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MYCELX-CHE

SYSTEM INITIAL START-

UP PROCEDURES FOR
JONES CREEK 40,000BPD
PWT PACKAGE

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SYSTEM INITIAL START-UP PROCEDURES

Initial Start-up Procedure Part 1: Only has one 3Phase Separator (V-105) Online

This procedure is intended to enable field personnel to cold start-up the MYCELX system and verify
that the automated controls are functioning properly for operation with only one 3PH separator (V-
105) online.

Before conducting part one of the system start-up, ensure all of the following preparations have
completed:

- All mechanical assembly and installation of the MYCELX treatment system (i.e. equipment,
piping, support structures and instrumentation assembly, layout completion, hydrotest,
pneumatic equipment function test, pump test, etc)
- All electrical assembly and installation of the MYCELX treatment system (i.e. cable runs, panel
wiring terminations, pumping equipment and instrumentation wiring, power testing,
instrumentation configuration and function test, etc)
- Verify upstream and downstream process equipment and tanks have all been tested and ready
for operation.
- Verify that the upstream 3PH separator (V-105) is currently fully flooded and sending all fluids
to the oil pipeline or other viable method.
- Verify that at least one REGEN vessel is ready for operation.
NOTE: REGEN vessel with new media has to let the media soak in water inside the vessel and
then be backwashed to remove the fines before they are ready for operation. Clean water in
T-107 is required for this.
- Ensure that there is a viable method in place for handling the treated water.
- Ensure there is a viable plan for continuing plant operations in the event the MYCELX water
treatment system needs to be shutdown.

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It is recommended that a minimum of 3 persons are involved in performing this procedure (field
operator, system controls engineer/technician that has extensive knowledge of the automated
controls programmed for this system, and plant control room operator) and that they have two-
way radios to communicate with one another to coordinate the start-up of the system.
Use extreme caution and follow all job site safety regulations and requirements while performing
this procedure.

1. Approach the location of the filter vessels /skids using pre-defined safe entry points/paths.
2. Have field personnel walk through the entire system with P&ID drawings and familiarise
themselves with the equipment.
2a. Identify vessels, valves and any local indicating instruments such as pressure gauges,
level transmitters, differential pressure gauges and flow transmitters.
3. Walk the perimeter of the location and observe the equipment and surrounding
ground/deck, etc for evidence of a leak in the equipment.
4. Ensure both (V-105 & V-205) 3PH separator vessels water leg valves (LCV-105 & LCV-205)
are in CLOSED positions.
4a. Access the HMI to put the LCV-105 and LCV-205 valves into MANUAL CLOSE positions if
not done already.
5. Walk down system to check that all manual valves downstream of LCV-105 and LCV-205
(i.e. isolation, drain, vent, and choke valves) are in their assigned positions to allow for
proper flow throughout the system. If a valve is out of position, change it to be correct,
note the current position and difference and immediately report to site supervisor of start-
up to verify that the valve position is correct.
6. Observe local indicating pressure gauges/transmitters to verify that they are undamaged
and installed properly. A change from the norm shall be reported to site supervisor.
7. Access the HMI to verify that all the system automated settings are correct.
7a. Verify REGEN backwash settings are setup correctly.
7b. Verify Decant tank transmitter settings are setup correctly.

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7c. Verify all alarm set points are setup correctly.

7d. Verify all 3PH level controls are setup correctly.
7e. Verify user account and date/time settings are setup correctly.
8. Access the HMI to put vessels online, process pumps in MANUAL + OFF, other pumps in
AUTO, Polisher Outlet Control Valve CV-610 in MANUAL + OPEN 100% and other control
valves in AUTO.
8a. Press online button for the V-105 3PH separator that is ready for service (V-105).
NOTE: Make sure the LCV-105 valve stays closed.
8b. Press online button for Coalescer vessels that are ready for service (VE-310 & VE-320).
8c. Press AUTO button for Coalescer oil pumps that are ready for service (PD-310 & PD-
311).
8d. Access REGEN vessels settings and press AUTO button for specific vessel(s) that is ready
for operation. NOTE: This will put REGEN vessels control valves into AUTO mode.
8e. Press MANUAL + OFF buttons for VFD process pumps that are ready for service (P-510,
511 & 512).
8f. Press AUTO button for water recycle pumps that are ready for service (P-530 & P-531).
8g. Press AUTO button for oil recycle pumps that are ready for service (P-320 & P-321).
8h. Press AUTO button for backwash pumps that are ready for service (P-520 & P-521).
8i. Press AUTO button for Polisher Outlet Control Valve CV-610.
9. Verify that there is a viable amount of water in the online 3PH separator (V-105) to be
sent to the MYCELX system and that the 3PH separator is pressurised adequately to send
water over to MYCELX system.
10. Start flowing water through the system by opening the online 3PH separator vessel’s water
leg valve (LCV-105).
10a. Access the HMI to put the LCV-105 valve into AUTO position
NOTE: If any critical problems occur and the system is not operating correctly,
shutdown the system by pressing the ESD button on the MYCELX control panel.

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11. Bump check all vents valves and observe for liquid or gas flow from the purge line (be sure
the purge line is safely routed to ground containment or other acceptable location for local
HSE guidelines).
12. Verify the flowrate through thesystem via FIT-610 and begin filling the clean water tank T-
107.
13. Adjust the control valve CV-610 to maintain the minimum flow rate ( 4,000 bbl/day).
14. Monitor the oil-water interface in the 3PH separator and avoid sending any oil to the
MYCELX system. Shutdown system to avoid sending oil layer to MYCELX system if needed.
15. Once the clean water tank T-107 is sufficiently filled, initiate a 15 minutes backwash cycle
via the HMI through a REGEN vessel with new media to remove the media fines.
16. Repeat as needed to remove all the media fines of all the Regen vessels with new media.
NOTE: In order to perform all the REGEN backwash cycles, T-107 will need to be filled over
and over again with treated process water.
17. After the media fines have been removed put the REGEN unit ONLINE via the HMI.
18. Setup the FIC-610 flow control loop so that the system can be setup to automatically
maintain a specific flow rate.
18a. Access the HMI 3PH level control settings-“Level into Flow” screen.
18b. Press the “A” button for FIC-610 controller.
18c. Tap on the grey input box for the SP input of the FIC-610 controller and enter in
desired flow rate. NOTE: For initial start-up it is recommended to operate the system
at the minimum design flow rate of 4,000bbl/day.
18d. Put CV-610 and process pumps P-510, 511, 512 in AUTO.
NOTE: The FIC 610 control loop will adjust the CV-610 and process pump
automatically to maintain the desired flowrate effectively, then the flow control loop
will need to be tuned by a controls specialist via the Flow Control Parameters Pop up
Screen
19. Continuously monitor the system run and stop as needed to avoid sending the oil layer in
the 3PH separator over to the MYCELX system.

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20. Target a desirable oil-water interface level in the 3PH separator by increasing or decreasing
the flow rate of the system via FIC-610 SP adjustments.
21. Set up the cascade control loop so that the LIC-305 level control loop influences the set
point of the FIC-610 control loop and so that the system can be set up to maintain a
specific oil-water interface in the 3PH separator by adjusting the flowrate.
21a. Access the HMI 3PH level control settings- ‘’level into flow’’ screen.
21b. Press the ‘A’ button for the LIC-305 level controller to be put into Auto Mode.
21c. Have the DCS operator in plant control room input the desired oil-water interface set
point.
21d. Press ‘C’ button for the FIC-610 controller. The control loops will now effect one
another and are operating as cascade control loop.
21e. CV-610 and process pumps P-510, P-511 and P-512 need to be in AUTO.
NOTE: If the cascading control loops are unable to reliably maintain the oil-water interface
level of the 3PH separator effectively, then the LIC-305 control loop will need to be tuned
by a controls specialist via the flow control parameters Pop up screen
22. Have field operator walk down the system to check for leaks and to inspect all the
instrumentation and rotating equipment to verify its working as expected.
23. Take water samples throughout the system. Take photos of the water samples and
perform any onsite analysis that is available.

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Initial Start-up Procedure Part TWO: Bringing 2ND 3PH Separator (V-205) Online

This procedure is intended to enable field personnel to cold start-up the MYCELX system and verify
that the automated controls are functioning properly for operation with both 3PH separators (V-105
& V-205) online.

Before conducting Part 2 of the system start-up, ensure all of the following preparations have
completed:

- Complete Part 1 of the system start-up and have the system operating safely with one 3PH
separator online already.
- Verify that the second upstream 3 Phase Separator (V-205) is currently fully flooded and
sending fluids to the oil pipeline or other viable method.
- Verify that all MYCELX equipment are ready for operation.
- Ensure that there is a viable method in place for handling the treated water.
- Ensure there is a viable plan for continuing plant operations in the event the MYCELX water
treatment system needs to be completely shutdown.

It is recommended that a minimum of 3 persons are involved in performing this procedure (field
operator, system controls engineer/technician that has extensive knowledge of the automated
controls programmed for this system, and plant control room operator) and that they have 2-way
radios to communicate with one another to coordinate the start-up of the system.
Use extreme caution and follow all job site safety regulations and requirements while performing
this procedure.

1. Approach the location of the filter vessels /skids using pre-defined safe entry points/paths.
2. Have field personnel walk through the entire system with P&ID drawings and familiarise
themselves with the equipment.

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2a. Identify vessels, valves and any local indicating instruments such as pressure gauges,
level transmitters, differential pressure gauges and flow transmitters.
3. Walk the perimeter of the location and observe the equipment and surrounding
ground/deck, etc for evidence of a leak in the equipment.
4. Ensure the system is effectively operating already with only one (V-105) 3PH separator
vessel online and verify that the new 3PH Separator vessel’s (V-205) water leg valve (LCV-
205) is in CLOSED position.
4a. Access the HMI to put the LCV-205 valve into MANUAL CLOSE positions if not done
already.
5. Walk down system to check that all manual valves downstream of LCV-105 and LCV-205
(i.e. isolation, drain, vent, and choke valves) are in their assigned positions to allow for
proper flow throughout the system. If a valve is out of position, change it to be correct,
note the current position and difference and immediately report to site supervisor of start-
up to verify that the valve position is correct.
6. Observe local indicating pressure gauges/transmitters to verify that they are undamaged
and installed properly. A change from the norm shall be reported to site supervisor.
7. Access the HMI to verify that all the system automated settings are correct.
7a. Verify all alarm set points are setup correctly.
7d. Verify new 3PH level controls are setup correctly.
8. Verify that there is a viable amount of water in the new online 3PH Separator (V-205) to be
sent to the MYCELX system and that the 3PH Separator is pressurised adequately to send
water over to MYCELX system.
9. Start flowing water through the system by opening the new 3PH Separator (V-205) water
leg valve (LCV-205).
9a. Access the HMI 3PH level control settings – “Level Difference” screen.
9b. Put the LCV-105 valve into MANUAL OPEN 100% position.
NOTE: If any critical problems occur and the system is not operating correctly, shutdown
the system by pressing the ESD button on the MYCELX control panel.

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10. Switch V-205 separator’s water leg (LCV-205) to MANUAL OPEN 100% position as well.
10a. Access the HMI to put the LCV-205 valve into MANUAL OPEN 100% position.
11. Manually adjust both LCV-105 & LCV-205 as required to balance the water flow pulled
from each 3PH Separator. The goal is to get the water levels in both 3PH Separators to be
both stabilized near their set points.
12. Press online button for the new (V-205) 3PH Separator that is to be brought into service.
NOTE: The LIT-205 reading and DCS operator water level set point for V-205 will now be
utilised in conjunction with the signals from V-105 to determine process pump speeds, CV-
610 position, and LCV-105 & LCV-205 positions (when in AUTO).
13. Keep LCV-105 and LCV-205 in manual and adjust their positions as needed to equilibrate
both Separator water levels and observe how the pumps and CV-610 valve are adjusted
automatically. If they are not adjusting properly then the Controls Specialist will need to
troubleshoot and possibly retune these loops.
14. Continue to have field operator walk down the system to check for leaks and to inspect all
the instrumentation and rotating equipment to verify it working as expected.
15. Press “A” button next to both LCV-105 & LCV-205 to put them into auto and observe which
positions they stabilise to. If the system becomes unstable return back to manual control
of these valves and stabilise the separator levels manually. Be prepared to perform an ESD
if critical error or issue arises.
16. If needed, have the trained controls specialist re-tune the LDIC 305 control loop by
pressing the LDIC 305 bubble icon on the Level Difference screen to open the Level control
parameters screen.
NOTE: The trained controls specialist may be able to access the PLC programming to adjust
additional settings for the actual LCV valve function graphs.
17. Once the system is stabilised, it is recommended to watch the system closely and perform
system inspections every shift.
18. Take photos of the water samples and perform any onsite analysis that is available.