 riser and a 12 riser via two FTAs,
located beneath the FPSO, which supplies Schiehallion North and Loyal. The
five water injection trees are supplied individually from the 10 & 12 plastic-lined
flowlines via two connected water injection manifolds M22 & M22A; these are
connected to pipeline FTAs with 10 and 12 flexible jumpers. The water injection
tree controls are supplied by an umbilical jumper from the UTA to an SCM on
one of the trees. This provides direct hydraulic control functions for all water
injection trees.
Schiehallion North
Schiehallion North is located some 2.7 km to the North East of the FPSO and
has three water injection wells. The wells are supplied with injection water
through a 10, plastic-lined flowline from the FPSO through a three-porch water
injection manifold via 6 bore flexible wellhead jumpers. The flowline also
extends via a 10 flexible jumper from one end of the manifold to the FTA on the
end of a 10 plastic-lined pipeline which is routed to the Loyal wellsite. Control
functions to the trees are provided from a UTA to an SCM on one of the trees.
This controls the other tree using direct hydraulics, and has a spare connection
for the third tree.
Page 41 of 158
Loyal
Loyal is located 6.1 km North of the FPSO and has four water injection wells.
The water injection supply is provided from the FPSO by a 10 flowline which is
routed via the Schiehallion North manifold. The four water injection trees are
supplied individually from the 10 plastic-lined flowline via a separate four-porch
water injection manifold which is connected to the pipeline FTA with a 10
flexible jumper. The water injection tree controls are supplied by an umbilical
jumper from the UTA to the SCM on one of the trees. This provides direct
hydraulic control to the other three water injection trees.
16
From Water
Injection
Pumps P-45001A/B/C/D
12 Water Injection
Swivel N-45080
12 Water Injection Manifold
Future Riser
Connection (blanked off)
9 ID
Flexible
Riser
9 ID
Flexible
Riser
11 ID
Flexible
Riser
FTA
FTA
FTA
Injection water
to North-West Drill
Centre (HOLD)
FTA
FTA
Central Manifold
North Manifold
Schiehallion
Central WI Wells
Schiehallion
North WI Wells
FTA
West Manifold
Schiehallion
West WI Wells
FTA
KEY
Riser
FTA
Jumper
Flowline
Loyal
WI Wells
Page 42 of 158
Components
Location
ID No
Size
Turret
Turret
12-WI-450803
-
12"
12
Under FPSO
seabed
Seabed
Central
Central
Central
Central
Central
Central
Central
Central
Central
Central
Central
Central
Central
Central
10-R-180
FTA-180-92
12-L-180
FTA-180-93
10-J-180
MAN-180-92
06-W-105-922
XTI-105-92P
06-W-105-923
XTI-105-92Q
06-W-105-921
XTI-105-92N
06-W-105-924
XTI-105-92R
06-W-105-923
XTI-105-92T
10-J-180-921
9.5
10/12
12
12/10
10
10
6
N/A
6
N/A
6
N/A
6
N/A
6
N/A
10
Central
Central
Central
Central
Central
Central
Central
Central
06-W-105-927
XTI-105-92U
06-W-105-925
XTI-105-92S
06-W-105-928
XTI-105-92V
06-W-105-929
XTI-105-92W
6
N/A
6
N/A
6
N/A
6
N/A
Under FPSO
Seabed
Seabed
Seabed
West
West
West
West
West
West
West
West
West
West
West
West
West
West
West
West
Table 3
10-R-182
FTA-182-92
10-J-185-921
FTA-185-92
10-L-185
FTA -185-93
FTA 26
10-J-185-93
MAN-185-92 M22
06-W-125-923
XTI-125-92Q
06-W-125-922
XTI-125-92P
06-W-125-921
XTI-125-92 N
10-J-185-923
06-W-125-924
XTI-125-92R
06-W-125-925
XTI-125-92S
12-J-185-926
Page 43 of 158
9.5
10
10
10
10
10
10
10
6
N/A
6
N/A
6
N/A
10
6
N/A
6
N/A
12
Table 3
North
North
North
North
North
North
North
North
North
North
North to Loyal
10-L-182
FTA-182-93
10-J-182
MAN-182-92
06-W-135-922
XTI-135-92P
06-W-135-921
XTI-135-92N
06-W-135-923
XTI-135-92Q
10-J-186-921
10
10
10
10
6
N/A
6
N/A
6
N/A
10
North to Loyal
10-L-186
10
Loyal
10-J-186-922
10
Loyal
Loyal
Loyal
Loyal
Loyal
Loyal
Loyal
Loyal
Loyal
MAN-185-92
06-W-145-923
XTI-145-92Q
06-W-145-922
XTI-145-92P
06-W-145-921
XTI-145-92N
06-W-145-924
XTI-145-92R
10
6
N/A
6
6
6
N/A
6
N/A
Page 44 of 158
11 60 lb/ft Casing
Nipple
11 x 9-5/8 Crossover
Perf. pup and bull plug
Page 45 of 158
The potential for a vacuum condition in the water injection system due to
reservoir under-pressure.
Hydraulic surge due to closure of the wing valves, with the potential for the
shut-in pressure to exceed the system design pressure under certain
circumstances and for the transient pressures during the shut-in process to
exceed the maximum over-pressure allowances on some components.
Due to the above points, the shut-in of the wells is a compromise between the
requirement to shut-in quickly to prevent a vacuum in the riser and cross-flow
between wells and the requirement to shut-off slowly to prevent hydraulic surge
in the system. To this end, any water injection trip will also close all subsea
water injection wing valves with wing valve closure staggered over a period of 60
seconds to reduce the surge problem. This allows the run down of the pump
and the closure of the pump discharge valve to occur before the closure of the
last wing valve (once the water injection system is fully operational). The set
point for opening the overboard dump valve on each pump ensures that the
system pressure prior to shut down is relatively low thus reducing the risk of
over-pressure due to surge.
Protection of the wing valves against erosion is not possible and therefore
closure against full operating pressure will occur under some circumstances.
However, on a planned shut down of the water injection system, it is beneficial to
close the wing valves and shut in pumps in a sequence that minimises the wear
on the valves. To ensure that surge considerations are taken into account, safe
operating limits for each well must be adhered to.
Corrosion Management
Refer to the Corrosion Management Strategy Z-8000-ZS-4027.
The subsea components of the water injection system are constructed from
corrosion resistant alloys. The flexible risers and flowline jumpers have a duplex
carcass, the flexible well jumpers have a stainless steel 316 carcass, the carbon
steel flowlines are provided with polyethylene lining and all other major
components are alloy 625 clad carbon steel. Injection water is de-oxygenated to
a level of <20 ppbv and OS-2 scavenger is employed, if required, to ensure that
the sweet service design of the subsea system is satisfactory. During operation,
corrosion management of the water injection system is limited to monitoring of
the oxygen content of the injected water. There is no capability to intelligent pig
the water injection system.
The well tubing is fibre glass-lined. However this lining can be damaged during
well workovers giving the potential of the L80 carbon steel tubing to corrode.
The maintenance of the water injection oxygen specification is primarily to
protect against this corrosion potential.
No subsea chemical injection is required in the water injection system.
Page 46 of 158
Duration
Condition
< 20 ppb
> 20 ppb
> 2 hours
50-500 ppb
> 500 ppb
> 3 hours
> 1 hour
Normal Operations
Inject Oxygen Scavenger to
bring down level
Shutdown Injection
Shutdown Injection
Table 4
Scale Deposition
The potential for scale deposition is relatively low. However, to mitigate against
the risk of deposition, the subsea system will be protected from scale deposition
by the continuous injection of scale inhibitor on the FPSO.
2.10
Components
Slot Number
Tree Tag No.
SCSSV
UIMV
IWV
AMV
XOVT
Injection pressure &
temp.
Annulus Pressure
WI Flowmeter
MP Hydraulic Supply
Pressure Sensor
HP Hydraulic Supply
Pressure Sensor
Schiehallion Central
CW12
CW13
Schiehallion Central
CW16
XTI-10592P
105931P
105933P
105934P
105935P
105937P
PTT-105922P
XTI-10592R
105931R
105933R
105934R
105935R
105937R
PTT-105922R
XTI-10592T
105931T
105933T
105934T
105935T
105937T
PTT-105922T
PT-105923P
FT-105929P
PT-105991N
PT-105923R
FT-105929R
PT-105991Q
PT-105923T
FT-105929T
PT-105991T
PT-105992N
PT-105992Q
PT-105992T
Table 5
Page 47 of 158
Components
Slot Number
Schiehallion West
WW04
WW05
Schiehallion North
NW02
NW03
XTI-12592P
125931P
125933P
125934P
125935P
125937P
PTT-125922P
XTI-12592Q
125931Q
125933Q
125934Q
125935Q
125937Q
PTT-125922Q
XTI-13592P
135931P
135933P
135934P
135935P
135937P
PTT-135922P
XTI-13592Q
13591Q
135933Q
135934Q
135935Q
135937Q
PTT-135922Q
PT-125923P
FT-125929P
PT-125991N
PT-125923Q
FT-125929Q
PT-125991N
PT-135923P
FT-135929P
PT-135991N
PT-135923Q
FT-135929Q
PT-135991N
PT-125992N
PT-125992N
PT-135992N
PT-135992N
Components
Slot Number
Loyal
Table 5
LW05
LW06
XTI-14592P
145931P
145933P
145934P
145935P
145937P
PTT-145922P
PT-145923P
PT-145929P
PT-145991N
XTI-14592Q
145931Q
145933Q
145934Q
145935Q
145937Q
PTT-145922Q
PT-145923Q
PT-145929Q
PT-145991N
PT-145992N
PT-145992N
Component
Schiehallion Central
Slot Number
CW11
CW10
XTI-10592N
105931N
105933N
105934N
105935N
105937N
PTT-105922N
PT-105923N
PT-105929N
PT-105991N
PT-105992N
XTI-10592Q
105931Q
105933Q
105934Q
105935Q
105937Q
PTT-105922Q
PT-105923Q
PT-105929Q
PT-105991Q
PT-105992Q
Table 6
Page 48 of 158
Components
West
Loyal
Slot Number
WW06
LW04
XTI-12592N
125931N
125933N
125934N
125935N
125937N
PTT-125922N
XTI-14592N
145931N
145933N
145934N
145935N
145937N
PTT-145922N
PT-125923N
FT-125929N
PT-125991N
PT-145923N
PT-145929N
PT-145991N
PT-125992N
PT-145992N
Components
North
Central
Slot Number
NW01
CW15
XTI-13592N
135931N
135933N
135934N
135935N
135937N
PTT-135922N
XTI-10592S
105931N
105933N
105934N
105935N
105937N
PTT-105922N
PT-135923N
PT-135929N
PT-135991N
PT-105923N
PT-105929N
PT-105991N
PT-135992N
PT-105992N
Table 7
Components
Slot Number
Tree Tag No.
SCSSV
UIMV
IWV
AMV
XOVT
CHI
Injection pressure & Temp. Sensor
Annulus Pressure Sensor
Injection Pressure Sensor
WI Flowmeter
Injection Choke Position Indicator
MP Hydraulic Supply Press. Sensor
HP Hydraulic Supply Press. Sensor
Table 8
XTI-10592V
105931V
105933V
105934V
105935V
105937V
105926V
PTT-105922V
PT-105923V
PT-105924V
FT-105929V
ZI-105926V
PT-105991V
PT-105992V
Schiehallion Central
CW19
XTI-10592W
105931W
105933W
105934W
105935W
105937W
105936W
PTT-105922W
PT-105923W
PT-105924W
FT-105929W
ZI-105926W
PT-105991W
PT-105992W
Page 49 of 158
Remotely
Operated
ROV Operated
N/A
CW17, 18, 19 only
Yes
N/A
Yes
Yes
Yes
N/A
Yes
Yes
No
No
Yes
N/A
Yes
No
N/A
No
No
No
N/A
NO
No
Yes
Yes
No
Table 9
Note:
Type 1 wells at the West, Loyal and North drill centres share the same
control function on the subsurface safety valves. Hence, opening of
the valve on one tree will also open the valve on the tree sharing this
function, i.e. the following valves are operating by the same command:
SCSSV125931P and SCSSV125931Q
SCSSV135931P and SCSSV135931Q
This implies that the interlock sequences for these two wells are
dependent on the position of valves on both Xmas trees.
2.11
2.12
Page 50 of 158
2.13
Well
CW10
CW11
CW12
CW13
CW15
CW16
CW17
CW18
CW19
WW04
WWO5
WWO6
WWO8
WW09
NW01
NW02
NW03
LW04
LW05
LW06
IWV
Closed
Closed
Closed
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Isol
Valve Status
IMV
SCSSV
Closed
Closed
Open
Open
Isol
Open
Isol
Open
Open
Open
Open
Open
Open
Open
Open
Open
Open
Open
Isol
Open
Open
Open
Open
Open
Open
Isol
Open
Open
Open
Open
Open
Open
Open
Open
Isol
Isol
Open
Open
Open
Open
Table 10
Date
Date
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
03/05/2004
Time
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
16:30
49.7
80.5
19.8
41.7
54.5
70.1
43.2
109.3
37
38.2
68.4
68.5
99.2
Page 51 of 158
Cluster
Slot name
DTI Name
Zone
Duty
Central
CW10
C08
T31a/T31b
Water Injector
CW11
CW12
C02
C04
T31a
T31a/T34/T35
Water Injector
Water Injector
CW13
CW15
C09
C14
T31a
T31 a
Water Injector
Water Injector
CW16
CW17
C16
C19
T31 a
T31 a
Water Injector
Water Injector
CW18
CW 19
WS29
C21
T31 a
T31a
Water Injector
Water Injector
WW04
WW05
W06
W07
T34a/T34b/T31a
T31qa
Water Injector
Water Injector
WW06
WW07
W03
W05
T31a/T31b
T31a
Water Injector
Water Injector
WW08
WW09
W08
W09
T31a
T31 a
Water Injector
Water Injector
NW01
NW02
N03
N02z
T34
T31 a
Water Injector
Water Injector
NW03
LW04
N01z
L02
T31a
T35b
Water Injector
Water Injector
LW04A
LW05
L02A
L05
T35b
T35
Water Injector
Water Injector
LW06
LW10
L06
TBC
T35
Water Injector
Water Injector
LW11
FP03
TBC
TBC
Water Injector
Water Injector
FP04
FW01
TBC
TBC
Water Injector
Water Injector
FW02
FW03
TBC
TBC
Water Injector
Water Injector
West
North
Loyal
North West *
* Proposed
Table 11
Page 52 of 158
FIC-441001 also provides output to the stroke control of the methanol injection
pumps P-82601A/B to ensure that the amount of methanol injected for
regeneration of the stripping gas (see below) is in proportion to seawater flow
through V-44101. The calibration of the methanol pumps should be periodically
checked to ensure that injection rates are correctly matched with seawater flow.
Refer to Z-8000-BB-4051 for details of the Methanol System.
Seawater outlet from V-44101 is continuously monitored for chlorine and oxygen
content by AT-441017 and AT-441018 respectively.
Note:
All actuated valves relay positional information to the CPS using limit
switches, with the exception of control valves.
Page 53 of 158
3.2
Page 54 of 158
3.3
Page 55 of 158
3.4
Sequence
Local Control
Protect
Local Display
Display pre selected parameters via serial link in the CCR.
Remote control pre selected parameters via hardwire from the CCR.
The turbine control panel is electrical switch-based and allows command input
and indicates status. In addition to this when included a video display device
exhibits control parameters.
Instrumentation is included in the turbine package to report operating conditions
to control the system and control devices to receive control outputs from primary
and backup control systems.
Pre selected parameters can be monitored via serial link in the CCR and pre
selected parameters can be controlled via hard wire in the CCR.
Figure 10 shows the control system block diagram for the gas turbine and link
with the CCR.
Sequence functions monitor and sense events and perform computations to
operate components in the system. Sequence elements include:
Start
Load
Stop
Post lube
Arm the system: - turning on the electrical supply and resetting any alarm
or shutdown malfunctions.
The turbine should only be started from the CCR and the Solar Turbine
Control Panel has had the key removed to the central control room. The
key can be issued from there under the permit to work system when
required for maintenance access or following a Cooldown Lockout or
Fast Stop Lockout.
Page 56 of 158
Initiate start: In summary, once a start has been initiated the control
system performs a lube and driven equipment system check, starts
package fans, performs a fuel shutoff valve test and pre-crank status
check.
Page 57 of 158
Operator control
CENTRAL CONTROL
ROOM
REMOTE
CONTROL
REMOTE
DATA
Page 58 of 158
3.5
Page 59 of 158
3.6
The choke is adjusted by ROV from the intervention vessel when the associated
well is on-line. The swab valves (annulus and tubing) are remotely operated but
only from an intervention vessel and not from the FPSO. These valves provide
flow paths into the water injection well for the intervention rig and are only
required to be operated when such work is ongoing. They must remain under
control from the intervention vessel and therefore cannot be operated from the
FPSO. The swab valves remain closed when the well is under control from the
FPSO and they have no part to play in any operational scenario. It should be
noted that once the workover riser is connected through the tree cap then all
actuated tree valves operable from the FPSO are operable from the Intervention
Vessel.
Page 60 of 158
4.
4.1
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Pre-start Checks
Procedure
Confirm that water injection system is mechanically complete and that
all associated Work Permits have been closed out.
Purge deaerator tower if required.
Note:
Purging must be carried out following intrusive maintenance.
Purging is not required if the system is to be started after a
short-term shutdown (i.e. with a normal operating seawater
level in the deaerator).
Confirm that turret and subsea system are prepared for water injection.
Confirm that the manual valves are positioned as detailed in the Startup column of the Valve Position Tables.
Confirm that instrument air supply is available.
Confirm that the seawater distribution system is operational.
Confirm that a methanol supply is available to the de-aeration package.
Confirm that a nitrogen supply is available to the de-aeration package.
Confirm that power is available to the water injection pumps from the
HV switchroom (switchboard SWBDB(P)) as below:
P-45001A - cubicle A
P-45001B - cubicle W
P-45001C - cubicle X.
Confirm that power is available to the auxiliary lube oil pumps (water
injection pumping packages) from the LV aft switchroom (440V
switchboard SWBDA(P)) as listed below:
P-45002A - cubicle BF3
P-45002B - cubicle AHR5
P-45002C - cubicle BF11.
Confirm that power is available to the water injection pumps lube oil
heaters EEH-45001A/B/C from EDB-83801 in the LV aft switchroom.
Confirm that power is available to the stripping gas blowers from the LV
aft switchroom (440V switchboard SWBDA(P)) :
P-44201A - cubicle DF8
P-44201B - cubicle AGR8.
Confirm that power is available to the de-oxidiser vessel start-up heater
EEH-44201 from the LV aft switchroom (440V switchboard SWBDA(P) cubicle LR5).
Confirm that the de-aeration package trace heating system is
operational.
Confirm that FIC-441001 is set to manual and that FCV-441001 and
FCV-441019 are closed.
Confirm that power is available for 4th Water Injection pump and gas
turbine auxiliaries, control systems and the fuel gas heater.
Confirm that the following shutdown valves are closed.
XV-441024 - nitrogen supply
XV-442026 - methanol supply
XV-441028 - air supply.
Signature
Page 61 of 158
4.2
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Signature
Page 62 of 158
4.3
Step
1
2
3
4
6
7
8
9
10
11
12
13
14
15
Signature
Page 63 of 158
4.3
Step
16
17
18
19
4.4
Signature
The main drive motor & auxiliary lube oil pumps are manually
started/stopped via their start/stop pushbutton on the front of the
ECP. Manual control is for maintenance/testing purposes only.
ECP Auto
CPS Auto
Page 64 of 158
LOCAL/CPS START
Assuming all on-skid trips and PSD/ESD trips are healthy and all necessary
drives available, the pumps can be started. Irrespective of start mode, the CPS
start permissive is required. The CPS start permissive is dependent on:
suction pressure above 3 barg (measured by loop PI-450141)
discharge valve closed XV-450146)
activation of operator pushbutton.
This CPS start permissive is only valid for 20 minutes, if the pump has not
started by then it times out and the operator must reactivate the CPS pushbutton
(assuming the valve position and pressure have not changed).
Local Start: for either Manual or ECP Auto only the CPS start permissive is
required, all other status/indication can be monitored at the ECP.
CPS Start:
Upon receipt of the pump running signal, CPS drives the overboard dump valve
FCV-450145 fully open for 20 seconds. Thereafter the FIC is placed in auto
FCV to control the FCV. The water goes overboard until the discharge valve XV450146 is manually opened via CPS and forward flow to the turret is established.
Start Sequence Summary
1. Pump Stopped.
2. Pump Permitted to Start AND (ECP Mode AND Start P/B) OR (CPS Mode
AND Remote Start).
3. Start Aux Lube Oil Pump, Reset Low Lube Oil Press Alarm, Injection Pump
Sequence Initiated Sent to CPS.
4. Lube Oil established and Aux. Pump Running, Start Timer running (10 secs).
5. Main Injection Pump Main Drive Started. Confirmed Running.
6. Command Discharge Valve to Open, enable minimum Flow Valve Control.
Repeat Pump Running to CPS. Remove Lube Oil Override.
7. Discharge Pressure Established.
8. Start Timer Initiated ( 10 Sec,)
9. Stop Auxiliary Lube Oil Pump. Start Sequence Complete.
The required water injection rate is set by the position of the ROV-operated
subsea choke valves on each water injection wellhead.
All stops are operable regardless of mode selected. The mode selector is keyoperated, the key being removable when in CPS Auto.
Page 65 of 158
Procedure
Signature
Confirm that the water injection pumps P-45001A/B/C are prepared for
operation. This procedure covers start-up of water injection using a single
injection pump A, B or C. Additional pumps can be started as required
when injection flow is established.
Ensure that water injection riser(s) are correctly lined up, eg:
Schiehallion Central riser selected:
HV-180855 open - riser 10 block valve
HV-180853 closed - NRV bypass 2 globe valve
Schiehallion West, North and Loyal riser selected:
Confirm that injection pumps are fully primed. Vent valves on pumps
suction and discharge lines can be used to purge air from the pump.
Open pump equalisation line valves to charge the water injection system
to 5 bar (i.e. de-aerator pressure). (HV-450133/4 or HV-450233/4 or HV450333/4).
After charging to 5 bar, close the pump equalisation line valves. (HV450133/4 or HV-450233/4 or HV-450333/4).
10
11
12
When subsea system is charged, close the equalising line and open the
pump discharge valve (XV-450146 or XV-450246 or XV-450346).
13
For selected injection well, confirm wells upper master valve is open.
Notes:
14
15
16
Page 66 of 158
Step
Procedure
17
For the selected injection well, confirm that the surface controlled subsea
safety valve (SCSSV) is open.
Note:
Signature
18
19
20
21
Once pressure has equalised, close crossover valve and open wing valve
to continue injection.
22
23
Plot pressure and flow readings on graph provided with the Well
Operating Limits, associated with the selected injection well, to determine
whether operating conditions are within the allowable range.If conditions
are outside allowable ranges, stop injection and report findings.
24
25
4.5
Page 67 of 158
Procedure
Confirm that the gas turbine and auxiliary system are mechanically
complete and that all associated work permits have been closed-out.
Verify that the water seals from the oil cooler drip pan are filled with
water and valves are open.
Verify that the water seal from the oil filter drain is filled with water and
the valve is open.
Verify that water seals from the combustion air coalescer and turbine
enclosure HVAC intake coalescers are water filled.
Verify that the valves from the lube oil system are closed. HV-864513,
HV-864514, HV-864515. Reference drg: 37W022F0146-A-8000-GP0090.02-2C.
Confirm that instrument air supply is available.
Confirm that the Fuel gas supply is available.
Confirm that the cooling medium is available
Confirm that the flare system is available.
Confirm that the open drain is available.
Confirm that power is available from the switch room.
Check inside the turbine enclosure for any signs of leakage.
Close Enclosure doors.
Confirm that the enclosure F&G system is operational,
Confirm that CO2 deluge cylinders are charged and armed.
Start selected enclosure ventilation fan and confirm flow rate is
acceptable by checking that the correct pressure is being maintained
using the operating pressure transmitter
Signature
Procedure
Confirm that the gearbox is mechanically complete and that all
associated work permits have been closed-out.
Signature
Procedure
Confirm that all associated work Permits are closed out.
Confirm HVAC air fan is running and that the fan and air pressure is
being sustained and is remaining above the LER set point. (Indication
lights should be green.)
Signature
Control System
Step
1
Procedure
Confirm that all associated work permits have been closed-out.
Signature
Procedure
Verify that the fence area on the main walk way below the valve
access platform is intact and present to prevent water up to 60 oC
dripping on to personnel during start up.
Signature
Procedure
Confirm that the water injection system is mechanically complete and
that all associated Work Permits have been closed out.
Confirm that the manual valves for the pump are positioned for
normal operation as detailed in this document.
Confirm that valves XV-450501, XV-450446 & FCV-450445 are shut.
Confirm that the pump is fully primed. If necessary use the vent
valves on the pumps suction and discharge lines to purge air from the
pump. Confirm pump casing drain valve HV-450443 is closed.
Confirm that all instrument impulse line valves are open.
Signature
Page 68 of 158
Request Permissive to Start the Turbine is firstly initiated from the start-up
graphic by pressing the push button (XHS-450450). A signal is sent to set up the
following valve positions:
If the fuel gas temperature in the supply system is above 10 oC upstream of XV850005, permissive to open XV-850005 will be given even at the maximum delta
P across the PCV-850012, i.e. 55barg1 barg = 54 bar.
If the fuel gas supply temperature is below 10 oC and the pressure above 17 barg
downstream of PCV-850012 or the delta P is less than 38 bar across the PCV850012, then a permissive to open XV-850005 will be given.
Once the Request Permissive to Start the Turbine is initiated there may be a
requirement for the water injection PSD Reset button to be pressed depending
on the status of the 4 th water injection system trips; e.g. if trips exist, overrides
will be required to be set before enabling reactivation of valves XV-450446, XV450501 and XV-850005.
2
Permissive to Start the Turbine is given once the status of the valve positions
is checked by the PLC:
In addition, the PLC will check whether the permissive to start the turbine is
given by the Solar Turbine Control Panel or not. This permissive is indicated by
XI-450407. All required permissives are indicated on the start-up graphic when
they are fulfilled. The request to start turbine to idle will only be given once the
Request to Start Turbine to Idle push button XHS-450451 has been pressed.
Once all the permissives are healthy XI-450450 illuminates, which is permissive
to start. This will be valid for 20 minutes; if this is exceeded and the request to
start the turbine is not given the following will occur;
XV-850005 closes
Start up overrides, which were set will be removed.
Request to Start Turbine to Idle from the start graphic may be requested by
using XHS-450451 pushbutton (when the start permissive is active). On
detection of this, the TCP will proceed through the start sequence to bring the
turbine to 70% of the design speed. A start request indication will be displayed
through XI-450408. Simultaneously, a request is sent to switch on the Fuel Gas
Heater ETP-85002. When the speed has reached idle status, the Solar Turbine
Control Panel will send a signal back to the CPS to indicate that the turbine is
ready to load through XI-450430. This forms the feed forward permissive.
When the differential pressure across the pump is larger than 2.0 bar, the
minimum flow controller FIC-450445 will be activated and the FCV-450445 will
be allowed to operate under automatic control. The minimum flow of 330 m 3/hr
will be achieved in a pre-determined time to prevent pump damage.
Page 69 of 158
Request to Feed Forward Flow: When the turbine is ready to load the operator
operates the Feed Forward pushbutton (XHS-450452) from the start-up screen.
When this has been initiated, the start-up graphics indicate Request to Feed
status through XI-450452. Feed Forward is based on the differential pressure
across the discharge valve XV-450446 (Differential Pressure Indicator PDI450446). There are two routes:
Once the normal Feed Forward is established, the pump speed will be manually
entered from the Control and Safety System (C&SS). The CPS logic will switch
SIC-450453 from auto to manual control mode and XI-450453 will indicate the
set point speed of the turbine.
5
Request to Trip Turbine to Idle: To trip the turbine to idle pushbutton XHS450454 must be operated. This will generate an on screen indication that a Trip
Turbine to Idle has been requested. On detection of XHS-450454 the CPS will
close XV-450446 and XV-450501 after a 30 second time delay. The CPS output
XHS-450454 sends a signal to the TCP which will proceed through the slow to
idle sequence and bring the pump to idle speed. As XV-450446 closes, FIC450445 and FCV-450445 will open under PID (Proportional, Integral and
Derivative) control to protect the pump against low flow rates.
A cool down signal, indicated by XI-450410, will be generated to indicate a trip to
idle/ Normal stop has occurred. The TCP will remain at idle for 3 hours before
performing a full stop sequence, unless the feed forward button is pressed within
the 180 mins. Restart to Feed Forward can only occur under these conditions:
XV-450446 CLOSED
XV-450501 CLOSED
Turbine tripped to idle.
Once feed forward is re-activated, the CPS will automatically bring the turbine up
to idle speed and ready to load before re-feeding forward.
Start faults may include:
Permissive not given to open the inlet fuel gas valve XV-850005
Fault: The gas from the fuel gas heaters is less than 10 oC and 17 barg,
and too cold to enter the engine burner management system
Correction:
P&ID drawing: 37W022f0146-A-8000-GP-0090.00-2C
Open valve HV-850538 and HV-850539 until permission is given.
Permissive not given start the turbine
Fault: Fast stop or Cooldown lock-outs have occurred
Correction: Reset LER acknowledge & reset switches.
Table 12
Page 70 of 158
Figure 12 shows the turbine start-up graphic displayed in the CCR and can be
found in the screen for pump C and D, Figure 13.
Figure 13 CCR Graphic Display Screen for Water Injection Pumps C & D
Page 71 of 158
Description
HV-450527
HV-450501
HV-450502
HV- 450505
HV-450506
HV-450411
HV-450412
HV-450513
HV-450514
HV-450515
HV-450522
HV-450521
HV-450525
HV-450526
Start-up
Position
Closed
Open
Closed
Open
Closed
Closed and
blanked off
Open
Closed and
blanked off
Open
Closed
(Locked)
Open
Open
Closed
Closed
Normal
Operation
Closed
Open
Closed
Closed
Closed
Closed and
blanked off
Closed
Closed and
blanked off
Open
Closed
(Locked)
Open
Open
Closed
Closed
Pump P-45001D turbine valve positions for start-up and normal operation are:
Valve Tag
Number
HV-804807
HV-520503
HV-520510
HV-520511
HV-815502
HV-815503
Description
Start-up
Position
Open
Open
Closed
Closed
Open
Closed and
blanked off
Open
Normal
Operation
Open
Open
Closed
Closed
Open
Closed and
blanked off
Open
HV-815515
HV-815514
Closed and
blanked off
Closed
Closed and
blanked off
Closed
HV-864510
HV-864516
Closed
Closed
HV-864511
Closed
Closed
HV-864512
Closed
Closed
HV-864518
Closed
Closed
HV-864513
Closed
Closed
HV-864514
Closed
Closed
HV-864515
Closed
Closed
Page 72 of 158
4.6
The internal free volume of the exhaust path to be purged is 1236 cu ft.
4.7
Properly maintain and adjust all gas turbine, controls and exhaust system
as recommended by the manufacturer.
Ensure that any exhaust gas valves are installed correctly and are
working properly; particularly the free passage of exhaust gas to the
atmosphere must be maintained during the engine start-up and
operation.
Ensure that the exhaust collector and the exhaust system liquid drains
are operating properly.
Maintain fuel quality. Any deviation from the required specification could
lead to a malfunction of the fuel control system.
Step
1
2
3
4
5
6
Procedure
Ensure all relevant personnel are aware that the 4 th water injection pump
is about to be started. Make a tannoy announcement.
Get the key to the turbine control panel from the CCR, under Permit to
Work
Rotate OFF/LOCAL/REMOTE Key switch (S101) to LOCAL position.
Verify LOCAL Light (DS101) is illuminated.
Select Operation Summary display screen.
Press LAMP TEST switch (S113). Verify all indicator lights illuminate.
Signature
Page 73 of 158
7
8
9
10
11
12
13
14
Press and release the ACKNOWLEDGE Switch (S117) and then press
and release RESET Switch (S114) to acknowledge and clear any alarm
or shutdown indications.
Select alarm summary display screen and check for alarm and shutdown
indications. Correct any alarm and shutdown indications that remains
Verify that AUTO/MANUAL switch is in AUTO
Verify READY light (DS177) illuminates and [Ready] is highlighted on
Operation Summary Display screen
Rotate OFF/LOCAL/REMOTE keyswitch (S101) to REMOTE position.
Verify that Ready to start light turns green on the start up screen for the
turbine in the CCR.
Check fuel gas pressure on the LER control panel.
Return the key to the turbine control panel back to the CCR under Permit
to Work.
Note: If any malfunctions remain the READY light will not illuminate. If this
occurs the malfunction must be corrected and the ACKNOWLEDGE
Switch and RESET Switch (S114) must be pressed again to reset the
malfunction circuit.
WARNING: The turbine package is now ready for operation from the CCR.
When the turbine is ready to start, running and stopping, DO NOT
ROTATE the OFF/LOCAL/REMOTE keyswitch (S101) to the LOCAL position.
If the switch is rotated to the LOCAL position all remote operation functions
cease and all control is lost between turbine package and CCR.
When the turbine has totally stopped the OFF/LOCAL/REMOTE keyswitch
(S101) can be rotated to the LOCAL position.
On the turbine control panel there is a START Switch (S110) that has been
disabled. The reason for this is that if the turbine is started from the LER, the
water injection pump may be damaged.
The Key to the turbine control panel is held in the CCR and can only be
used under a Permit to Work. Under normal operation, Keyswitch S101
should be in the REMOTE position at all times.
Note: Finally perform the post start sequence and compare against norms. If
significant deviations are present shut down the engine and determine the
cause.
The control system monitors the temperatures, system pressures, engine speed,
vibration levels and other indicators. It also provides throttling (fuel topping) to
compensate if parameters are exceeded, indicators for malfunctions on the
operator display, and displays alarms providing automatic control of the engine
shutdown and the post lube unit.
Page 74 of 158
4.8
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Procedure
Check that the water inlet that connects the demineralised water source
and the tank water inlet is opened.
Signature
Open the following valves: HV-803700, HV-803711, HV-803701, HV803702 and control the water rate by HV-803710.
The vent valve is also opened and the tank filled with water until it begins
to flow out of the vent valve.
Open valve HV-530501, vent line on the skid
Close the water inlet.
Close the following valves: HV-803700, HV-803711, HV-803701, HV803702 and globe HV-803710
Close the vent valve HV-530501
Open the on-line air inlet valve to pressurize the tank to normal working
air pressure 6.9 barg and then close the air inlet valve.
Open valve HV-804805 and HV-804808.
Leave the tank under pressure for 10 minutes. There should be no
pressure drop or leakage to any of the fittings.
Slowly open the drain valve and allow the water to safely run to the drain
until the tank pressure is zero.
Open valve HV-864517
Close the drain valve, remove and clean and replace filter inserts from
the air water and chemical Y inlet strainers
Close valve HV-864517
Engine on-crank or on-line wash nozzle/manifold ring assembly pressure is checked thus:
Step
1
2
3
4
Procedure
Open the demineralised water inlet valve and the vent valve and half fill
the tank.
Open the on-crank or online air inlet valve to pressurize the tank to 2.0
barg. Connect the corresponding hoses between the tank outlet and the
on-line or on crank wash manifold inlet and slowly open the tank wash
fluid outlet.
If any leaks occur tighten the fittings. Repeat this procedure increasing the
pressure each time until the max working pressure of 6.9 barg is reached
without leaks.
Pressure test the atomising nozzles to confirm correct spraying. If any of
them appear blocked disconnect them and back flush the nozzle tip
through the orifice with a commercial electrical instrument cleaner
followed by high-pressure air or water.
Signature
Page 75 of 158
Cleaning Solution
(Volume/Dosage)
Gallons
Solution
Rinse
16
252
Distilled
Water to
solution
Ratio.
4:1
N/a
Flow GPM
Air
Pressure
Psig1
Air Flow
SCFM
4.4
4.4
85-100
85-100
4.6
4.6
Cleaning Solution
(Volume/Dosage)
Gallons
Solution
Rinse
16
8
Distilled
Water to
solution
Ratio.
4:1
N/a
Flow GPM
Air
Pressure
Psig1
Air Flow
SCFM
1.7
1.7
85-100
85-100
1.8
1.8
Notes:
1) The optimum pressure at the injectors is between 90-100 Psig (6.1-6.9 barg)
measured at the skid edge connection.
2) This is the recommended dosage. Compressor should be rinsed until a clean waste
stream is noted in engine drains.
Procedure
Confirm that engine is stabilised and at operating speed
Confirm that ambient temperatures are above 4 oC
Close all valves on the pressure injection tank
Open the wash cart vent valve and the wash cart water inlet valve
Fill the cart with the required amount of water and then close the tank
water inlet valve and disconnect the water supply
Connect the hose to the chemical source and the chemical inlet
Open the cart chemical inlet valve and fill the tank as required
Close the chemical inlet valve and disconnect the chemical supply
Close the Cart vent valve
Pressurise the tank to normal working pressure by opening the cart air
inlet valve and leave the valve open for the duration of the on-line
wash to maintain a steady injection pressure and flow
By selecting the appropriate on-line wash key and by opening the fluid
outlet valve start the on-line wash
Use all the cleaning solution in the tank
Signature
Page 76 of 158
4.9
Procedure
Signature
Purge the line for 2-3 minutes by leaving the air inlet valve open.
Close the air inlet valve and leave the outlet open to allow the cart
pressure to drop between 1.4 and 2.1 barg.
Select the appropriate function key to switch off the on-line cleaning,
close the fluid outlet valve and disconnect supply hose
Slowly open the vent valve and allow the pressure to discharge to 0
barg.
Within 20 minutes of the chemical wash a water rinse should be
performed to ensure the Cart is free of the Chemical Solution/ Water
mixture.
Open the water inlet valve and fill the cart with the required amount of
demineralised water.
Close the water inlet valve, disconnect the hose and flush the system
as above when the chemical wash was completed.
Compare performance figures with those before the wash and confirm
the contamination factor has decreased below 5%.
Instrument
Suction to pump
PI-450441
Suction to pump
PA-450442
PI-450443
PA-450444
FIC-450445
FA-450446
PDI-450446
ZI-450445
Value
Normal: 4.6 Barg
High Alarm: 7 Barg
Low Alarm 3 Barg
Trip high: 8 Barg
Trip Low: 2 Barg
Normal: 207-223 Barg
High Alarm: 250 Barg
Low Alarm 100 Barg
Trip high: 260 Barg
Trip Low: 95 Barg
Normal: 930 m3/h
Over speed case: 1150 m3/h
Low Alarm: 290 m3/h
Trip low: 280 m3/h
Normal: 0
Start up: 0 to 256 barg
Normal value: 0 to 100 % open
Page 77 of 158
Instrument
DE Vibration
YI-450400X
DE Vibration
YI-450400Y
DE Seal Pressure
PI-450416
PI-450417
DE Journal Bearing
Temperature
TI-450405
TI-450406
NDE Vibration
YI-450401X
NDE Vibration
YI-450401Y
TI-450407
TI-450408
TI-450409
Pump Speed
SI-450404
Pump HP
XI-450425
Value
Range: 0 to 150 m
Normal: 5 m
Alarm: 100 m
Trip: 125 m
Range: 0 to 150 m
Normal: 6 m
Alarm: 100 m
Trip: 125 m
Range: 0 to 2.5 Barg Normal: 0
Barg
Alarm: 0.3 Barg
Trip: 0.5 Barg
Range: 0 to 2.5 Barg
Normal: 0 Barg
Alarm: 0.3 Barg
Trip: 0.5 Barg
Range 0 to 200 oC
Normal: 59 oC
Alarm: 90 oC
Trip: 100 oC
Range 0 to 200 oC C
Normal: 37.6 oC
Alarm: 90 oC
Trip: 100 oC
Range: 0 to 150m
Normal: 11 m
Alarm: 100 m
Trip: 125 m
Range: 0 to 150m
Normal: 11 m
Alarm: 100 m
Trip: 125 m
Range: 0 to 200 oC
Normal: 42 oC
Alarm: 110 oC
Trip: 120 oC
Range: 0 to 200 oC
Normal: 42 oC
Alarm: 110 oC
Trip: 120 oC
Range: 0 to 200 oC
Alarm: 90 oC
Trip: 95 oC
Range: 0 to 4000 RPM
Normal: 3650 RPM Design
Over speed: 3833 RPM
Range: 0-11 MW
Normal: 6.56 MW Design
Overspeed: 8.075 MW
Page 78 of 158
Instrument
Value
TI-450414B
TI-450414A
TI-450412
Axial
ZI-450405
Accelerator
XI-450408
YI-450405Y
Range: 0 to 200 oC
Alarm: 70 oC
Trip: 75 oC
Range: 0 to 200 oC
Alarm: 70 oC
Trip: 75 oC
Range: 0 to 200 oC
Alarm: 100 oC
Trip: 105 oC
Range: 1-0-1 mm
Alarm: 0.1 mm
Range: 0 to 25 mm/s rms
Alarm: 7.0 mm/s rms
Trip: 18.0 mm/s rms
Range: 0 to 150 m
YI-450405X
Alarm: 63 m
Trip: 93 m
Range: 0 to 150 m
YI-450406Y
Alarm: 63 m
Trip: 93 m
Range: 0 to 150 m
YI-450406X
Alarm: 97 m
Trip: 142 m
Range: 0 to 150 m
TI-450413
TI-450415B
TI-450415A
TI-450411
Alarm: 97 m
Trip: 142 m
Range: 0 to 200 oC
Alarm: 100 oC
Trip: 105 oC
Range: 0 to 200 C oC
Alarm: 70 oC
Trip: 75 oC
Range: 0 to 200 oC
Alarm: 70 oC
Trip: 75 oC
Range: 0 to 200 oC
Alarm: 110 oC
Trip: 115 oC
Expected Operating Data for Water Injection Pump P-45001D Gas Turbine.
Description
Instrument
Value
SI-450405
TI-450422
PDI-450401
PDI-450402
PI-450432
Normal: 3 barg
Range: 0 to 20.7 barg
Page 79 of 158
TI-450433
FI-850005
TI-450434
PI-450433
TI-850099
YI-450415X
YI-450415Y
YI-450412
TI-450417
Y-450407X
Y-450407Y
SI-450406
YI-450408X
YI-450408Y
YI-450409X
YI-450409Y
YI-450410X
YI-450410Y
YI-450411
TI-450431
Range: 0 to 1000 oC
Set point: 290 oC
0 to 2177 kg/hr
Range: 0 to 1000 oC
Normal: 24 barg
Alarm low: 22 barg
Alarm high: 27.6 barg
Trip low: 19.7 barg
Trip High: 28.6 barg
Range: 0 to 41.4 barg
Normal: 35.2 oC
Alarm low: 31 oC
Alarm high: 45 oC
Trip low: 28 oC
Trip high: 55 oC
Range: 0 to 150 oC
Normal: 13.5 m
Maximum: 100.5 m
Range: 0 to 150 m
Normal: 12 m
Maximum: 100.5 m
Range: 0 to 150 m
Range: -1 to 1 mm
Range: 0 to 150 oC
Normal: 9 m
Maximum: 100.5 m
Range: 0 to 150 m
Normal: 6 m
Maximum: 100.5 m
Range: 0 to 150 m
Maximum: 100%
Range: 0 to 120 %
Normal: 13.5 m
Maximum: 100.5 m
Range: 0 to 150 m
Normal: 13.5 m
Maximum: 100.5 m
Range: 0 to 150 m
Normal: 16.5 m
Maximum: 100.5 m
Range: 0 to 150 m
Normal: 15 m
Maximum: 100.5 m
Range: 0 to 150 m
Normal: 27 m
Maximum: 100.5 m
Range: 0 to 150 m
Normal: 24 m
Maximum: 100.5 m
Range: 0 to 150 m
Normal: -0.08 mm
Range: -1 to 1 mm
Range: 0 to 150 oC
Page 80 of 158
Instrument
Value
Voltage
Current
Motor Speed
XI-450424
XI-450423
Si-450407
Range: 0 to 500 V
Range: 0 to 600A
Range: 0-5000 RPM
Instrument
Value
XI-450428
Range: 0 to 20 mm/s
Instrument
TI-450424
Header Temperature
TI-450425
PI-450434
Header Pressure
PI-450435
PDI-450405
PI-450436
TI-450426
PI-450437
LI-450401
TI-450427
PI-450438
Value
Normal: 57.6 oC
Maximum: 68 oC
Range: 0 to 150 oC
Alarm: 71 oC
Trip: 82.2 oC
Normal: 60.2 oC
Maximum: 68 oC
Range: 0 to 150 oC
Alarm: 71 oC
Trip: 82.2 oC
Normal: 3.4 barg
Range: 0 to 6.89 barg
Alarm: 1.86 barg
Trip: 1.03 barg
Normal: 3.45 barg
Range: 0 to 6.89 barg
Alarm: 1.86 barg
Trip: 1.03 barg
Range: 0 to 6.89 barg
Alarm: 2.07 barg
Range: 0 to 6.89 barg
Range: 0 to 150 oC Normal:
63.7 oC
Range: 0 to 37.3 mbarg
Range: 0 to 711 mm
High alarm: 550 mm
Low alarm: 483 mm
Maximum: 121 oC
Range: 0 to 150 oC
Maximum: 121 oC
Range: 0 to 150 oC
Maximum: 121 oC
Range: 0 to 150 oC
Maximum: 121 oC
Range: 0 to 150 oC
Range: 0 to 6.89 barg
PI-450439
TI-450428
TI-450429
TI-450430
Page 81 of 158
Instrument
Value
XI-450426
On / Off
Enclosure Temperature
TI-450432
Range: 0 to 150 oC
High alarm: 75 oC
XI-450427
On / Off
PI-450420
PDI-450404
Flow
Produced
Water m3/h
Electric
pumps
Turbine
driven
pump
Pump Discharge
Pressure Barg
Total flow rate: m3/h
Flow from
Deaeration
Tower
m3/h
1411
1490
Running
A, B, C
Design
Speed
Pressure: 206.2
Flow rate: 2901
1890
Running
A, B, C
Design
Speed
Pressure: 234.9
Flow rate: 1890
1890
Running
A, B
Design
Speed
Pressure: 221.9
Flow rate: 1890
1890
Running
A, B
Over
Speed
Pressure: 231.8
Flow rate: 1890
1890
Running
A, B, C
Not
Running
Pressure: 210.7
Flow rate: 1890
300
Not running
Over
Speed
Pressure: 271.9
Flow rate: 300
300
Not running
Design
Speed
Pressure: 246.3
Flow rate: 300
1150
Not running
Over
Speed
Pressure: 208.6
Flow rate: 1150
1631
1490
Running
A, B, C
Over
Speed
Pressure: 206.1
Flow rate: 3121
10
930
Not running
Design
Speed
Pressure: 210
Flow rate: 930
3650 PRM
3833 RPM
Page 82 of 158
4.10
300
250
200
BHIP Limit
Erosional Velocity Limit
Surge Limits
O pe rating Line
O p Pt
150
100
50
0
100
200
300
400
Page 83 of 158
The additional limes on this plot show the expected operating point of the water
injection based on the seawater injection choke position. This line covers the
range of possible injection indices expected for this well (dotted line) and the
most likely injection index range (solid line). This line is primarily for information.
Operation outside this line indicates incorrect choke position, an unexpected
choke performance or an unexpected reservoir performance.
If operation of the well is outside this limit, the well must be shut in and advice
obtained. It may be required that the ROV choke position will need to be
modified before injection can recommence.
Note:
The allowable operating envelope will change during field life and this
plot will be updated on a regular basis.
Page 84 of 158
4.11
Total duration of all pressure excursions that are above the design
pressure of 270 barg, and below a 20% overpressure threshold of 359.1
barg.
Total duration of all pressure excursions that are above the 20%
overpressure threshold of 324 barg, and below a 33% overpressure
threshold of 359.1 barg.
This can be achieved if the pump operates above its design speed or in an event
of the discharge being closed. Figure 13 shows the pressure excursion graphic
displayed on the screen in the CCR and can be found in the screen for pump C
and D.
Page 85 of 158
4.12
4.13
Description
Stripping Gas Blowers
Nitrogen Top-up Line
Instrument Air Top-up Line
Methanol Supply Line
Seawater Inlet Line
Action
Stopped
Closed
Closed
Closed
Closed
Page 86 of 158
The system control valves can be moved to their shutdown positions thus.
Valve Tag No.
FCV-441001
FCV-441019
FCV-441021
PCV-441023
FCV-441027
TCV-442014
Shutdown
Position
Closed
Open
Closed
Closed
Closed
Open
Description
Seawater Inlet Valve
Overboard Dump Valve
Stripping Gas Vent Valve
Nitrogen Top-up Valve
Instrument Air Inlet
Stripping Gas Exchanger Bypass
Description
Antifoam
Calcium nitrate
Scale Inhibitor
Oxygen Scavenger
Signature
The deaerator package is now shutdown. However, the system trace heating
should not be isolated until the deaerator has been drained and vented.
Additionally, each of the drain valves within the seawater pipework should be
opened to ensure that no liquid is present.
The only subsea condition that will cause the water injection trees to close in is
loss of hydraulic fluid, typically due to umbilical snagging.
VACUUM CONDITIONS ON SHUTDOWN
When the water injection pumps shutdown and discharge valves are closed, the
reservoir pressure is such that water will be drawn into the formation, causing a
vacuum to be pulled in the flexible risers. To prevent this condition, injection well
wing valves are closed following shutdown of the injection pumps. Additionally,
the risers are reinforced with steel liners to cope with vacuum conditions.
ISOLATION FOR MAINTENANCE
The water injection pumps are only provided with a single discharge isolation
valve due to space limitations. The water injection pumps must therefore be
shut down and locked out to achieve positive isolation for maintenance. The
water injection wells are not capable of back-pressuring the FPSO and therefore
work may be carried out without closing the turret isolation valves. The subsea
well wing and master valves must be closed to prevent pulling a vacuum and
drawing air into the system.
Page 87 of 158
Procedure
Shutdown of main pump using operating procedure
Ensure all well injection wing valves are closed.
Monitor annulus pressure on PI-105923n to ensure that it
remains within allowable operating range (0-310 barg)
Close UIMV
Close SCSSV
Re-open UIMV
Trend WHCIP on PI-105922n
Carry out flowline depressurisation back to FPSO using turret
drain valve.
Continue to trend WHCIP for 1 hour after full depressurisation
Close UIMV & AIMV
Signature
SHUTDOWN NOTES:
On shut-down of the water injection system there are four key considerations:
The potential for a vacuum condition in the water injection system due to
reservoir under-pressure.
Hydraulic surge due to closure of the wing valves, with the potential for
exceeding the over-pressure allowances on some components, if the system
is operated at above maximum steady state injection rate limits.
Closure of the wing valves against the main water injection pumps, leading
to a transient under-pressure in the well which could damage the downhole
sand screens.
Excessive wear of the water injection wing valve if it is closed against the
main pump.
The inclusion of a carcass in the water injection risers and subsea flexible
jumpers allows for vacuum conditions to exist in the system without the potential
for collapse of the internal liner in these components. However, the system
should be operated with the intention of minimising the potential for this
condition. This is primarily aimed at reducing the time taken to restart the
system, but also provides assurance against collapse of the polyethylene liner
within the water injection flowlines.
A similar philosophy to that used on the system start-up will be employed for a
planned shutdown. Therefore, the main pumps will initially be shutdown whilst
maintaining the water supply by using the produced water booster pumps or
seawater lift pumps. This will be followed by closure of all wing valves and then
shutdown of the produced water booster pumps or seawater lift pumps.
For an unplanned shut-down the water injection tree wing valves will be
automatically closed on loss of al l water injection pumps.
Page 88 of 158
IWV closes
UIMV closes
AMV closes
XOVT closes
Red Shutdown
as Yellow Shutdown above, but in addition
SCSSV closes
Page 89 of 158
4.14
The CRT may initiate a Normal Shutdown from the CCR or LER. The
gas turbine will trip to idle speed, which will be indicated on the start up
graphics. When the turbine remains in idle speed for 180 minutes, it will
be totally stopped. If the CTR initiates request to restart feed forward
XHS-450455 before this time, the CPS logic will bring the pump
automatically back on line.
The CRT may Fast Stop the turbine using XHS-450456 from the CPS
(see Control System Stop, below). The CPS logic will send a signal to
TCP S511-1 to trip the turbine to full stop. When the turbine comes to a
full stop the CPS system will turn off the fuel gas superheater and shut
valve XV-850005 instantaneously, XV-450446 and XV-450501 will close
after a 30 second delay. (Note this does not depend on a return of a
turbine full stop signal. This will happen on detection of Fast stop the
turbine XHS-450456). As XV-450446 closes, flow rate through the pump
reduces and FIC-450445 will open under PID control to protect the pump
from damage at low flow rates.
The operator may Emergency Stop the turbine from the TCP in the LER
or from two different locations outside of the skid. The TCP will total stop
the turbine, the Solar Turbine Control Panel will send a signal to the CPS
and will be indicated on the start up graphics.
The turbine can be stopped from the CCR or LER, push buttons on the skid or
by the control system. The system has the following stop functions:
Normal Shutdown from the CCR or LER, or Trip Turbine to Idle Speed
from the CCR - the turbine will trip to idle speed, run for 3 hours and total
stop
Manual Emergency Stop from the LER or from skid pushbuttons - the
turbine will total stop
Turbine Overspeed
Page 90 of 158
This will be indicated by Cool down on the start-up screen for the pump in the
CCR. The Solar/Silvertech control systems will trip the gas turbine to idle speed,
reset speed controller to 70% of turbine design speed, run for 180 minutes and
total stop. The pump can be brought back on line by activating the request to
restart feed forward button on the start-up screen for the turbine in the central
control room. After the engine coasts to a stop and the rundown timer expires, a
preset lubrication cycle will be initiated.
When the gas turbine is brought to idle speed or a total stop, the CPS will initiate
the following for the water injection pump P-45001D:
Tag Number
P-45001D
XV-450446
XV-450501
Description
4th Water injection pump
Pump discharge valve
Pump discharge equalisation valve
Action
Stopped
Closed after a timer
delay of 30 seconds
Shut
The system control valves can be moved to their shutdown position thus:
Tag Number
FCV-450445
Description
Pump minimum flow valve
Action
Open
Gas Turbine to Full Stop will indicate on the start-up screen for the pump in the
CCR. The engine shuts down immediately with no cool down cycle. After the
engine stop, the post lubrication cycle will be initiated.
Page 91 of 158
When the gas turbine is brought to a total stop, the CPS will initiate the following
for the water injection pump (P-45001D):
Tag Number
P-45001D
XV-450446
XV-450501
Description
4th Water injection pump
Pump discharge valve
Pump discharge equalisation valve
Action
Stopped
Closed after a timer delay
of 30 seconds
Shut
The CPS will initiate the following for the water injection pump P-45001D driver:
Tag Number
XV-850005
XS-850003
Description
Fuel Gas Valve
Fuel Gas Heater ETP 85002
Action
Closed
Trip
The system control valves can be moved to their shutdown position thus:
Tag Number
FCV-450445
Description
Pump minimum flow valve
Action
Open
Page 92 of 158
Cooldown Stop
If a cooldown stop has been initiated, the engine is shut down in the same
manner as a normal stop. There are two types of cooldown stops; cooldown
non-lockout and cooldown lockout.
sensor failure
lube tank level low
lube tank overpressure
Fast Stop
If a fast stop has been initiated, 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.
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 are the most severe shutdown types and require corrective
action before the package can be restarted.
Page 93 of 158
Fast stop lockouts respond to conditions that can cause serious damage if
operation continues. Investigation for damage is required. Corrective action
may be required before restart. These conditions include high bearing
temperatures, high T5 temperature, node failure, transmitter failures, pump
high thrust bearing temperature, gearbox high thrust bearing temperature,
pump high vibration and gearbox high temperature.
WARNING: When a fast stop shutdown has been initiated due to fire
detection, the post-lube oil pump will remain energised for a preset
rundown period. After the preset rundown period expires, the post-lube
oil pump will be de-energized for 20 minutes. After the 20 minute time
period expires, the post-lube pump will cycle on and off for a preset
post-lube period. If unsafe conditions still exist, the operator must
manually abort the post lube cycle by opening the contactors for the
post-lube and back-up lube oil pumps.
Page 94 of 158
4.15
4.16
Winterisation
The demineralised water line to the wash cart should be emptied of water when
the temperature falls below 5 deg C, to prevent freezing in the pipe, by opening
valve HV-803709 (P&ID: 37W022F0146-A-8000-GP-0090.01-2C). There are
two sets of drain water traps underneath both the HVAC (two traps) and
combustion air Intakes (one trap) that are not winterised. A TQ has been raised
to have these winterised.
Page 95 of 158
4.17
Start-Up of TT4000
1.
2.
3.
4.
5.
6.
Shutdown of TT400
1.
2.
3.
4.
5.
Shutdown of Computer
1.
2.
3.
4.
Page 96 of 158
5.
5.1
One multi-core cable for readback at the SCM of up to 3 off 4-20mA sensors
on the manifold (valve position sensor, pressure and temperature sensor).
Page 97 of 158
5.1.1
Interlocks
Interlocks serve to reduce valve wear. Interlocks when the MCS is in
OPERATOR mode are:
Wing valve cannot be opened unless the Upper Master Valve is open
Upper Master Valve cannot be opened or closed unless Wing Valve is
closed
SSSV cannot be opened unless upper master valve and wing valve are
open
SSSV cannot be closed unless the upper master valve is closed.
Note:
Tag No.
PG 450 803
Instrument Type
Pressure Gauge
FE 180 800A
FE 180 800B
Flow Element
(Central Riser)
FE 182 800A
FE 182 800B
(West/North/Loyal Riser)
dP sss929n
Flow venturi
PTT sss922n
PT sss923n
Pressure/ Temperature
Transmitter
Pressure Transmitter
Table 11
Page 98 of 158
The following table explains what the setting is for each instrument on the xtree.
Instrument
PTT
d/s IWV
pressure
Design
PTT
d/s IWV
0/ 380 bara
temperature
Design
PT
@ XOUT
-30/ 80 C
pressure
Design
FT
Design
PI
on MP
hydraulic
supply
0/ 380 bara
flowrate
0/ 331m3/d
pressure
Design
0/ 569 bara
PI
on HP
hydraulic
supply
pressure
Design
0/ 569 bara
none
none
none
none
none
Annulus pressure
near the maximum
operating pressure
Table 12
Lo
Indicates the
pressure is
getting near to
the riser drawing
a vacuum
Indicates that
the temperature
approaching the
minimum design
temperature of
the risers
Annulus
pressure near
min. operating
pressure
none
LoLo
Indicates that
the riser has
drawn a vacuum
Low pressure on
MP hydraulic
supply; valves
are closing , and
should be
closed under
controlled
manner
Low pressure for
the HP hydraulic
supply, close the
valves in
controlled
manner
Valves closing.
Hydraulic valves
should be closed
Indicates that
the temperature
near the
minimum design
temperature of
the risers
Annulus
pressure near
min. operating
pressure
none
Valves closing.
The valves
should be
closed.
For alarms set on each xtree see Doc: Schedule of Alarm Settings, Doc No: S-9000-GY-9200.
5.2
Set by FIC-441019
945 m3/hr (minimum flow)
5 barg
98 - 140 kg/hr
150C
40 60 litres/hr
Page 99 of 158
5.3
Device
PI-450441
PI-450443
FIC-450445
ZI-450445
ZLH/ZLL-450446
ZLH/ZLL-450501
Location
Remote
Remote
Remote
Remote
Remote
Remote
Monitoring of pre-selected operating data for turbine, gearbox and pump will be
carried out by using a serial link between TCP and CCR.
Failure of microprocessor
Detection of fire
Detection of engine overspeed by backup overspeed monitor
Pressing of emergency stop switch.
The backup relay system will maintain lube oil pump operation to avoid
possible damage to the engine or driven equipment.
Switches:
Off/Local/Remote switch can be in the following positions:
Off: start sequence is inhibited.
Local: Turbine can be operated from the LER, but this is FORBIDDEN.
Remote: Turbine should only be operated from CCR, normal operation. The
Turbine MUST NOT be operated from the LER.
Rotating the switch to the off position when the unit is operating will initiate a
control system stop of the engine with no cool down cycle.
The key to the panel is held in the CCR and is only released under a Permit to
Work.
The key is only required if Cool-down Lockout or Fast Stop Lockout occur,
and for maintenance.
Pushbuttons:
Emergency stop: This initiates immediate engine shutdown, with no cool-down
cycle.
Horn Silence: This initiates the silence Audible Alarm Horn after an alarm or
shutdown has occurred. Additional alarm or shutdowns will re-activate the alarm
horn. To re-activate the horn silence, the button has to be pressed.
Acknowledge: This initiates the acknowledgement of alarms or shutdown and
activates the Reset switch, which allows the system to be reset when an alarm or
shutdown becomes inactive.
Reset: This initiates clearing of alarms or shutdown indicators, and the reset
control system.
Start is permitted only if shutdowns are inactive and the control system has been
reset.
Lamp Test: This initiates illumination of all indicator lights. If all of the lights are
illuminated it indicates that all of the light circuits are intact.
Other Switches:
Back-up Reset: Rotary, two-position (off, on) switch, rotated clockwise to reset
the back-up relay system. The back-up relay system cannot be reset until after
the acknowledge and reset buttons are pressed. The back-up light will indicate
when the back-up relay system has been reset.
Normal Stop: This initiates the cool down stop sequence. The engine speed is
reduced to idle speed. Idle speed is maintained for a pre-selected cool down
time before fuel gas is shut off and the engine shuts down.
Start: The Start switch on the local panel has been disabled and can only be
started from the CCR.
Auto/Manual: Split type, dual-function switch, with individual indicator lights,
illuminates to indicate mode selection. This switch should ALWAYS be in Auto.
Decrease: This initiates a decrease of speed from the LER, this is FORBIDDEN.
Increase: This initiates an increase of speed from LER, this is FORBIDDEN.
Device
XI-450407
XI-450440
XI-450430
XI-450409
XI-450410
XI-450411
XI-450412
XI-450413
XI-450414
XI-450415
XI-450416
XI-450417
XI-450418
XI-450420
XI-450421
XI-450422
XI-450456
SI-450405
TI-450422
PDI-450401
PDI-450402
PI-450432
TI-450433
TI-450434
FI-850005
PI-450433
TI-850099
XI-450419
YI-450415X
Location
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Monitoring
Power turbine BRG 5-Y-axis
Power turbine axial
Power turbine trust bearing
Power turbine BRG 4-X-axis
Power turbine BRG 4-Y-axis
Gas producer NGP PV
Power turbine BRG 3-X-axis
Power turbine BRG 3-Y-axis
Power turbine BRG 2-X-axis
Power turbine BRG 2-Y-axis
Power turbine BRG 1-X-axis
Power turbine BRG 1-Y-axis
Gas producer axial
Gas producer trust bearing
Device
YI-450415Y
YI-450412
TI-450450417
YI-450407X
YI-450407Y
SI-450406
YI-450408X
YI-450408Y
YI-450409X
YI-450409Y
YI-450410X
YI-450410Y
YI-450411
TI-450431
Location
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Device
TI-450414B
TI-450414A
TI-450412
ZI-450405
XI-450408
TI-450410
YI-450405Y
YI-450405X
YI-450406Y
YI-450406X
TI-450413
TI-450415B
TI-450415A
TI-450411
Location
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Device
XI-450424
XI-450423
SI-450407
Location
Remote
Remote
Remote
Device
XI-450428
Location
Remote
Device
TI-450424
TI-450425
PI-450434
PI-450435
PDI-450405
PI-450436
TI-450426
PI-450437
LI-450401
TI-450427
TI-450428
TI-450429
TI-450430
PI-450438
PI-450439
Location
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Device
XI-450426
TI-450432
XI-450427
PI-450420
PDI-450404
Location
Remote
Remote
Remote
Remote
Remote
Device
YI-450400X
YI-450400Y
PI-450416
PI-450417
TI-450405
TI-450406
YI-450401Y
YI-450401X
TI-450407
TI-450408
TI-450409
SI-450404
XI-450425
Location
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Remote
Figures 19-21 show the graphic display screens for the gas turbine where the following
parameters can be monitored:
Pump power
Enclosure pressure & temperature
Enclosure vent fan on/off
Enclosure Filter DP
Gas turbine not running or running. When the speed of turbine is less than 5%
of the design speed, this will be indicated as not running
Gas turbine air inlet filter DP
Operating data in the fuel gas system.
Figure 20
Figure 21
6.1
De-aerator HIPS
The de-aerator HIPS shutdown valves XXV-441002 and XXV-441040 must be
manually reset following activation.
Note:
A high-high level HIPS is installed on the inlet to the deaerator tower to prevent
the column overfilling. The support pallet steelwork is adequate for the
occasional (less than once a year) flooding of the tower, however, no appraisal
for fatigue has been performed. Therefore, it is important that each flooding
occasion is logged.
The HIPS is arranged as a level transmitter initiated a one-out-of-two voting
system acting on two independent ESD valves and located on the inlet to the
vessel. The HIPS level transmitters and shutdown valves are driven via the
hard-wired ESD system.
The deaerator also has a primary protection system in the form of a high high
level shutdown switch acting on the upstream shutdown valve, XXV-441040, via
a dedicated CPS solenoid. The primary shutdown system operates via the
software based CPS system.
The HIPS comprises the following:
HIPS Transmitters
LT-441013
LT-441014
High-high Setpoint
3050 mm
3050 mm
XXV-441002
XXV-441040 (via a dedicated ESD solenoid)
High-high setpoint
2600 mm
The HIPS is installed on the deaerator as the vessel relief valves are not
designed for full seawater flow relief.
PSD Resets
Field inputs which have caused a trip, after the measurement goes healthy,
require to be reset in the PSD system. This is achieved at the operator
workstations as follows:
1. On Main System graphic select PSD, this will display PSD
Shutdown/Reset Page.
2. On this page all process systems status will be displayed, i.e. input trip, output
trip etc. On this page against each process system there is a reset
pushbutton. If all field inputs for the process are healthy, the reset can be
pressed and the status of input trips should change from red to green.
Note: Any field inputs which require a start-up override, and are therefore active
due to plant not running, require a start-up override applied before the reset is
pressed.
SUBSEA AND WATER INJECTION TREES
Refer to Cause and Effect S-9000-GC-9002
Input Cause
Red Shutdown
Input
F&G or Manually
from CCR
Yellow Shutdown
F&G or Manually
from CCR
PSD
Action
Closes all wells, wing
valves, master valves,
annulus valves, SCSSV
and crossover valve.
Closes all wells, wing
valves, master valves,
annulus valves, SCSSV
and crossover valve.
Closes wing valves.
Input
Action
LT-441010
CPS
LT-441010
CPS
FT-441010
CPS
FT-441010
CPS
FT-441019
CPS
FT-441019
CPS
PT-441003
CPS
PT-441003
CPS
TT-441008
CPS
TT-441008
CPS
AT-441018
CPS
AT-441017
CPS
Alarm
Input
Action
AT-441017
PS-441034
AT-441017
LS-441033
PT-441021
PT-441021
AT-441026
PDT-442027
PDT-442027
PDT-442004
PDT-442004
TT-442002
TT-442005
FT-442008
FT-442008
TT-442014
TT-442014
TT-442015
TT-442015
PDT-442016
AT-442019
FT-442025
FT-442025
FT-441027
Purge controller in
field
Purge controller in
field
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
FT-441027
CPS
Alarm
Input
Action
LT-441013
ESD
LT-441014
ESD
LT-441032
PSD
LT-441015
PSD
TT-441007
PSD
PT-441020
PSD
PT-441020
PSD
FT-442009
PSD
FT-442009
PSD
TT-442018
PSD
TS-442017
MCC
TS-442016
MCC
TT-441030
AT-442019
PSD
CPS
6.2
6.2.1
Alarm
GEC Purgepak PM 45001A
(mounted on front of UCP) PAL-450163
Injection pump P-45001A
DE journal bearing vibration high
YAH-450100 x/y
Injection pump P-45001A
DE journal bearing
vibration high sensor fail YA-450100 x/y
Injection pump P-45001A
NDE journal bearing
vibration high YAH 450101 x/y
Injection pump P-45001A
pump NDE journal bearing vibration high sensor
fail
YA 450101 x/y
Injection pump motor
PM-45001A motor
DE journal bearing
vibration High
YAH-450102 x/y
Injection pump motor
PM-45001A DE journal bearing vibration high
sensor fail
YA-450102 x/y
Injection pump motor
PM-45001A NDE journal bearing vibration high
YAH-450103 x/y
Injection pump motor PM-45001A NDE journal
bearing vibration
high sensor fail
YA-450103 x/y
Injection pump P-45001A
DE journal bearing
TAH-450105
Injection pump P-45001A
DE journal bearing
temperature sensor fail
TA-450105
Injection pump P-45001A
NDE journal bearing
TAH-450106
Injection pump P-45001A
NDE journal bearing
temperature sensor fail TA-450106
Injection pump P-45001A
I/B thrust bearing TAH-450107
Injection pump P-45001A
I/B thrust bearing
temperature sensor fail TA-450107
Input
PT-450163
Action
EPS
YT-450100X/Y
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
YT-450100X/Y
YT-450101X/Y
YT-450101X/Y
YT-450102x/Y
ECP Mounted
hardwired available in
CCR via Data Link
YT-450102x/y
ECP Mounted
hardwired available in
CCR via Data Link
YT-450103 x/y
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
YT-450103 x/y
TT-450105
TT-450105
TT-450106
TT-450106
TT-450107
TT-450107
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
(contd)
6.2.1
Input
TT-450108
TT-450108
TT-450110
TT-450111
TT-450111
TT-450109
TT-450110
TT-450112
TT-450112
TT-450113
TT-450113
TT-450114
TT-450114
TT-450115
TT-450115
PT-450116
Action
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
CPS
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
(contd)
6.2.1
Input
Action
PT-450116
PT-450117
PT-450117
LT-450120
ECP Mounted
hardwired
available in CCR
via Data Link
ECP Mounted
hardwired
available in CCR
via Data Link
ECP Mounted
hardwired
available in CCR
via Data Link
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
hardwired
available in CCR
via Data Link
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
CPS
CPS
CPS
CPS
ESD via ECP
ESD via ECP
ESD via ECP
ESD via ECP
ESD via ECP
ESD via ECP
ESD via ECP
ESD via ECP
ESD via ECP
ESD via ECP
ESD via ECP
ESD via ECP
ECP
TT-450128
TT-450128
TT-450128
TT-450131
PT-450134
PT-450136
PT-450141
PT-450141
PT-450143
PT-450143
YT-450100
YT-450101
YT-450102
YT-450103
YT-450105
YT-450106
TT-450110
TT-450111
TT-450112
TT-450113
TT-450114
TT-450115
PT-450135
PT-450134
PT-450135
PT-450136
LT-450139
LT-450139
6.2.2
Input
Action
PT-450263
EPS
YT 450200X/Y
YT-450200X/Y
ECP Mounted
hardwired available
in CCR via Data Link
Ditto
YT-450201X/Y
Ditto
YT-450201X/Y
Ditto
YT-450202x/Y
Ditto
YT-450202x/y
Ditto
YT-450203 x/y
Ditto
YT-450203 x/y
Ditto
TT-450205
Ditto
TT-450205
Ditto
TT-450206
Ditto
TT-450206
Ditto
TT-450207
Ditto
TT-450207
Ditto
TT-450208
Ditto
TT-450208
Ditto
TT 450209
CPS
TT-450210
ECP Mounted
hardwired available
in CCR via Data Link
Ditto
TT-450210
TT-450211
TT-450211
ECP Mounted
hardwired available
in CCR via Data Link
ECP Mounted
hardwired available
in CCR via Data Link
6.2.2
Input
Action
TT-450212
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
Annunciator
ECP Mounted
Annunciator
TT-450212
TT-450213
TT-450213
TT-450214
TT-450214
TT-450215
TT-450215
PT 450216
PT 450216
PT 450217
PT 450217
LT 450220
TT 450228
TT 450228
TT 450228
TT-450231
PT 450234
PT 450234
PT 450235
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
6.2.2
Input
Action
PT 450236
ECP Mounted
Annunciator
ECP Mounted
Annunciator
PT 450236
LT 450239
PT 450241
ECP Mounted
Annunciator
ECP Mounted
Annunciator
CPS
PT 450241
CPS
PT 450243
CPS
PT 450243
CPS
YT-450200
YT-450201
YT-450202
YT-450203
YT-450205
YT-450206
TT-450210
TT-450211
TT-450212
TT-450213
TT-450214
TT-450215
PT-450235
LT 450239
6.2.3
Input
Action
PT-450363
EPS
YT 450300X/Y
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
YT-450300X/Y
YT-450301X/Y
YT-450301X/Y
YT-450302x/Y
YT-450302x/y
YT-450303 x/y
YT-450303 x/y
TT-450305
TT-450305
TT-450306
TT-450306
TT-450307
TT-450307
TT-450308
TT-450308
TT-450309
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
CPS
6.2.3
Alarm
Injection pump motor PM-45001C
air circuit temperature
TAH-450310
Injection pump motor PM-45001C
air circuit temperature sensor fail
TA-450310
Injection pump motor PM-45001C DE journal
bearing temperature high
TAH-450311
Injection pump motor PM-45001C DE journal
bearing temperature sensor fail
TA-450311
Injection pump motor PM-45001C NDE journal
bearing temperature high
TAH-450312
Injection pump motor PM-45001C NDE journal
bearing temperature sensor fail
TA-450312
Injection pump motor PM-45001C winding U
temperature high
TAH-450313
Injection pump motor PM-45001C
winding U temperature sensor fail
TA-450313
Injection pump motor PM-45001C
winding V
temperature high TAH-450314
Injection pump motor PM-45001C
winding V
temperature sensor fail TA-450314
Injection pump motor PM-45001C
winding W temperature high
TAH-450315
Injection pump motor PM-45001C
winding W temperature sensor fail
TA-450315
Injection pump P-45001C
DE seal pressure high
PAH-450316
Injection pump P-45001C
DE seal pressure high
sensor fail
PA-450316
Injection pump P-45001C
NDE seal pressure high
PAH-450317
Injection pump P-45001C
NDE seal pressure high
sensor fail PA-450317
Injection pump motor PM-45001C
coolant leakage LAH-450320
Injection pump P-45001C
lube oil reservoir temperature
TAH-450328
Input
TT-450310
TT-450310
TT-450311
TT-450311
TT-450312
TT-450312
TT-450313
TT-450313
TT-450314
TT-450314
TT-450315
TT-450315
PT-450316
PT-450316
PT-450317
PT-450317
LT-450320
TT-450328
Action
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
hardwired available in
CCR via Data Link
ECP Mounted
Annunciator
ECP Mounted
Annunciator
6.2.3
Alarm
Injection pump P-45001C
lube oil reservoir temperature TAL-450328
Injection pump P-45001C
lube oil reservoir temperature
sensor fail TA-450328
Injection pump P-45001C
lube oil cooler outlet temperature
TAH-450331
Input
TT-450328
PT-450334
TT-450328
TT-450331
Action
ECP Mounted
Annunciator
ECP Mounted
Annunciator
PT-450341
ECP Mounted
hardwired
available in CCR
via Data Link
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
ECP Mounted
Annunciator
CPS
PT-450341
CPS
PT-450343
CPS
PT-450343
CPS
YT-450300
YT-450301
YT-450302
YT-450303
YT-450305
YT-450306
TT-450310
TT-450311
TT-450312
TT-450313
TT-450314
TT-450315
PT-450335
PT-450334
PT-450335
PT-450336
PT-450336
LT-450339
LT-450339
6.3
37W022F0146-A-8000-GP-0090.05/06/07-2C
37W022F0146-A-8000-GP-0090.03-2C
Alarm
Input
Action
XA-450400
CPS
XA-450401
CPS
XA-450402
CPS
XA-450403
CPS
XA-450404
CPS
XA-450405
CPS
XA-450406
CPS
XA-450407
CPS
XA-450408
CPS
XA-450409
CPS
XA-450410
CPS
XA-450411
CPS
XA-450412
CPS
XA-450413
CPS
XA-450418
CPS
XA-450414
CPS
XA-450419
CPS
XA-450415
CPS
XA-450416
CPS
XA-450417
CPS
PI-450441
CPS
PI-450441
PI-450443
PI-450443
FIC-450445
CPS
CPS
CPS
CPS
Figure 22
Figure 23
Figure 24
Figure 25
Figure 27
DISCHARGE
SUCTION
Figure 28
6.4
Input
PT-450442
PT-450442
PT-450444
PT-450444
FT-450446
TT-850005
TT-850005
TT-850006
PT-850005
Action
Intertrip to water injection system,
close discharge XV-450446,
equalisation XV-450501, fuel gas XV850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
Intertrip to water injection system,
close discharge XV-450446,
equalisation XV-450501, fuel gas XV850005, trip fuel gas heater ETP85002 and fast stop gas turbine
Intertrip to water injection system,
close discharge XV-450446,
equalisation XV-450501, fuel gas XV850005, open overboard dump valve
XV-450445, trip fuel gas heater ETP85002 and fast stop gas turbine
Intertrip to water injection system,
close discharge XV-450446,
equalisation XV-450501, fuel gas XV850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
Intertrip to water injection system,
close discharge XV-450446,
equalisation XV-450501, fuel gas XV850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
Intertrip to water injection system,
close discharge XV-450446,
equalisation XV-450501, fuel gas XV850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
1 out of 2 voting (TT-850005 and TT850006).
Intertrip to water injection
system, close dischargeXV-450446,
equalisation XV-450501, fuel gas XV850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
1 out of 2 voting (TT-850005 and TT850006).
Intertrip to water injection
system, close discharge XV-450446,
equalisation XV-450501, fuel gas XV850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
Intertrip to water injection system,
close discharge XV-450446,
equalisation XV-450501, fuel gas XV850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
Input Cause
Injection pump P45001D fuel
gas system pressure PALL850005
Input
PT-850005
Solar
CUST553
Intertrip
Intertip
Action
Intertrip to water injection system
close discharge XV-450446,
equalisation XV-450501, fuel gas
XV-850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
Intertrip to water injection system
close discharge XV-450446,
equalisation XV-450501, fuel gas
XV-850005 and trip fuel gas heater
ETP-85002.
Intertrip to water injection system
close discharge XV-450446,
equalisation XV-450501, fuel gas
XV-850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
Close discharge XV-450446,
equalisation XV-450501, fuel gas
XV-850005, trip fuel gas heater ETP85002 and fast stop gas turbine.
6.5
Input
PT-450142
PT-450142
TT-450109
PT-450144
PT-450144
FIT-450146
PT-450242
PT-450242
TT-450209
PT-450244
PT-450244
FIT-450246
PT-450342
PT-450342
TT-450309
PT-450344
PT-450344
FIT-450346
Action
Trip pump A via HV switchboard
and close discharge XV-450146
Trip pump A via HV switchboard
and close discharge XV-450146
Trip pump A via HV switchboard
and close discharge XV-450146
Trip pump A via HV switchboard
and close discharge XV-450146
Trip pump A via HV switchboard
and close discharge XV-450146
Trip pump A via HV switchboard
and close discharge XV-450146
Trip pump B via HV switchboard
and close discharge XV-450246
Trip pump B via HV switchboard
and close discharge XV-450246
Trip pump B via HV switchboard
and close discharge XV-450246
Trip pump B via HV switchboard
and close discharge XV-450246
Trip pump B via HV switchboard
and close discharge XV-450246
Trip pump B via HV switchboard
and close discharge XV-450246
Trip pump C via HV switchboard
and close discharge XV-450346
Trip pump C via HV switchboard
and close discharge XV-450146
Trip pump C via HV switchboard
and close discharge XV-450346
Trip pump C via HV switchboard
and close discharge XV-450346
Trip pump C via HV switchboard
and close discharge XV-450346
Trip pump C via HV switchboard
and close discharge XV-450346
Trips water
injection pumps
P-45001A/B/C/D and closes
discharge valves
6.6
Table 14
Master Xtree
1
Slave Xtree
2
7
9
8
10
These sequences are typical for tree shutdown and follow directly from 1 to 10:
The master xtree shutdown would be in the sequence of 1,3,5,7,9 and the
slave xtree in the sequence of 2,4,6,8,10.
The IWV sequence of valve closure would always be 1 followed by 2.
The UMIV valve closure could be 3 followed by 4 or 4 followed by 3.
The AMV valve closure: 5 and then 6 or 6 and then 5, etc.
The same typical and alternative shutdown sequences apply to all of the
following tables. Table 15 shows the shutdown sequences for West and Loyal
injection centres, which have two slave xtrees to a master xtree.
Valve
Master Xtree
Second Slave
First Slave
Xtree
2
Water injection
wing valve
water injection
master valve
water injection
annulus valve
cross-over valve
SCSSV
10
13
11
14
12
15
6.6.1
Time Delay
after valve
closed (s)
30
15
15
90
Valve
Tag Number
IWVsss934n
UIMVsss933n
AMVsss935n
XOVTsss937n
Master Xtree
1
Slave Xtree
2
Table 17
Sequence of Master and Slave Xtree Shutdown
on Yellow ESD for Central and North Water Injection Drill Centres
Valve
Master Xtree
Second Slave
First Slave
Xtree
2
Water injection
wing valve
water injection
master valve
water injection
annulus valve
cross-over valve
SCSSV
10
13
11
14
12
15
Table 18
Sequence of Master and Slave Xtree Shutdown
on Yellow ESD for West and Loyal Water Injection Drill Centres
6.6.2
6.7
DESIGN PARAMETERS
The design flowrates for existing drill centres and water injection wells are:
Design Flowrate (mbpd)
maximum well flowrate
design drill centre flowrate
allowable drill centre flowrate
Schiehallion
Central
50
140
154
Schiehallion
West
50
100
96
Schiehallion
North
50
100
149
Loyal
30
30
87.5
MAOP*
Transient Surge Pressure
(barg)
(barg)
FPSO riser base
323
315.7
347.3
Schiehallion Central
323
312
343.3
West
323
314
345.4
North
323
316
347.8
Loyal
323
322
354.9
* This is equivalent to the maximum allowable operating pressure @ LAT of 276 barg.
28 degC
60 degC
63 degC
Shutdown
Normal Shutdown:
Process Shutdown:
Start-up
The normal well start up sequence is:
7.
FAULT FINDING
7.1
7.2
Surge in the higher speed range could be indicated by a loud roar and/or
popping noises plus engine failure to accelerate to rated speed.
If surge occurs, shut down the engine immediately to prevent the rapid buildup of
damaging temperatures. After the engine has coasted to a stop, attempt to
restart as usual. If a surge occurs a second time, contact Solar Turbines
Customer Service.
Explosive Atmosphere
Dangerously explosive accumulations of natural gas, fuel fumes, oil tank vent
leakage, or solvent fumes must be avoided at all times. This is achieved by
proper ventilation, elimination of leaks, and by confining the use of solvents to
appropriate maintenance facilities
7.4
HV-441004
HV-441005
HV-441121
HV-878031
HV-878032
HV-878033
HV-441112
HV-441003
HV-441080
HV-441020
HV-441021
HV-441023
HV-441022
HV-441024
HV-441025
HV-441017
HV-441019
HV-441026
HV-441100
HV-441012
HV-441013
HV-441014
HV-441016
Description
Start-up
Position
Closed and
blanked
Closed and
blanked
Closed and
blanked
Open
Closed and
blanked
Closed
Closed and
blanked
Closed
Closed
Open
LO*
LO*
LC*
LC*
Closed
Closed
Open
Closed
Closed
Closed
Closed and
blanked
Closed and
blanked
Open
Closed
Normal
Operation
Closed and
blanked
Closed and
blanked
Closed and
blanked
Open
Closed and
blanked
Closed
Closed and
blanked
Closed
Closed
Open
LO*
LO*
LC*
LC*
Closed
Closed
Open
Closed
Closed
Closed
Closed and
blanked
Closed and
blanked
Open
LO
Description
PCV-441023 U/S block valve
PCV-441023 D/S block valve
PCV-441023 D/S block valve
PCV-441021 U/S block valve
PCV-441021 D/S block valve
FCV-441027 U/S block valve
FCV-441027 D/S block valve
P-44201A inlet
P-44201A outlet
P-44201B inlet
P-44201B outlet
FI-442025 U/S drain valve
HV-442021
HV-442026
HV-442027
HV-442031
HV-442029
HV-442030
HV-442035
HV-442039
HV-442041
HV-442040
Start-up
Position
Open
Open
Open
Open
Open
Open
Open
CSO
CSO
CSO
CSO
Closed and
blanked
Open
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed
Closed
Open
Open
Open
Open
Normal
Operation
Open
Open
Open
Open
Open
Open
Open
CSO
CSO
CSO
CSO
Closed and
blanked
Open
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed
Closed
Open
Open
Open
Open
Description
Instrument air supply block valve
Air supply to 4-way block valve
Air supply to discharge valve
Air supply to minimum flow valve
Spare air supply valve
Spare air supply valve
Lube oil tank T-45001A drain
HV-450104
HV-450106
Start-up
Position
Open
Open
Open
Open
Closed
Closed
Closed and
blanked
Open
Closed and
blanked
Normal
Operation
Open
Open
Open
Open
Closed
Closed
Closed and
blanked
Open
Closed and
blanked
Valve Tag
Number
HV-450105
HV-450109
Description
X-45001A cooling medium return
X-45001A cooling medium return line drain
HV-450139
HV-450110
HV-450111
HV-450113
HV-450114
HV-450115
HV-450116
HV-450117
HV-450140
HV-450118
HV-450119
HV-450103
HV-450102
HV-450143
HV-450122
HV-450130
HV-450123
HV-450124
HV-450131
HV-450132
HV-450144
HV-450141
HV-450142
HV-450125
HV-450126
HV-450127
HV-450128
HV-450134
HV-450133
HV-450129
Start-up
Position
Open
Closed and
blanked
Closed and
blanked
Open
Open
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed
Open
Closed
Open
Open
Open
Open
Closed
LO
Closed and
blanked
Open
Open
Closed and
blanked
Closed
Closed and
blanked
Closed
Closed and
blanked
Open
Open
Open
Open
Closed
Closed and
blanked
LO
Normal
Operation
Open
Closed and
blanked
Closed and
blanked
Open
Open
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed
Open
Closed
Open
Open
Open
Open
Closed
LO
Closed and
blanked
Open
Open
Closed and
blanked
Closed
Closed and
blanked
Closed
Closed and
blanked
Open
Open
Open
Open
Closed
Closed and
blanked
LO
Description
Instrument air supply block valve
Air supply to 4-way block valve
Air supply to discharge valve
Air supply to minimum flow valve
Spare air supply valve
Spare air supply valve
Lube oil tank T-45001B drain
HV-450204
HV-450206
HV-450205
HV-450209
HV-450239
HV-450210
HV-450211
HV-450213
HV-450214
HV-450215
HV-450216
HV-450217
HV-450240
HV-450218
HV-450219
HV-450203
HV-450202
HV-450243
HV-450222
HV-450230
HV-450223
HV-450224
HV-450231
HV-450232
Start-up
Position
Open
Open
Open
Open
Closed
Closed
Closed and
blanked
Open
Closed and
blanked
Open
Closed and
blanked
Closed and
blanked
Open
Open
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed
Open
Closed
Open
Open
Open
Open
Closed
LO
Closed and
blanked
Open
Open
Closed and
blanked
Closed
Normal
Operation
Open
Open
Open
Open
Closed
Closed
Closed and
blanked
Open
Closed and
blanked
Open
Closed and
blanked
Closed and
blanked
Open
Open
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed
Open
Closed
Open
Open
Open
Open
Closed
LO
Closed and
blanked
Open
Open
Closed and
blanked
Closed
Valve Tag
Number
HV-450244
Description
Discharge line vent
HV-450241
HV-450242
HV-450225
HV-450226
HV-450227
HV-450228
HV-450234
HV-450233
HV-450229
Start-up
Position
Closed and
blanked
Closed
Closed and
blanked
Open
Open
Open
Open
Closed
Closed and
blanked
LO
Normal
Operation
Closed and
blanked
Closed
Closed and
blanked
Open
Open
Open
Open
Closed
Closed and
blanked
LO
Description
Instrument air supply block valve
Air supply to 4-way block valve
Air supply to discharge valve
Air supply to minimum flow valve
Spare air supply valve
Spare air supply valve
Lube oil tank T-45001C drain
HV-450304
HV-450306
HV-450305
HV-450309
HV-450339
HV-450310
HV-450311
HV-450313
HV-450314
HV-450315
HV-450316
HV-450317
HV-450340
Start-up
Position
Open
Open
Open
Open
Closed
Closed
Closed and
blanked
Open
Closed and
blanked
Open
Closed and
blanked
Closed and
blanked
Open
Open
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed
Open
Closed
Normal
Operation
Open
Open
Open
Open
Closed
Closed
Closed and
blanked
Open
Closed and
blanked
Open
Closed and
blanked
Closed and
blanked
Open
Open
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed and
blanked
Closed
Open
Closed
Valve Tag
Number
HV-450318
HV-450319
HV-450303
HV-450302
HV-450343
HV-450322
HV-450330
Description
PIT-450334 (lube oil supply) block valve
PT-450335 (lube oil supply) block valve
PIT-450317 (NDE seal pressure) block valve
PIT-450316 (DE seal pressure) block valve
Balance return line drain
Water inlet block valve
Water inlet drain valve
HV-450323
HV-450324
HV-450331
HV-450332
HV-450344
HV-450341
HV-450342
HV-450325
HV-450326
HV-450327
HV-450328
HV-450334
HV-450333
HV-450329
Start-up
Position
Open
Open
Open
Open
Closed
LO
Closed and
blanked
Open
Open
Closed and
blanked
Closed
Closed and
blanked
Closed
Closed and
blanked
Open
Open
Open
Open
Closed
Closed and
blanked
LO
Normal
Operation
Open
Open
Open
Open
Closed
LO
Closed and
blanked
Open
Open
Closed and
blanked
Closed
Closed and
blanked
Closed
Closed and
blanked
Open
Open
Open
Open
Closed
Closed and
blanked
LO
Description
Injection water to V-43001 drain valve
HV-450002
HV-450003
HV-450005
HV-450012
HV-450007
HV-450006
HV-450013
HV-450014
HV-450008
HV-450009
HV-450010
Start-up
Position
Closed and
blanked
Closed
Open
Closed
Open
Closed &
blanked
Open
Closed and
blanked
Open
Closed and
blanked
Open
Closed and
blanked
Normal
Shutdown
Closed and
blanked
Closed
Open
Closed
Open
Closed and
blanked
Open
Closed and
blanked
Open
Closed and
blanked
Open
Closed and
blanked
Closed
Open
Closed
Closed
Closed
Closed
Set at a value of 2.3
(i.e. 23% or 1.7 turns)
Closed
Open
Closed
Closed
Closed
Closed
Set at a value of 2.3
(i.e. 23% or 1.7 turns)
Open
Open
Closed
Closed
REPORT NO:
S/UTG/ /02
BP Exploration - Schiehallion
PRINCIPAL RECIPIENT:
COMMISSIONED BY:
ISSUING DEPARTMENT/DIVISIONS: UTG
PREPARED BY:
______________
Chris Savvides
________________
Vincent Tam
SUMMARY
This report describes the results of the study for the dispersion of hot exhaust gas from the
proposed Water Injection 4th Gas Turbine, on the Schiehallion FPSO. The study consisted of the
following:
Assessment of the turbine exhaust temperature distribution on helicopter and crane operations for
two turbine locations and various exhaust orientations
Quantify the temperature and air quality (Nitrogen dioxide - NO 2 and Carbon Monoxide CO, see
Footnotes
) concentrations for the chosen exhaust location and configuration and assess
1 & 2
impact on Helideck, crane and personnel at different locations on the FPSO where they could be
normally present.
The results showed that with the current Gas Turbine location, forward of the Crane pedestal at
frame 40, with the exhaust discharging at an elevation of 55m and pointing forward, there should
be minimal impact on the Helideck, Crane operations or to air quality.
INTRODUCTION
The Schiehallion FPSO has been operating off the west of Shetland since 1998. Due to the
requirement of water injection, a 4th Gas Turbine will need to be installed to provide the extra
power.
As part of safety requirements, the hot plume characteristics from a gas turbine need to be
assessed and quantify so as not impair Helideck, crane or other operations. There is also a
requirement to demonstrate that the air quality meets UK regulations. This report summarises
the findings of the computational study to find the best location and orientation of the 4 th Turbine
Exhaust so that the effects of the hot exhaust plume would have a MINIMUM impact on the
Helideck, crane operations and at other manned areas.
The fluid flow software FLACS has been used for the plume dispersion calculations. BP has
extensively used FLACS for a lot of projects involving dispersion and gas accumulation
calculations. It has been validated for a number of large-scale experimental data.
Sulphur Dioxide is not considered because Sulphur is not present in the Schiehallion fuel gas
supply.
1
Particulate matter is not considered, as the level present in the Taurus 70 exhaust gas is very
low (to be quantified by Solar).
2
Objectives
The main objectives of this analysis were to:
Assess the impact of the exhaust plume of the proposed 4th Gas Turbine on Helideck and
Crane operations. Identify the location and orientation of the turbine exhaust that would
have minimum impact on Schiehallion operations
Quantify the availability of the Helideck and Crane based on the wind conditions and
temperatures distribution and also assesses the effect of the exhaust gases on the
manned areas for the different locations and exhaust orientations. For Helideck
operations, it is a requirement that the isothermal line at 20m directly above the Helideck
is less than +2 degrees above the ambient temperature (Footnote 3)
Quantify the air quality (NO 2 and CO) levels in manned areas for the final Gas Turbine
location.
The Civil Aviation Authority (CAA) paper 99004 Section 4.1.4 includes a sentence stating CAP
437 requires that notification to operators be given if temperatures in excess of 2 C above
ambient are liable to exist above the Helideck. Section 4.2.3 also states Minimisation of the
impact of hot exhausts (see Section 4.1.4) has generally been regarded as keeping the Helideck
free of excess temperature, at least to a reasonable height (say greater than 20m above deck
level). Ideally, in conjunction with flight operations planning, approach and take-off flight paths
should also be considered.
3
The following Turbine Data [3] has been used in the simulations:
Load Case
Turbine Load
1
2
Exhaust Flow
Rate kg/s
100% at 5 C
100% at 23o C
o
27.7
24.9
Exhaust Gas
Temperature,
NO2
o
C
488
506
CO
Concentration
Concentration
mg/m
74.03
72.78
mg/m 3
53.65
52.69
The NO2 exhaust analysis figures relate to Solonox Combustion. For this analysis it is assumed
that all oxides of nitrogen are considered to be nitrogen dioxide (NO 2). This is a worst case
assumption, which in practice means that calculated NO 2 levels would be slightly higher than
actual levels. This will (together with other factors discussed later in this document) provide
assurance that air quality will meet regulatory requirements.
4
Wind Conditions
For the preliminary investigations to evaluate the location and orientation of the turbine exhaust,
only winds at 6 m/s from Forward and Starboard (0-45 degrees) were considered as these would
have a direct impact on the Helideck operability, which was the primary reason for this
evaluation. For the final assessment, results were obtained for all wind directions at 6 and 12 m/s
so that the impact of the exhaust temperatures and NO 2 levels on the Crane boom, Crane cabin
and other manned areas is assessed. Table 2 lists all the weather conditions and the probability
of occurrence for the Schiehallion FPSO [4].
2.5 - 7.5
7.5 - 12.5
12.5 - 17.5
>17.5
% Probability
10-30
1.18%
8.26%
10.27%
7.56%
1.30%
28.6%
40-60
0.83%
5.90%
5.67%
1.18%
0.35%
13.9%
70-90
1.18%
2.13%
1.42%
0.24%
0.00%
5.0%
100-120
0.59%
2.24%
0.47%
0.12%
0.00%
3.4%
130-150
0.35%
0.83%
0.12%
0.00%
0.00%
1.3%
160-180
0.24%
0.83%
0.35%
0.00%
0.00%
1.4%
190-210
0.00%
1.65%
0.12%
0.00%
0.00%
1.8%
220-240
0.00%
0.35%
0.00%
0.00%
0.00%
0.4%
250-270
0.71%
1.89%
0.71%
0.00%
0.00%
3.3%
280-300
0.71%
2.60%
1.42%
0.24%
0.00%
5.0%
310-330
0.83%
3.90%
4.13%
1.42%
0.12%
10.4%
340-360
1.18%
8.97%
9.45%
5.55%
0.47%
25.6%
% Probability
7.8%
39.6%
34.1%
16.3%
2.2%
100.0%
Assessment Standards
For Helideck operations, it is a requirement that the isothermal line at 18m directly above the
Helideck is less than +2 degrees above the ambient temperature
The temperature of the Crane boom (wire rope & lubricant, warning lights, load sensors)
should not exceed 85o C [5]
The UK air quality regulations objectives (NO 2 and CO only) are defined in the Environment
Agency (EA) Guidance Notes [6] and are shown in Table 3 below:
Pollutant
Reference period
Limit Value
NO2
NO2
CO
Hourly mean
Annual mean
8 hour mean
200 g/m 3
40 g/m 3
11.6 mg/m 3
PRELIMINARY INVESTIGATIONS
Initially the 4th Gas Turbine was to be located on the lay-down area, Pallet 8 (Frame 35), just
forward of the Blast Wall. The distance of the discharging exhaust to the centre of the Helideck
would have been approximately 40 metres. The elevation of the exhaust was restricted to 47m,
as a higher exhaust would have interfered with Crane operations.
Preliminary investigations, examining different orientations of the exhaust, have shown that due
to its proximity to the Helideck and also the restriction on the elevation of the discharge, the
temperatures above the Helideck (hovering height) would be greater than +2 degrees C, which
would restrict safe helicopter operations for winds from the Forward to 20 degrees Starboard.
From the wind frequency table 2, this would have made the Helideck unavailable for almost 30%
of the time.
This factor was one of a number of reasons why the Pallet 8 location was changed to the Pallet 7
location.
E=115m
N=375m
Elevation=55m
Orientation
Diameter
900mm
For this location and orientation a full set of results is presented for the 2 cases listed in Table 1.
All wind directions and wind speeds of 0, 6 and 12 are presented. These represent about 85% of
all weather conditions. The other 15% are for higher wind speeds. One result for a 20 m/s wind
from the Forward direction gave similar results to the 12 m/s case.
Simulation
Number
Wind
Direction
Wind
relative to
Speed m/s
FPSO heading
060000
HELIDECK
NO2
Temp
Deg C
CRANE
BOOM
Crane
Cabin
Temp
Deg C
Living
Quarters
Process
Deck
NO2 Concentration
No Wind
060600
FWD
40
061200
062000
FWD
FWD
12
20
100
120
360600
BWD
260605
261205
260610
261210
260622
261222
260645
261245
260667
261267
260690
261290
260613
160622
161222
160645
161245
160667
161267
160680
161280
160690
161290
160600
161200
161213
STB 5
STB 5
STB 10
STB 10
STB 22.5
STB 22.5
STB 45
STB 45
STB 67.5
STB 67.5
STB 90
STB 90
STB 135
PORT 22.5
PORT 22.5
PORT 45
PORT 45
PORT 67.5
PORT 67.5
PORT 80
PORT 80
PORT 90
PORT 90
PORT 100
PORT 100
PORT 135
6
12
6
12
6
12
6
12
6
12
6
12
6
6
12
6
12
6
12
6
12
6
12
6
12
6
+5
+5
+3
Fwd crane
40
80
40
60
120
160
240
Fwd crane
80
120
60
120
300
Turret
80
+3
+15
+15
+5
+5
+8
+10
+17
40
Table 4: Load Case 1 - Temperature and NO 2 Concentrations on the Helideck, Crane and
other areas
Wind
Direction
Wind
relative to
Speed m/s
FPSO heading
070000
HELIDECK
NO2
Temp
Deg C
CRANE
BOOM
Crane Cabin
Temp
Deg C
Living
Quarters
Process
Deck
NO2 Concentration
No Wind
070600
FWD
40
071200
270605
271205
270610
271210
270622
271222
270645
271245
270667
271267
270690
271290
170622
171222
170645
171245
170667
171267
170690
171290
FWD
STB 5
STB 5
STB 10
STB 10
STB 22.5
STB 22.5
STB 45
STB 45
STB 67.5
STB 67.5
STB 90
STB 90
PORT 22.5
PORT 22.5
PORT 45
PORT 45
PORT 67.5
PORT 67.5
PORT 90
PORT 90
12
6
12
6
12
6
12
6
12
6
12
6
12
6
12
6
12
6
12
6
12
100
40
80
+5
40
60
120
80
80
+4
+15
+15
+5
Table 5: Load Case 2 - Temperature and NO 2 Concentrations on the Helideck, Crane and
other areas
60
As can be seen from the table, all the results are nearly identical to the previous load case.
Conclusions are similar to the load case 1.
NO2
Contaminant
level at exhaust
gas outlet
74,031g/m 3
74,031g/m 3
CO
53,650 g/m 3
53,650 g/m 3
40 g/m 3
Long-term EAL (Annual mean)
200 g/m 3
Short-term EAL (Hourly mean)
350 g/m 3
Long-term EAL (Annual mean)
10,000 g/m 3
Short-term EAL (Hourly mean)
1851
370
5.365
153.3
Limit Description
NO2
5,700 g/m 3
CO
35,000 g/m 3
40 g/m 3
350 g/m 3
Long Term
3
4
Annual Mean
142.5
9,600 g/m 3
Annual Mean
100.0
232,000 g/m 3
200 g/m 3
10,000 g/m 3
Hourly Mean
48.0
Annual Mean
23.2
The reasons for the differences between EALs and the OELs limits is explained in a section titled
Derivation of Environmental Assessment levels for Air in Appendix D of the Environment
Agency Guidance Note H1 [6]. A copy of this section is included in Appendix 1 of this document.
This shows how a factor of safety is applied between the HSE defined OEL or maximum
exposure limit (MEL) if there is a specific concern about the pollutant (e.g. a carcinogen) and the
environmental assessment level (EAL). The long and short term EALs for NO 2 were based upon
the Expert Panel on Air Quality Standards (EPAQS) guideline values. Also, the short term EAL
for CO was based upon the EC Daughter Directive 99/30/EC. However, for these exceptions the
philosophy of a large safety factor between OELs or MELs and EALs still applies.
An exhaust emissions study has already been carried out on the Schiehallion FPSO in May 2000
by Lindsay Ross (BP Occupational Health). This compared site readings with HSE OELs, rather
than Environment Agency EALs objectives. The measurement instrument used by Lindsay to
measure NO2 levels during this survey was not capable of reading NO 2 levels less than 0.5 ppm
(1900 g/m 3). It is not possible, therefore, to determine a precise impact of the exhaust from the
two LM6000 gas turbines at different locations on the FPSO. Only one reading taken by Lindsay
exceeded the 0.5 ppm measurement threshold value during his survey, but that reading was
taken directly at the point of emission from a fire pump diesel engine. The main conclusion of
the survey was that all emission measurements were very low and well within the respective
OELs with the majority being below the limit of detection of the equipment used.
Use of the EA EAL values rather than HSE OELs does provide a level of assurance that air
quality on the Schiehallion FPSO will be much better than required to meet occupational health
requirements. The EA Guidance Note H1 [6] describes how operators can show that their
proposals represent the Best Available Techniques (BAT) to prevent and minimise pollution from
an installation. Use of the modelling approach for the 4 th WI pumps GT exhaust can be
demonstrated to meet this requirement. There are arguments for and against use of safety
factors implicit in the use of EALs, as follows:
The proposed location of the 4th Gas Turbine, forward of the Crane
pedestal at frame 40, with the exhaust discharging at an elevation of 55m and
pointing forward at an angle of 10 degrees above horizontal, should have
minimal impact on either the Helideck or Crane operations
There should be no additional explosion hazard, provided the gas from the
fuel line is dispersed above the process deck
The air quality will remain within acceptable health guidelines (see
following discussion).
REFERENCES
A suite of EALs derived in this consistent manner is not currently available, therefore,
interim values based on published information have been adopted. The list below
shows the sources from which information has been obtained. For consistency, risk
based values proposed by the World Health Organisation or given in the IRIS database
have been excluded.
Currently some 460 substances or groups of substances are authorised by the
Regulators for release to the environment and many of these may be released to air.
However, established environmental criteria (other than a limited number of EQSs) are
available for only a small fraction of this number. For example, in the case of releases
to air, EPAQS have produced guideline values for only six substances (Ozone,
Benzene, Carbon Monoxide, Sulphur Dioxide, Particles and 1,3 Butadiene, nitrogen
dioxide, PAHs and lead) and the WHO Air Quality Guidelines contain values for 27
substances.
Information sources :
Ideally, EALs for those substances where there are no existing criteria would be derived
direct from toxicological data on the effects of the pollutant on a particular receptor.
However, an assessment of this type would be a very substantial undertaking which
could only be considered over an extended timescale. One approach to overcoming
this problem is to make use of occupational exposure limits which provide an
assessment for a specific receptor (i.e. adult human workforce) of the toxicological
effects of a pollutant. These values might then be progressively revised as further
information and resources allow. Indeed a similar approach to this was followed by the
then Factory Inspectorate in 1968 when a large number of occupational standards were
adopted from the American Conference of Governmental Industrial Hygienists (HMSO
1968) which has since been progressively revised by the Health and Safety Executive
on the basis of new information and UK experience.