Qaal

UPPER ZAKUM POM: 8
SOUTH SATELLITE PLATFORM Chapter: 4

PLANT OPERATING MANUAL Section: 1
PROCESS SHUTDOWN AND START-UP Revision: 0
CONTENTS
1 EMERGENCY SHUTDOWN PROCEDURES .......................................3

1.1 Introduction ...............................................................................3
1.2 Emergency Response...............................................................4
2 BLACK START .....................................................................................6
2.1 Introduction ...............................................................................6
2.2 Black Start Reset.......................................................................7
2.3 Emergency Diesel Generator 222-GD-001 ............................18
2.4 Instrument Air System............................................................20
2.5 Reinstatement of 22kV Supply...............................................22
3 LEVEL 1 SHUTDOWN AND START-UP ............................................24
3.1 Shutdown.................................................................................24
4 LEVEL 2 SHUTDOWN AND START-UP ............................................29
4.1 Shutdown.................................................................................29
4.2 Start-up ....................................................................................31
5 LEVEL 3 SHUTDOWN ........................................................................34
5.1 Shutdown.................................................................................34
5.2 Start-up ....................................................................................35
6 LEVEL 4 SHUTDOWN AND RESTART .............................................36
6.1 Shutdown.................................................................................36
6.2 Start-up ....................................................................................37
7 PLANNED SHUTDOWN .....................................................................42
7.1 Introduction .............................................................................42
7.2 Process Shutdown..................................................................43
7.3 SSP Process Bypass ..............................................................44
7.4 Separator Shutdown ...............................................................47
7.5 Planned Shutdown by System ...............................................56
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8 START-UP FROM LEVEL 1 SHUTDOWN .........................................57

8.1 Introduction .............................................................................57
8.2 Fuel Gas System .....................................................................58
8.3 Flare System............................................................................58
8.4 Drain System ...........................................................................59
8.5 Production Separator .............................................................60
8.6 Oil Booster Pumps..................................................................63
8.7 Crude Oil Transfer Pumps......................................................65
8.8 Oil Trunkline ............................................................................66
8.9 Gas Trunkline ..........................................................................66
8.10 Water Injection System...........................................................67
Tables
4.1.1 – Purge Times.......................................................................................23
4.1.2 – Level 2 Shutdown from Fire and Gas Initiation...................................31
4.1.3 – 222-LSHHH-1 Trip Reset ...................................................................40
4.1.4 – 222-LSLLL-5 Trip Reset .....................................................................40
4.1.5 – 222-PSL-105/PSH-106 Trip Reset .....................................................41
4.1.6 – 222-PSL-153 Trip Reset.....................................................................42

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1 EMERGENCY SHUTDOWN PROCEDURES
1.1 INTRODUCTION
An Emergency Shutdown (ESD) is a rapid response to protect personnel,

plant and equipment from injury or damage resulting from a major release
to atmosphere of hydrocarbon gas or liquid caused by process plant or
equipment failure or a fire.
With the potential for fire and explosion, the shutdown logic ensures that plant
and equipment shuts down in a safe manner and all safety conditions must
be met before it can be reset and restarted. For an overall view and
understanding of the Shutdown Philosophy refer to the following illustrations:
SSP-04-01-001 South Satellite Level 1 Total Emergency Platform

Shutdown Depressurised
SSP-04-01-002 South Satellite Fire & Gas Protection System
Note: For further details of specific fire and gas input signals and output
actions associated with the shutdown system refer to Chapter 5.
The ESD logic on the South Satellite Platform (SSP) is divided into four levels
to reflect the level of risk to the entire platform. They range from a total
platform shutdown and power failure to relatively minor, equipment specific
process stops. The different levels of shutdown are detailed below:
• Level 1 – Total Emergency Platform Shutdown Depressurised
• Level 2 – Total Process Shutdown Pressurised
• Level 3 – Shutdown Process Sections Pressurised
• Level 4 – Equipment Safety Trips

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On SSP (and NSP) there is only one depressurised Level 1 Shutdown and is
initiated by the following:
• Certain Zone Fire and Gas Input Signals
• Other input Signals, eg Pushbuttons, FCC Commands, LCR

Pushbuttons and PLC-1 and 2
In the event of a Level 1 Shutdown the only equipment, which remains live,
is the diesel firewater pump.
1.2 EMERGENCY RESPONSE
Emergency actions to incident and accident will vary from case to case. For all
anticipated types of incidents or Emergencies, ZADCO has Emergency
Response Procedures, which are designed to effectively manage a given
scenario so as to provide maximum protection and safety to personnel,
equipment and the environment.
The Upper Zakum Field Complex, including SSP is controlled and monitored
from Field Control Centre (FCC).
For details of the ZADCO Emergency Response Plan refer to the ZADCO
HSE Procedures Web Site:
http://www.zadco.com/hsee/HSE%20Procedures/New%20Procedures/
ERC-HSE%2003%2001%20FINAL%20May%2018.doc
Specific actions for on site personnel in the event of an emergency situation

arising are as detailed below.
On-scene Commander (Senior Operator on site) shall:
• Obtain initial assessment information and request assistance, prior to

proceeding to the emergency scene
• Make the necessary PA announcement indicating specific area of

emergency
• Inform FCC
• Proceed to the emergency scene and start taking corrective actions
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• Request assistance from trades personnel as required
• Assess situation and take necessary actions ie ESD, depressurisation

etc
• Maintain contact with the Emergency Control Centre (ECC) at all times
• Co-ordinate any fire fighting action with the Fire and Safety Technician
• Confirm POB, initiate search and rescue when required
• If abandonment is necessary, proceed to muster point and prepare all

personnel for abandonment
The on site Duty Operator shall:
• Proceed to the scene of the emergency and take actions as instructed

by SSP Senior Operator
• If abandonment is necessary, proceed to muster point
The Fire and Safety Technician and Muster Checker shall respond as per
their Emergency Team designated duties.

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2 BLACK START
2.1 INTRODUCTION
A coincident 60% gas detection inside any of the Modules as detailed in the
following list will cause all electrical supplies to be isolated and a Level 1
De-pressurised shutdown through fire and gas output signal XX-583 into the
ESD system. This situation can be considered as a Black Start condition.
The power supply to the fire and gas panel is also isolated under these
conditions. The power supply is isolated after a time delay of approximately
65 seconds. Only the diesel fire water pump remains running.
• Control Room
• Module 10 Battery Room
• Module 9 Emergency Diesel Generator Room (Air Intake and Room)
• Module 9 Essential Services Switch Room (Air Intake and Room)
• Module 9 Battery Room
Refer to the following illustration for specific details of the gas detection input
devices and output actions, which cause a Black Start condition.

For further details of the various inputs and outputs associated with the fire
and gas system refer to Chapter 5.
The Black Start procedure is a sequence of manual operations to ensure each

module is purged, ventilated and pressurised with air before reinstatement of
power to the relevant area.
Before restarting any plant or equipment that has tripped by shutdown action,
the relevant resets are essential.

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2.2 BLACK START RESET
This procedure is structured to give the response team a guideline for

the restart of the SSP after a Level 1 Shutdown, power failure and
depressurisation, otherwise know as a Black Start.
Black Start reset can only be conducted onsite and cannot be done remotely.
The Black Start reset sequence requires a team comprising of a minimum of

the following discipline personnel:
• One Production Supervisor
• One Senior Operator
• One Safety Officer
• One Electrical Supervisor, Senior Authorised Electrical Person (SAEP)
• One HVAC Technician
• One Instrument Technician
• Telesystem Engineer
The team shall be equipped with the relevant safety equipment and shall carry
out a preliminary check of SSP to confirm that the situation, which culminated
in the shutdown, is now clear.
Each room or enclosure shall be gas tested in strict rotation by a minimum of

two personnel, each wearing Breathing Apparatus (BA). Each room shall
have the fire dampers opened and purged as necessary (refer to Table 4.1.1).
So as to establish emergency power, the purging sequence will start with the
Emergency Diesel Generator Room

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The Black Start operating sequence chart shows the main steps that are to be
taken to re-start the platform. For further details refer to:
SSP-04-02-001 South Satellite Black Procedure with Gas Present in

Rooms
SSP-04-02-002 South Satellite HVAC System Black Start Sequences
SSP-04-02-003 South Satellite Black Start Operating Sequence Chart
The Black Start sequence is influenced by safety considerations such as

interlocks which are included in the system to prevent electrical equipment
from being used in an area before it has been purged satisfactorily.
Consequently, the 22kV electricity supply cable from the Central Complex
cannot be energised until after the electrical sub-station has been purged. In
order to provide power to enable this to be done, it is necessary to use the
Emergency Diesel Generator (EDG).
The EDG room must be checked for hydrocarbons and H2S and if necessary
purged prior to attempting to start the EDG.
2.2.1 HVAC Start-up
Refer to illustration:
SSP-04-02-002 South Satellite HVAC System Black Start Sequences
Step Operation Comments

CAUTION: DUE TO THE POSSIBILITY OF THE PRESENCE OF GAS IN
THE EDG ROOM, ESSENTIAL SERVICES AND MODULE 9
BATTERY CHARGER ROOM, BREATHING APPARATUS
(BA) MUST BE WORN BEFORE ENTERING.
1 Lock out Emergency Generator start circuit to prevent the
generator starting before the purge is completed.
2 Carry out gas check in Emergency Generator, Essential
Switchboard, Battery and Charger Rooms.
3 Gas Free/Gas Detected?
If gas is detected, the four rooms should be purged as detailed in
Steps 4 to 8.
If no gas is detected, proceed to Step 7.

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2.2.1 HVAC Start-up (cont’d)

4 Open the following Black Start Purge Dampers by operation of the
‘Group 1’ three way valve.
Fire Dampers: FD-35, 36 and 37 EDG Room.
Fire Dampers: FD-38 and 55 – Void – Plant Room.
Fire Dampers: FD-50, 105 and 106 – Essential Switch Room.
Interconnecting doors to be kept closed.
5 Manually start the Direct Current (DC) powered purge Supply Fans,
SF 3 and SF 4 via PB-206 to commence purge of the above rooms.
PB-206 is located outside the EDG Room.
6 Continue purge until rooms are gas free as indicated with portable
gas detector (recheck every 15 minutes).
Refer to the table 1 in Paragraph 2.5 of this document for an
estimate of the purge time for each room.
7 Switch off all outgoing Circuit Breakers (CB) and ensure all CBs on
48V DC Battery Charger (BC) System; BCO-13 and MCB-8 on
Battery Charger Distribution Board (BCDB) BCDBO-13 are open.
8 Ensure all circuit breakers on 125V DC Battery System BCO-12
and Main Circuit Breaker, MCB 6 on Distribution Board BCDBO-12
are open.
9 On authorisation from Production Supervisor, put 48V DC Battery
Charger, BC-013 into Bypass Mode.
10 On authorisation from Production Supervisor, put 125V DC Battery
Charger, BC-012 into Bypass Mode.
11 Close the Battery Circuit Breaker and the Load Circuit Breaker for
Battery Chargers, BC-013 and BC-012.
12 When the EDG room is confirmed as gas free, Close the 125V DC
circuit breakers for the Essential Services Switchboard. Tripping
and closing supplies-CB13 and CB14 on BCDB-012.
Production/Safety to confirm gas free.

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125V DC is now available for tripping/closing the circuit breaker for the
essential services switchboard.
48V DC is now available for alarm indication on the essential switchboard
and for emergency lighting in Class 1 Div 1 Group 0 requirements.
13 Close the 48V DC Circuit breakers for the following:
Essential switchboard alarm indication.
Shutdown Bypass panel CP-14.
14 Isolate all outgoing circuit breakers on the Essential Switchboard,
SB-011.
15 In the Essential Switchgear Room, put HVAC Black Start Panel,
CP-14 in bypass mode and energise.
16 Open the following dampers from the Black Start Dampers Air
Station by operation of the ‘Group 2’ three way valve:
Fire Damper, FD-32 and 33in Void Plant Room.
Fire Damper FD-34 in EDG Room.
SOD-13, Ventilation Fan SF-1.
SOD-14, Ventilation Fan SF-2.
SOD-15, EDG Room Exhaust.
17 Start the Essential Services Generator.
Generator ready to take up voltage.
After Start-up of the Emergency Diesel Generator the remaining steps of the
Black Start reset procedure may be completed.
18 Start EDG room supply fan SF-1 by PB-196 located at air intake
outside Module 9.
If SF-1 fails to start, manually start Fan SF-2 from PB-201 located
near air intake outside Module 9.

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19 From the Black Start Fire Damper Air Station, manually close the
following ‘Group 1’ dampers:
FD-35: Inlet Air Ducting to Purge Fan, SF-3.
FD-36: Outlet Ducting from Purge Fan, SF-3.
FD-37: EDG Room Exhaust Ducting.
FD-38: Charger Room and Essential Services Room Exhaust
Ducting.
FD-50: Essential Services Switch Room Exhaust Ducting.
FD-55: Essential Services Switch Room Exhaust Ducting.
FD-105: Charger Room Inlet Ducting.
FD-105: Charger Room Exhaust Ducting.
20 Stop the Black Start Purge Fan, SF-3 at Pushbutton PB-205 in the
EDG Room.
21 From the Black Start Fire Damper Air Station, manually open the
‘Group 3’ three way valve to open the following dampers:
FD-2 and 6: HVAC Plant Room.
FD-8, 9 and 18: Outside System-1 Plant Room.
FD-67: Ducting to Galley.
FD-68: Ducting to Inst. and Telemetry Room.
FD-70: Module 9 Void Area.
FD-72: Ducting into Control Room.
FD-77: Ducting out of Control Room.
FD-79: Ducting out of Inst. and Telemetry Room.

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21 FD-71: Ducting out of Washroom.
FD-81: Ducting into Washroom.
FD-82: Ducting in Washroom.
FD-85: Extract for system 1 plant 2 outside Module 9.
FD-104: Ducting into Control Room.
SOD-1: Outlet Ducting, Air Supply Fan, K-0008A.
SOD-3: Outlet Ducting.
MOD-001: Air Outlet Ducting, K-008B-Exhaust.
MOD-002: Air Inlet Ducting, K-008B-Fresh Air.
MOD-003: Close-Circulating Damper.
22 Start system 1 Inertia Filter Fan, EF-1 from PB-156 or open SOD-4
and start EF-2 from PB-161.
PB-156 and PB-161 are located outside Module 9.
23 Carry out gas check in Control Room, Module 10 Charger Room
and plant room.
Breathing Apparatus (BA) MUST be worn before entering.
24 Gas Free/Gas Detected.
25 If gas is detected, the three rooms should be purged as detailed in
Step 22 to 24.
26 Start system 1 plant 1Supply and Extract Fans K-008A/B by
PB-141 and 136 located outside Module 9 to give minimum air
changes as indicated in the Table 4.1.1 of this manual.
27 Continue purge until Control Room, Plant Room and Charger
Room are gas free as indicated by a portable gas detector.

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Carry out the following steps to energise the HVAC panel, Fire and Gas
Panel and to energise the Essential HVAC switchboard.
28 At the Essential Switchboard, Close the breaker for the 48V DC
Battery Charger, BC-010 No 1.
29 At Battery Charger, BC-010 No 2 put the Selector Switch to
Bypass, close the Battery and Rectifier Breakers.
30 Open all outgoing Circuit Breakers inside 48V DC Distribution
Boards BCDB-010A, B and D.
31 At Battery Charger BC-010 No 2, Close the Load Breaker in order
to supply BCDB-010A.
32 From BCDB-010A, close the outgoing Feed Breaker to BCDB-
010B Circuit Breaker No 1.
33 From inside BCDB-010B, close the HVAC Essential Switchboard
Breaker No 22 (48V DC) and close the EDG Control Panel
Breaker, No 29.
34 At the HVAC Control Panel, CP-2, isolate all the incoming and
outgoing circuits.
35 At CP-2 panel, put the Fire and Gas input shutdowns to the HVAC
panel in Bypass mode.
36 At BCDB-010A, close the HVAC Control Panel Breakers No 7
and 8.
37 At BCDB-010D, close the Fire and Gas Panel Breakers No 1 and 2
38 Energise the Fire and Gas and HVAC Panels in the Control Room.
39 Switch electrical supplies from the HVAC Black Start Panel, CP-14
to HVAC Control Panel, CP-2 by turning selector switch at CP-14
to Normal.

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40 Restore power supply to Fire Damper Solenoid valves:
Energise all Fire Damper solenoids via switch on HVAC panel.
Reset red pushbutton on the Shutdown Relay Panel No 1.
Energise the 220V AC ‘GUTOR’ inverter in module 10 Battery
Charger Room.
41 Isolate all outgoing circuits from the HVAC switchboard in the
HVAC Plant Room.
42 From 125V DC BCDB-012, close the HVAC board tripping Circuit
Breakers No 9 and 10, close HVAC switchboard closing supply
CBs No 11 and 12.
Battery Charger Room, Module 9.
43 At the Essential Services Switchboard (Module 9) close the
outgoing 380V Feeder Circuit Breaker to the HVAC Panel Supply.
Incomer No 1 at HVAC Essential Switchboard will automatically
close.
44 Carry out gas check in Void Plant Room, Module 10 Battery Room,
Sewage Treatment Room and Module 3 Workshop.
Breathing Apparatus (BA) MUST be worn before entering
45 If gas is detected, the rooms should be air purged as detailed in
Step 48 to 50.
46 Manually close the following dampers from the Black Start Fire
Damper Air Station by operation of the Group 4 3-way valve:
FD-39/40 in Diesel Fire Pump room.
SOD-28/29 in Diesel Fire Pump room.
Fire Dampers, FD-104 in Control Room.

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47 Manually open the remaining dampers (except Group 6) from the
Black Start Fire Damper Air Station by operation of the Group 5
valve:
Circulating damper Module 10 will remain closed.
SOD-5, 7, 9 and 11 Void Plant Room
SOD-12 Module 10 Battery Room
SOD-26 Module Sewage Treatment
SOD-27 Module 3 Workshop
SOD-20 Air Supply to Electric Pump
SOD-23 Stairwell Exhaust Air Duct
SOD-24 Exhaust Air Duct, Cellar Deck
SOD-25 Exhaust Air Duct, Diesel fire Pump
SOD-19 Outside Module 9
SOD-17 System 2 Air Supply
SOD-22 Electric Fire Pump Return Duct
SOD-31 Supply to Diesel Fire Pump
MOD-011 Exhaust Damper
MOD-012 Fresh Air Damper
48 Manually start the following Extract Fans From Void Plant Room.
EF-4 From Pushbutton PB-171.

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A 30-minute System 1 air purge of all rooms has now commenced.
49 Continue purge until all rooms are gas free as indicated with
portable gas detector.
Breathing Apparatus (BA) MUST be worn before entering.
All automatic gas detectors for air purged rooms should indicate No Gas.
Module 10: Module 9: Module 3:
Control Room EDG Room Workshop
Accommodation area Essential Services Room Air Compressor Room
Store and Dining Area Battery Room Sewage Room
Charger Room Charger Room EFWP
Galley Switch Gear Room DFWP
Washroom HVAC Room Jockey Pump Room
Battery Room
50 Check area around Instrument Air Compressor 222-B-001 with
portable gas detector.
If gas is detected, do not proceed with Instrument Air Package
Start-up.
51 Start Instrument Air Package (Compressor A on Essential Services
Board).
52 Charge HVAC instrument air system for Modules 9 and 10.
53 Energise all remaining fire dampers and reset to OPEN. Purge all
remaining areas of Modules 9 and 10.
Minimum 5 Air changes required.
If gas is detected, Continue with air purge.
If no gas is detected proceed to next step.

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54 Check that all Automatic Gas detectors on the Fire and Gas cubicle
are indicating No gas within Modules 9 and 10.
All areas within Modules 9 and 10 are now purged and gas free.
55 Switch fire and gas input bypass switches on 223-CP-002 to
Normal position.
56 Switch Supplies from bypass panel 223-CP-026 in the Essential
Services Switchroom to 223-CP-002 in the Control Room.
57 Energise all outgoing circuits from HVAC control panel except
circuits to:
• Electric Fire Pump Room
• Jockey Fire Pump Room
• Workshop
• Ensure internal pressure control in all areas is operative
58 Start Potable Water Pump 223-P-015.
Refer to Chapter 3 Paragraph 7.
59 Start Chilled Water Generation system and pump 223-P-013.
Refer to Chapter 3 Paragraph 8.
Manually override high temp cut out on water chillers until normal
operating temp is reached.
60 Switch HVAC to Automatic Control.
61 Isolate all electric supplies to electric fire pump, jockey and
workshop rooms to prevent auto start-up.
62 Energise electrical supplies from Central Complex and energise
electrical systems within Modules 9 and 10.
380V Utilities Switchboard available.
63 Manually Open shut off dampers in Electric Fire Pump Room vent
system and reset to Open Fire dampers.
64 Start vent fan 223-K-012A and purge room.
Minimum 5 Air changes required.

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Purge completed. Check with portable gas detector for presence of gas.
If gas is detected continue with air purge. If no gas is detected proceed to
Step 60.
65 Electric Fire Pump Room now fully purged.
Remove inhibits on HVAC panel 223-CP-002.
Remove inhibits on electrical supplies to electric fire pump room.
Ensure pressure control is operative.
66 Electric Fire Pump is now available if required after reinstatement of
22kV supply.
The Black Start of the HVAC system is now complete.
2.3 EMERGENCY DIESEL GENERATOR 222-GD-001
The following details provide the necessary information for the start-up of the
Emergency Diesel Generator after Level 1 Shutdown and electrical isolation.
This start-up is part of the overall Black Start Reset procedure as referenced
at Paragraph 2.2 Step 11. For further details of the Emergency Generator
Switchgear Sequence, Emergency Lighting and Black Start Panel refer to the
following illustrations:
SSP-04-02-004 South Satellite Logic Diagram Emergency Generator and

Switchgear Sequence
SSP-04-02-005 South Satellite 222 BC 013 & 222 BCDB 013 Emerg
Lighting & Black Start Panel
Prepare and Operate Essential Services Diesel Generator
• Ensure that fuel oil is available from the Fuel Oil Tank S-002
• Ensure that valves in the Diesel Fuel supply and return lines to the
Essential Services Generator Day Tank S-003 are open
• Confirm air flaps are open

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• Ensure that oil in diesel engine is at correct level
• Ensure that the Cooling Water Header Tank V-021 and Cooling Water
Receiver V-016 for the diesel engine are full
• Ensure that valves in the cooling water circuits are open
• Check that the governor oil level is correct
• Reset trips and alarms
• Check that the following are in Auto mode
• Pre-lube Oil Pump
• Oil Pre-heater
• Water Pre-heater
• Cooling Water Fan Coolers
At the EDG Control Panel select the diesel engine controller Normal/Bypass
to Bypass mode. This switch is mounted inside the control panel.
Select the auto-manual selector switch to Manual using HS-242 and start the
EDG using the manual Pushbutton PB-107.
Check the EDG and confirm that the Generator is operating normally and no
alarms are active.
Manually close the main EDG Circuit Breaker and energise the Essential
Services Switchboard and Charger Circuits for Essential Services
Switchboard and Bypass Panel.
Select the auto-manual switch to AUTO mode and Close the following Circuit
Breakers:
• EDG Package
• Lifeboat Package
• 125V DC Battery Charger BC-012 No 1

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• 48V DC Battery Charger BC-013 No 1
• EDG Room HVAC Supply Fans SF-1 and SF-2
• Fuel Oil Pump P-007A
The Emergency Diesel Generator is now on line and the SSP Black Start
continues from Paragraph 2.2 Step 12.
2.4 INSTRUMENT AIR SYSTEM
As soon as the utilities have been purged, the instrument air system may
be operated.
The following details provide the necessary information for the start-up of the
Instrument Air Compressor A after Level 1 Shutdown and electrical isolation.
This start-up is part of the overall Black Start Reset procedure as referenced
at Paragraph 2.2 Step 50.
Air Compressor K-001A and B are supplied from the essential switchboard.
Air Compressor K-001C can only be started once the 22kV supply has been
reinstated and non-essential 380V AC switchboard is normalised.
The details provided in the following description are specifically for

222-K-001A as Lead and 222-K-001B as Standby.
• Complete the normal pre-start checks as detailed in Chapter 3

Section 1 such as cooling water levels and lube oil levels
• Open all compressor drain valves to check for moisture and drain as
required
• Carry out a visual check of the system and confirm that the position of
manual valves on the instrument air system has not been changed
from the operating position at the time of shutdown
• Confirm that all control instrumentation is energised
• Check that MCC selector switches for all instrument air compressors,
air coolers, cooling water pumps and dryers are in the On position

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• Check the breakers on the Essential Services Switchboard for the

following drives to ensure they are in the closed position. Close if
required:
− 222-K-001A/B Instrument Air Compressors
− 222-EM-003A/B Compressor Fans
− 222-P-008A/B Compressor Cooling Water Pumps
Bypass shutdown relays inside the local control panel to enable local start
prior to the reset of the shutdown system at PD-1.
Select LOCAL control of compressor 222-K-001A using HS-243 on the

compressor control panel. Turn compressor selector switch, HS-244 to Lead.
Select 222-K-001B as the stand-by compressor.
Start Cooling Water Pump 222-P-008A and Cooling Water Fin Fan Cooler
222-EM-003A using pushbuttons 222-PB-70 and 222-PB-72 respectively.
Check the operating conditions of the Air Compressor Cooling Water Pump
and Cooling Water Fin Fan Cooler and confirm they are operating normally.
Start the compressor via Start Pushbutton 222-PB-110.
222-K-001B may be started at a later stage in the same way except that the
compressor selector switch 222-HS-246 should be turned to Standby.
Start Instrument Air Dryer 222-V-009A/B autotimer controller. Check that the
dryer sequence is operating correctly and the Dew Point is below -20°F. If the
dew point is not acceptable, open the drain valve at the header ends so that
the instrument headers may be purged.
Checks that all drain traps are functioning correctly.
When the receiver is fully charged, check that the compressor loads and
unloads automatically by the influence of the pressure switches.
The instrument air system is now in operation, operating on power from the
Essential Services Board. Ensure all Shafer actuated valves are reset and
ensure they are operational.
Normalise the deluge system by closing deluge valves that opened if the
instrument air pressure dropped to <50psig.

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2.5 REINSTATEMENT OF 22KV SUPPLY
At this point in the Black Start Reset procedure it can be considered that the
platform and all modules are purged and gas free.
Essential utilities such as HVAC, instrument air and firewater are available.
Electrical Supervisor to give clearance to receive 22kV power from the Central
Complex by closure of the relevant circuit breakers at Central Complex.
The Electrical Supervisor and Technician are responsible for energising the
6.6kV and 380V switchboards from the 22kV supply and the normalisation of
the essential services switchboard.
When 22kV power supply is available and all switchboards are energised with
normal power, the Essential Switchboard bus tie opens. At this stage the EDG
can be stopped.
The EDG should be switched to Auto mode before synchronising normal

supply to the essential bus.
Once the normal supply to the essential bus is connected by auto

synchronising relay, the EDG stops after 180 seconds.
All electrical switchboards (AC and DC supplies) incoming and outgoing circuit
breakers can be closed.
Normal power is now available.
The TDC database can be loaded.
The telemetry department should check that the Master Terminal Units
(MTUs) are operational and links with the FCC are functioning.
The black start reset is now complete and the utility systems are in normal
operation. The Platform Safety systems and Fire and Gas panel are in normal
operation.
Note: Level 1 Shutdown and depressurisation caused by inputs other than as

described for Black Start will require reset and start-up from this status
as main power supply is not affected.

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As each stage of the HVAC system is commissioned, the following purging

times are required to provide 5 complete volume air changes during Black
Start.
Table 4.1.1 – Purge Times
Module Area Purge Time

(minutes)
10 Control Room 10
10 Corridor 70
10 Battery Room 44
10 Charger Room 5
10 Galley 5
10 Washroom 25
10 Lounge/Dining Room 36
10 Cabin 1 40
10 Cabin 2 40
10 Store 50
9 Essential Service Room 30
9 Battery Room 50
9 Charger Room 40
9 Emergency Generator Room 30
3 Electric Fire Pump Room 12
3 Diesel Fire Pump Room 65
3 Workshop 60
3 Jockey Fire Pump Room 45
3 Instrument Air Compressor Room 25
3 Sewage Treatment Room 34
3 Stairwell 40
3 Airlock 60

UPPER ZAKUM POM: 8
3 LEVEL 1 SHUTDOWN AND START-UP
3.1 SHUTDOWN
A Level 1 Shutdown will occur as a result of 60% coincident gas detection as

previously described for Black Start cause.
In addition to these inputs, coincident gas, smoke and heat detection in

specific areas will also cause a Level 1 Shutdown and isolation of the
electrical supplies. These fire and gas inputs are relayed as a shutdown to the
ESD system from 222-CP-003 as output signal XX-583.
Activation of a deluge or manual release of Halon will also result in a Level 1

Shutdown as the satellite is unmanned. A manual selector switch, selected to
Level 2 Shutdown allows the output signal to cause a Level 2 Shutdown and
not a Level 1 Shutdown.
This selector switch is provided for manned and unmanned status of the
platform.
Specific details of all inputs that will cause a Level 1 Shutdown and all
associated output actions can be found on the following illustrations:

For further details of input and output devices and actions associated with fire
and gas detection refer to Chapter 5.
Specific Level 1 Shutdown can be summarised as follows:
• Pushbutton PB-128 located on the helideck
• Pushbutton PB-129 located on the helideck
• Pushbutton PB-130 located on boat landing east
• Pushbutton PB-131 located on boat landing west
• Pushbutton PB-132 located at escape craft north west

UPPER ZAKUM POM: 8
• Pushbutton PB-499 located at escape craft north east
• Pushbutton PB-109 located in the Control Room
• Pushbutton PB-525 located on panel
• Signal from telemetry system XXO-590 (2 off located on SER racks 4

and 8)
• Signal from the fire and gas system XX-583
• Signal from the PLC-1 Cabinet XXO-837 initiated from FCC Matra
PA/PZ Display
• Signal from the PLC-2 Cabinet XXO-838 initiated from FCC Matra
PA/PZ Display
Activation of any of the previously detailed Level 1 inputs will cause the
following simultaneous actions:
WHPT
All Wellhead flow line shutdown valves will close.
Production Separators
222-V-001A
• Oil Inlet Shutdown Valve 222-XCV-11
• Oil Inlet Step Operated Valve 222-HCV-170
• Oily Water Inlet 222-XCV-154
• Gas Outlet Valve to trunkline 222-HV-66
• Gas Outlet to Flare 222-HV-63

UPPER ZAKUM POM: 8
222-V-001B
222-V-001C
They are depressurised by opening vent valves XCV-12, XCV-15 and XCV-82
for Separators A/B/C respectively.
The associated Oil Booster Pumps P-001A/J and Crude Transfer Pumps
P-012A/D are stopped. The pump sequence is inhibited from starting the
standby pumps.
Closing Shutdown Valve 222-XCV-18 in the gas trunkline shuts off gas to the
Central Complex.
The product gas manifold is vented to flare by opening valve 222-HV-171.
Oil to the oil trunkline is stopped by closing valve 222-XCV-79.
Hydrocarbon drain tank pumps 222-P-009A/B are stopped.
Sump tank pump 222-P-005A is stopped.

UPPER ZAKUM POM: 8
Fuel gas to the flare system is stopped by closing valve 222-HV-74 separator
gas outlet header and 222-HV-80 fuel gas from gas trunkline.
The incoming water injection trunkline from Central Complex is shut-off by

closure of valve 222-HV-182.
Water injection outlet lines shutdown valves (HV-J) are closed.
Antifoam Injection Pumps 222-P-022A/B/C are stopped.
Corrosion Inhibitor (Oil) Pumps 222-P-020A/B are stopped.
Corrosion Inhibitor (Gas) Pumps 222-P-3/4 are stopped.
Biocide Injection (Oil) Pumps 222-P-1/10 are stopped.
Biocide Injection Pump 222-P-021 is stopped.
Firewater Jockey Pumps 222-P-004A/B are stopped.
Chlorine Injection Package 222-B-018A/B is shutdown.
Electric Fire Pump 222-P-003 is stopped
Instrument Air Compressors 222-K-001A/B/C are stopped.
Fuel Oil Pumps 222-P-007A/B are stopped.
222-XCV-157 on outlet of Fuel Oil Tank 222-S-002 is closed.
The starting of Emergency Generator 222-GD-001 is inhibited.
The HVAC system is shutdown.
All electrical supplies are isolated other than those required by the fire and
gas panel.
Diesel fire pump 222-P-016 is started if no gas is present in the pump room.
There will be a 60 second time delay prior to isolating 220V AC Inverter IV-11
supplying 220V AC UPS which feeds the MATRA Console, PLC Cabinets,
Operator Console and Data Concentrator.

UPPER ZAKUM POM: 8
There will be a 60 second time delay prior to isolating 220V AC Inverter Z5

equipment IV-1 supplying Distribution Board BCDB 011 which feeds the
Instrument Distribution Board, Platform Shutdown Cubicle PD-1, HVAC
Control Panel and Pump Sequence and Alarm Panel.
There will be a 1 second time delay prior to isolating the 48V DC Supplies to
Controls and Instruments, BC-010.
Emergency Lighting – 48V DC supplies from BC-013 is available for 6 hours if

the shutdown is caused by gas coincidence in all other areas except
coincidence detection in the control room, where power to the system is lost
instantly.
125V DC for switchgear tripping/closing from BC-012 will be lost in 6 seconds.

In case of gas coincidence in the control room, this supply will be lost
instantly.
For further details of input and output devices and actions associated with fire
and gas detection refer to Chapter 5.
The fire and gas panel will remain operational for 24 hours along with
navigational aids and some emergency lighting at escape points, which are
supplied by their own batteries.
Note: 48V DC power supplies to the fire and gas panel will be lost in
65 seconds in case of gas coincidence in the control room. BC-10-1
battery circuit breakers will trip after 65 seconds.
3.1.1 Level 1 Reset
Following investigation and rectification of the reason for the Level 1

Shutdown, the process can be reset and reinstated. The reset and start-up is
the same as after 22kV has been reinstated as previously detailed in Black
Start Reset.

UPPER ZAKUM POM: 8
4 LEVEL 2 SHUTDOWN AND START-UP
4.1 SHUTDOWN
A Level 2 Shutdown will shutdown all hydrocarbon process systems and

chemical injection. The specific input and output actions associated with a
Level 2 Shutdown are detailed in the following paragraphs.
4.1.1 Level 2 Shutdown Initiating Signals
• PB-133 in the Local Operation Room (LOR)
• Remote signal XX0-12 received from FCC
• Flare Knock-out Drum 222-V-003 High High Level 222-LSHH-22A/B
• Low pressure in the instrument air header PSLLL-592
• By a signal derived from within the shutdown system signifying that all
the separators are shutdown
• Fire and Gas signal XXO-584 from Fire and Gas Panel 222-CP-003
For detailed information and specific input and output actions for the
Emergency Shutdown and Fire Gas System refer to the following illustrations:
SSP-04-04-001 South Satellite Level 2 Separation Process Shutdown

Pressurised
Note: Further details and information for ESD Level 2 input and output
actions can be found in Chapter 5.

UPPER ZAKUM POM: 8
4.1.2 Level-2 Shutdown Actions
Upon initiation of this trip, the following responses/ actions automatically take
place and the separator valves close.
Valve 222-V-001A 222-V-001B 222-V-001C

Oil Inlet S/D Valve 222-XCV-11 222-XCV-14 222-XCV-81
Oil Inlet Step Valve 222-HCV-170 222-HCV-207 222-HCV-249
Oily Water Inlet 222-XCV-154 222-XCV-195 222-XCV-308
Gas Outlet Valve 222-HV-66 222-HV-72 222-HV-131
Gas Outlet to Flare 222-HV-63 222-HV-69 222-HV-128
• Oil Booster Pumps 222-P-001A/J stop
• Crude Oil Transfer pumps 222-P-012A/D stop
• Gas trunkline 222-XCV-18 closes
• Oil trunkline valve 222-XCV-79 closes
• Hydrocarbon Drain Tank Pumps 222-P-009A/B stop
• Sump Tank Pumps 222-P-005A stops
• Antifoam Injection Pumps 222-P-022A/B stop
• Corrosion Inhibitor Oil Pumps 222-P-020A/B stop
• Corrosion Inhibitor Gas Pumps 222-P-17/19 stop
• Biocide Injection Oil Pumps 222-P-1/10 stop
• Biocide Injection Pump 222-P-021 stops
A Level 2 Shutdown does not affect utility systems such as HVAC and
Instrument Air.
Automatic sequence systems are also unaffected by a Level 2 Shutdown.

UPPER ZAKUM POM: 8
4.2 START-UP
4.2.1 Operator Actions Following a Level 2 Shutdown Caused by

Fire and Gas Alarm
A Level 2 requires manual intervention in order to reset the trip at the

Shutdown Panel PD-1. The Level 2 cannot be reset remotely from the FCC.
This procedure assumes the SSP is manned. Upon initiation of a fire or gas
alarm all personnel should respond as per the platform muster procedures.
The steps required to confirm and rectify the cause of the shutdown and to
normalise the system are detailed in the following table:
Table 4.1.2 – Level 2 Shutdown from Fire and Gas Initiation
No Action By
1 Immediately confirm the cause of the shutdown FCC

SSP
2 Concurrently SSP personnel to respond as per safety SSP
instructions.
All non-essential personnel report to designated muster
station.
3 On confirmation of cause, the Senior Operator and SSP
operator shall investigate the source of the alarm.
If gas alarm, breathing apparatus to be worn and gas
monitor to be carried.
4 Check the SSP systems and confirm that: FCC
Power Supplies are functional.
Water Injection is in operation.
5 When the source of the fire and gas trip is established SSP
and rectified, the SSP operator shall reset the ESD 2
Trip at the Shutdown Panel PD-1.
6 Re-start the process in accordance with established FCC/
procedures. SSP
Note: For detailed start-up from a Level 2 Shutdown status refer to

Paragraph 8.5.

UPPER ZAKUM POM: 8
4.2.2 Operator Actions in the Event of a Level 2 Shutdown Caused by

Instrument Air Failure
No Action By
1 Check the alarm status of the air compressors and the FCC/
instrument air pressure at the instrument air receiver. SSP
If the alarm status indicates that one of the compressors
may be restarted and it is safe to do so, immediately
attempt to restart.
2 If an Air Compressor start is successful, allow the air SSP
pressure to stabilise at normal operating pressure of
±210psig.
Stop all non-essential consumers using air.
3 Carry out systems check and confirm all operating FCC/
utilities are normal. SSP
4 When it is confirmed all is normal, the SSP operator FCC/
shall reset the ESD-2 Trip at the Shutdown Panel PD-1. SSP
5 Re start the process in accordance with established SSP
procedure.

Paragraph 8.5.

UPPER ZAKUM POM: 8
4.2.3 Operator Actions in the Event of a Level 2 Shutdown Caused by

a High Level in the Flare KO Drum
No Action By
1 Confirm that the Flare KO Drum Alarm FCC/

222-LAHH-22A/B is active SSP
2 The SSP operator to check the Flare KO Drum sight SSP
glass and confirm the high level.
3 Following confirmation of the high level, carry out the FCC/
following: SSP
Check the level in the Hydrocarbon Drain Tank and if
necessary pump out the liquid level to the Separator.
This will require an override of the Level 2 signal at the
Shutdown Panel.
Ensure that the Hydrocarbon Collection Tank is at the
normal pressure of approximately 0.5 to 1.0psig
Drain the level in the Flare KO Drum to the Hydrocarbon
Drain Tank by opening the Level Controller bypass valve
if required.
Confirm that the LCV is fully open.
Investigate and rectify the possible malfunction of the
Flare KO Drum level controller and/or the reason for the
excessive liquid carry over of liquid into the Flare KO
Drum.
When the High Level is cleared and the reason for the
high level has been established and rectified, reset the
ESD-2 Trip at the Shutdown Panel PD-1.
4 Re start the process in accordance with established FCC/
procedures. SSP

Paragraph 8.5.

UPPER ZAKUM POM: 8
5 LEVEL 3 SHUTDOWN
5.1 SHUTDOWN
Refer to illustrations:
SSP-04-05-001 South Satellite Level 3 Shutdown Process Sections

Pressurised
This level of shutdown enables individual process systems and equipment to

be shutdown. Shutdown of these systems is by manual initiation of specific
pushbuttons.
Activation of any single pushbutton affects only the specifically related

process system or equipment and does not affect other process systems.
The three areas of process that are designated with specific Level 3
Shutdown pushbuttons are as detailed below.
• Separator Train A and associated pumps
• Separator Train B and associated pumps
• Separator Train C and associated pumps
• Oil from wellheads
• Water Injection
The shutdown can only be initiated manually, by pushbuttons located in the

control room, or by telemetry signal. The following pushbuttons shutdown the
designated section:
• Pushbutton PB-1 (XXO-198) Shuts down Separator Train A
• Pushbutton PB-3 (XXO-200) Shuts down Separator Train B
• Pushbutton PB-35 (XXO-604) Shuts down Separator Train C
• Pushbutton PB-524 (XXO-667) Shuts down Wellhead Oil flow lines
• Pushbutton PB-526 (XXO-669) Shuts down Water Injection

UPPER ZAKUM POM: 8
The shutdown sequence initiated by each of the pushbuttons is described

below.
Activation of Pushbutton PB-1, PB-3 or PB-35 initiates the following actions:
• Inlet valves to the respective separator are closed
• The separator gas to flare valve is closed
• The Crude Oil Transfer Pump is stopped and the pump sequence
system is inhibited from starting the standby pump. After a time delay
the gas outlet is then closed. After further time delay the oil booster
pumps are stopped
• The separator vent valve remains closed, leaving the system

pressurised
Activation of Pushbutton PB-524 initiates the closure of individual wellhead

flow line riser valves as follows:
HV-172 HV-173 HV-174 HV-176

HV-177 HV-179 HV-180
Activation of PB-526 or telemetry signal XXO-669 from the FCC initiates the
following actions:
• Pipeline Valve HV-182 closes, stopping the injection water supply from
the Central Complex
• Injection water lines to the wellheads are isolated by closure of their

individual valves
5.2 START-UP
During a Level 3 process shutdown the power distribution system is not

tripped. However, since the initiation of a Level 3 shutdown has been caused
by an operator action, checks must be carried out to ensure that the reason
for the shutdown initiation is cleared.
In exceptional circumstances, with the supervisor's approval, the active

shutdown initiation may be overridden at the shutdown panel following
confirmation from the field operator that the plant is in a safe condition.

UPPER ZAKUM POM: 8
Once the shutdown fault has been identified and rectified, the shutdown reset
can be given from the FCC (except for oil flow lines) or from the Local Control
Room and restart as per established procedures.
Re-opening of the Oil Inlet Lines will require a reset at SSP Shutdown
Panel PD-1.
Specific start-up details for the systems affected by a Level 3 Shutdown can
be found in Paragraph 8.5 and the subsequent paragraphs.
6 LEVEL 4 SHUTDOWN AND RESTART
6.1 SHUTDOWN
Refer to illustrations:
SSP-04-06-001 South Satellite Level 4 Equipment Safety Trips Water

Injection
SSP-04-06-002 South Satellite Level 4 Equipment Safety Trips Oil From
Wellheads Lines
SSP-04-06-003 South Satellite Level 4 Equipment Safety Trips Product
Gas to Central Complex
SSP-04-06-004 South Satellite Level 4 Equipment Safety Trips Separator
V-001A
V-001B
V-001C
A Level 4 Shutdown is automatically initiated and is a result of a process

parameter exceeding a pre-determined threshold limits.
A Level 4 Shutdown is also initiated as a cascade effect from higher levels

of shutdown.

UPPER ZAKUM POM: 8
The following systems are included in a Level 4 Shutdown:
• Water Injection
• Oil from WHPTs
• Gas Export to the Central Complex
• Separators 222-V-001A/B/C and Separator Trains A/B/C
6.2 START-UP
6.2.1 Level 4 Water Injection Shutdown
Step Action By
1 Call up SSP Module 11 Control Mimic and confirm FCC/
High Flow Alarm and subsequent isolation valve SSP
responded closed.
2 Investigate and if possible rectify the flow problem. FCC/
SSP
Operator intervention may be required at SSP
WHPT
and/or WHPT.
3 Reset the Level 4 by activation of XXO-688 and FCC/SSP
equalise the pressure upstream and downstream
of the HV.
4 Open IPSV at the affected WHPT. WHPT
5 Re-open the relevant Isolation HV Valve when the SSP
flow line has been pressurised.

UPPER ZAKUM POM: 8
6.2.2 Level 4 Shutdown Oil From Wellheads
Step Action By
1 Call up SSP Module 1 Control Mimic and confirm FCC
High or Low Pressure Alarm and subsequent ESD
valve responded closed.
2 Investigate and if possible rectify the cause of FCC/SSP
the alarm.
3 To prevent automatic reopening of the isolation FCC
valve, give a close signal from the FCC.
4 Reset the alarm condition at the SSP Shutdown SSP
Panel PD-1.
5 If the WHPT is tripped, reopen WHPT valves to FCC/SSP
bring the WHPT back on line and reopen the flow
line isolation valve at the SSP.
6.2.3 Level 4 Shutdown Produced Gas to Central Complex
Step Action By
1 Call up SSP Train 1 Control Mimic and confirm that FCC
222-PSL-147 is active and that 222-XCV-18 Gas
Trunkline Isolation Valve has closed.
HV-66, HV-72 and HV-131 will close if XCV-18
fails to close.
2 Investigate and if possible rectify the cause of the FCC
alarm.
If the pressure switch is active, repressurisation
may be necessary. This is achieved by opening
XCV-018, pressurising the system and normalising
PSL-147.
3 When the Low Pressure problem has been FCC/SSP
identified and rectified, reset the Level 4 Trip
Condition at the SSP Shutdown Panel-PD-1
4 Confirm that 222-XCV-18 re-opens. FCC/SSP
5 Confirm that separator operations are stable. FCC/SSP

UPPER ZAKUM POM: 8
6.2.4 Level 4 Shutdown Separators and Transfer Pumps
Most Level 4 Shutdown conditions can be reset remotely from the FCC and
the Separator restarted without intervention at the SSP.
The specific input devices associated with this level of shutdown for Train A is
detailed below, however the actions for Trains B and C are identical.
• 222-LSHHH-1A Separator Very High Level
• 222-LSHHH-1B Separator Very High Level
• 222-LSLLL-5 Separator Very Low Level
• 222-PSL-105 Separator Low Pressure
• 222-PSH-106 Separator High Pressure
• 222-PSL-190 Oil Trunkline Low Pressure
Upon initiation of this trip, the following actions automatically take place.
Production Separator 222-V-001A is isolated by closure of the following

valves.
• 222-XCV-11 Oil Inlet Shutdown Valve
• 222-HCV-170 Oil Inlet Step Valve
• 222-XCV-154 Oily Water Inlet Valve
• 222-HV-66 Gas Outlet Valve
• 222-HV-63 Gas Outlet to Flare
The associated Crude Oil Booster Pumps 222-P-01A/C and Crude Oil
Transfer Pumps 222-P-0012A/D stop.
The antifoam pump stops.
The following steps are required in order to normalise the system after the
different inputs as previously described.

UPPER ZAKUM POM: 8
Table 4.1.3 – 222-LSHHH-1 Trip Reset
Step Action By
222-LSHHH-1A/B is active and the shutdown of
the pumps and valves is in accordance with a
Level 4 Shutdown.
2 Investigate and rectify the cause of the high level FCC
alarm.
3 Clear the High Level. FCC
Reset Level 4.
Start a Transfer pump and operate until the High
Level clears.
Restart the Separator in accordance with
established procedures.
When 222-LSHHH-1A/B is active the Separator
Inlet Valve, HCV-170 is inhibited from opening.
Note: Following a reset, the separator system will trip again if the alarm
condition is not cleared within 10 minutes.
Table 4.1.4 – 222-LSLLL-5 Trip Reset
Step Action By
222-LSLLL-5 is active and the shutdown of the
pumps and valves is in accordance with a Level 4
Shutdown.
2 Investigate and rectify the cause of the low level FCC
alarm.

UPPER ZAKUM POM: 8
Table 4.1.4 – 222-LSLLL-5 Trip Reset (cont’d)
Step Action By
3 Reset Level 4. FCC
Clear the Low Level.
Establish a level in the Separator to clear the Low
Level Alarm.
When 222-LSLLL-5 is active, the Transfer Pumps
are inhibited from starting.
Table 4.1.5 – 222-PSL-105/PSH-106 Trip Reset
Step Action By
1 Call up SSP Train 1 Control Mimic and confirm FCC

that 222-PSL-105 or PSH-106is active and the
shutdown of the pumps and valves is in
accordance with a Level 4 Shutdown.
2 Investigate and rectify the cause of the low/high FCC/SSP
pressure alarm.
3 Initiating the Level 4 reset and venting separator FCC
gas to the flare via 222-PCV-117 will clear a high
pressure alarm
4 A Low Pressure condition will be rectified at restart FCC
of the separator.
Reset Level 4
established procedures

UPPER ZAKUM POM: 8
6.2.5 Level 4 Shutdown Oil Trunkline Low Pressure
If 222-PSL-190 detects a low pressure in the oil trunkline, after 60 seconds

a Level 4 Shutdown of the separator and transfer pumps will occur.
Table 4.1.6 – 222-PSL-153 Trip Reset
Step Action By
1 Confirm that 222-PSL-190 is active and the FCC
Separator and Transfer Pump Systems have
shutdown in accordance with a Level 4 Shutdown
2 Investigate and rectify the cause of the low- FCC
pressure condition. SSP
3 Reset the Separator Level 4 trip alarm for the first FCC
separator to be started.
Reset and restart further separators as necessary.
7 PLANNED SHUTDOWN
7.1 INTRODUCTION
A planned process shutdown takes place prior to carrying out a major

overhaul, or major repairs, or if the SSP is to remain out of operation for a
long time.
SSP is normally shutdown for maintenance/inspection of the following:
• Three Separator Trains
• Hydrocarbon Tank
• Flare Knock Out Drum
• Flare Tower

UPPER ZAKUM POM: 8
This procedure provides a step-by-step guideline on the actions required to

shutdown the SSP Oil/Gas Process. It is strongly recommended that the
planned shutdown be utilised to alternately function test the various SSP ESD
systems.
This procedure assumes that:
• Zirku/ADMA have been advised of the intention to shutdown SSP
• Field Production has taken the necessary steps for the manual
shutdown of the Wellhead Platforms (WHPT) feeding the SSP
7.2 PROCESS SHUTDOWN
Step Action By
1 Stop oil production from WHPTs by closing the FCC/WHPT
Wing and Header Safety Valves (HSV).
2 If required, stop Water Injection by call up of SSP FCC
Module 11 Mimic and initiate 222-XXO-669.
3 Prepare to shutdown the online Separator trains FCC
by allowing the level in the Separator to fall to
45% and stop the individual Transfer Pump
222-P-001A/D.
Close individual separator step valves
222-HCV-170/207/249.
Place Separator gas to Flare Pressure Control
Valves 222-PCV-117/130/205 to manual mode and
close fully.
Put Gas to Trunkline Pressure Control Valves
222-PCV-116/129/204 in manual mode and close
fully to isolate gas to the Central Complex.
An individual separator train can be shutdown via
222-XXO-198/200/604 via a control signal from
the FCC.
4 Stop the Corrosion Inhibitor and Biocide Injection
Package. Refer to Chapter 3.

UPPER ZAKUM POM: 8
The SSP is now in a pressurised shutdown mode; the subsequent actions are
dependant on the purpose for the initial shutdown. The following section
details the steps required to shutdown the SSP and maintain production
requirements.
CAUTION: ALTHOUGH THE SSP PROCESS PLANT WILL BE

BYPASSED, THE PLATFORM IS STILL LIVE AND WILL
REMAIN SO UNTIL ALL HYDROCARBONS ARE PURGED
FROM ALL THE SYSTEMS INCLUDING FLARE AND DRAINS
SYSTEMS AND MECHANICAL ISOLATIONS USING BLINDS
AND OR SPADES ARE PUT IN PLACE.
7.3 SSP PROCESS BYPASS
A 12in bypass line is provided from the platform intake manifold to the oil
trunkline, which allows crude oil from the wellhead platforms to be routed to
the Central Separation Platform (CSP) Separators.
This procedure provides a step-by-step guideline on the actions required

to bypass the SSP Gas/Oil Separation system whilst maintaining partial
production rates to the CSP Separators.
This procedure assumes that:
• SSP Separators 222-V-001A/B/C are on line receiving crude oil from

the SSP risers
• CSP Separators 235-V-001A/B are in operation
• Production has identified the platforms and well strings, which are
to remain on line to optimise production rates
• Zirku/Adma have been advised of the intention to bypass SSP with

a resultant reduction of production
• Nitrogen is available for purging
• All pigging operations from SSP Oil Flow Lines and Oil Trunkline are
suspended during bypass operations

UPPER ZAKUM POM: 8
Confirm that the following valves are in the closed position. Refer to the
schematic for the location of the valves.
Schematic Valve Description

No
1 222-HV-124 Oil Trunkline Pig Launcher, 222-V-005
outlet valve.
2 12in Ball Valve Isolation valve in the kicker line.
3 12in Ball Valve SSP bypass valve inlet to the pig launcher.
4 2in Gate Valve Corrosion Inhibitor (oil) injection line to pig
launcher.
5 2in Gate Valve Bypass of Pig Launcher Pressure Relief
Valve, 222-PSV-187.
6 ½in Gate Valve Pig launcher vent valve.
7 12in Ball Valve SSP bypass valve from Oil Feed
Manifold C.
SSP Bypass
6
4
1 222-XCV-79
222-V-005
Sub Sea Pipeline
to
Central Complex
Corrosion
Inhibitor
2 222-HCV-123 7
From Trunk Line To Water Injection

Oil Manifold Manifold

UPPER ZAKUM POM: 8
Step Action By
1 Connect a nitrogen hose to the pig Launcher purge SSP
point and pressurise the launcher to 150psig.
Perform leak test as per Steps 1 and 2.
2 Allow the Pig Launcher to stand for 30 minutes. If SSP
the pressure drops significantly then the leak must
be found and rectified before continuing with the
procedure.
Leak check can be done using soapy water
3 Close the ½in Purge Connection valve and SSP
disconnect the nitrogen hose.
4 Put oil trunkline Low Pressure Switch, FCC
222-PSL-190 into bypass mode.
5 Commence reducing SSP production rate to FCC/
approximately 100 000BPD. WHPT
Close in wells as per Production guidelines
6 Confirm that CSP operations are stable. FCC CSP
7 Open Pig Launcher outlet valve: 222-HV-124. SSP
8 Open the 12in valve in the inlet bypass line to SSP SSP
pig launcher kicker line.
9 Open the 12in valve at the SSP bypass line outlet SSP
from Oil Feed Manifold C.
10 Divert SSP oil risers from Oil Feed Manifolds A and SSP
B to Manifold C.
Each riser is capable of being routed to A, B or C
Manifolds.
11 Close Production Separator A, B and C 24in inlet SSP
valves.
12 ALLOW the Booster Pumps for SSP Production FCC
Separators A, B and C to trip on low level via
LSLL-32, LSLL-49 and LSLL-50 respectively.
The pumps trip on LL2 unless it is necessary to
defeat LL2.
13 STOP the Corrosion Inhibitor and Biocide Injection SSP
Package.

UPPER ZAKUM POM: 8
Step Action By
14 CLOSE the Oil Trunkline Pig Launcher Bypass SSP
Valve 223-HCV-123.
The SSP Gas Oil Separation system is now
bypassed.
15 CLOSE 222-PIC-116/129/204 on manual to isolate FCC
gas to the Central Complex.
Flaring shall be sanctioned only when absolutely
necessary.
16 CLOSE 222-HCV-76, the Gas Trunkline Pig SSP
Launcher Bypass valve.
Note: A CSP separator must be dedicated to receive bypassed production

from SSP in order to maintain pressures below the pipe rating of the oil
flow lines on SSP. All Oil Gas line PSVs to be isolated to Flare/HC
tanks. while operating in bypass mode.
7.4 SEPARATOR SHUTDOWN
The procedure provides step-by-step guidelines for the preparation of SSP

Separators for inspection. The procedure details the procedure for the the
isolation of 222-V-001A. However the procedure for 222-V-001B and C are
identical
This procedure assumes the following:
• The oil and gas separation systems are not in service
• Diverter valves to Oil Manifold A from all risers are closed.
• The level in Separator A is at a minimum
• The Hydrocarbon Drain Tank 222-V-019 and Hydrocarbon Drain Tank

Pumps 222-P-009A and B are operating normally

UPPER ZAKUM POM: 8
Close and disable the following valves:
Valve Description
222-XCV-11 Separator Inlet

222-HCV-170 Separator Inlet
222-XCV-154 From Hydrocarbon Drain Tank, 222-V-019
222-HV-63 Gas Outlet to Flare
222-PCV-116 Gas outlet to Gas Trunkline
222-PCV-117 Gas Outlet to Flare
222-HCV-67 222-PCV-117 Bypass valve
222-HV-65 Gas outlet to Gas Trunkline
222-HV-66 Gas outlet to Gas Trunkline
222-HV-208 Separator outlet to Booster Pumps 222-P-001A/B/C
Note: 222-HV-208 and the transfer pump suction and recycle valves should
not be closed before draining of separator is accomplished. This is to
enable the draining of the oil outlet line via 222-HV-208 and the pump
casing to the hydrocarbon drain tank.
222-V-001C is not equipped with an in line isolation valve similar to

Booster Pump P-001G/J suction lines.

UPPER ZAKUM POM: 8
Lock the following valves closed.
Valve Description
6in Valve Downstream of 222-XCV-154, from HC Drain Tank,
222-V-019.
2in Valve Booster Pumps 222-P-001A/B/C vent to separator.
2 x ½in Valve Corrosion Inhibitor (Gas) on gas outlet line.
½in Valve Biocide Injection to Separator inlet line (upstream valve).
6in Valve Upstream of Bursting Disc 222-PSE-109.
6in Valve Upstream of Bursting Disc 222 PSE-110.
2in Valve Upstream of 222-XCV-12, depressurising valve to flare.
24in Valve Downstream of 222-HCV-170, Separator Inlet Valve.
8in Valves Minimum flow recycle from Booster Pumps,
222-P-001A/B/C
Note: Minimum flow recycle from Booster Pumps P-001A/B/C to be left open
to enable draining of the recycle line through the Transfer pump
casing to the HC Drain Tank 222-V-019. On completion of recycle line
draining, the 8in valves are to be locked closed.

UPPER ZAKUM POM: 8
7.4.1 – Separator Draining and Flushing
Step Action By
1 Slowly drain the Separator to the Hydrocarbon SSP
Drain tank.
Foaming and carry over from the HC tank may
result if draining is carried out too fast.
2 When draining is complete, open 222-PCV-116 SSP
bypass and complete the depressurisation of the
separator.
3 Connect a water hose to the sample connection
SSP
point on the separator inlet line.
4 Connect N2 hose to the 2in bridle of Level SSP
Transmitter 222-LT-4.
While draining, the separator to be kept under a
positive N2 pressure.
5 Drain the separator to the hydrocarbon drain tank SSP
using 2 x 3in ball valves at the base of the
separator.
6 Open the ½in sample valve and displace the SSP
remaining oil to the separator.
7 Lock closed the ½in sample valve after the flush. SSP
8 OPEN HV-208 and Booster Pump P-001A Suction SSP
Valve, HV-81 and drain pump suction line via
pump casing to the HC drain.
Repeat for P-001B/C suction lines. HV-208 to be
closed/disabled on completion of draining.
9 OPEN Booster Pump P-001A recycle valve SSP
PCV-582 and drain pump recycle line via pump
casing to the HC Drain.
10 Repeat for P-001B/C recycle lines. Recycle block SSP
valves downstream of PCVs to be locked closed
on completion of draining.
11 Remove the ½in needle valve from the sample SSP
connection point upstream of HV-208 in the oil
outlet line.

UPPER ZAKUM POM: 8
7.4.1 – Separator Draining and Flushing (cont’d)
Step Action By
12 Connect a water hose to the sample connection SSP

point and flush/displace the remaining oil to the
separator.
The sample connection is only ¾in so flushing
must be maintained for a considerable time to
ensure displacement of the oil to the separator.
13 Drain the separator to the hydrocarbon drain tank. SSP
14 Connect a firewater hose to the 4in water FCC/SSP

connection line and commence filling the separator
with water to a level of 90%.
The level can be monitored locally from LG-3A or
from the FCC via LT-4.
15 When the level reaches 90%, shut-off the water SSP
supply and drain the separator to the hydrocarbon
drain tank.
PCV-116 bypass is acting as a vent during
separator filling.
16 Repeat the filling/draining exercise a further twice. SSP
After three times filling and draining, the separator is now chemically washed
with oil dispersant and degreaser.
17 Inject 800 litres of oil dispersant into the separator. SSP
18 Fill the separator to 90% level using the firewater SSP
connection line.
19 Close PCV-116 bypass valve when water level is SSP
at 90%.
20 Leave to soak overnight. SSP
21 After overnight soak, drain the separator and refill SSP
with water to 90%.

UPPER ZAKUM POM: 8
7.4.1 – Separator Draining and Flushing (cont’d)
Step Action By
The separator is now ready for inerting and draining as follows:
22 Using the Nitrogen (N2) connection, pressurise the SSP
Separator to 30psig.
23 Depressurise to flare via 222-PCV-116. SSP
24 Repeat steps 22 and 23 at least three times. SSP
25 Using a gas test meter or Draeger, test for SSP
separator hydrocarbon content aiming for <1%
LEL.
26 Repeat N2 purge until Lower Explosive Limit (LEL) SSP
is <1%.
27 With a separator N2 pressure of 5psig, drain the SSP
separator to the HC Tank.
Ensure all sight glasses are drained.
28 Close and Lock the 2 x 6in Ball valves from the SSP
Separator to the hydrocarbon drain tank.
29 CLOSE and Lock the 2 x 4in Ball valves upstream SSP
of 222-PSV-107/108.
30 CLOSE and Lock the 6in Ball valve from the SSP
separator to the open drain.
7.4.2 Separator 222-V-001A Spading List
The separator can now be spade isolated as detailed on the following list:

UPPER ZAKUM POM: 8
Blind Installed Blind Installed Blind Removed Blind Removed

P&ID No Size Rating Location, Line No and Designation
Date Signed Date Signed Date Signed Date Signed
222 152 502 14in 150 Gas Outlet Line
222 152 502 14in 150 Second Gas Outlet Line
222 152 502 6in 150 From Hydrocarbon Pump Line
222 152 502 2in 150 Flare line upstream XCV-12
222 152 502 24in 150 Separator Oil Inlet
222 152 502 6in 150 Flare line upstream of PSV107/108
222 152 502 6in 150 Flare line upstream of PSE109/110
222 152 502 2in 300 Booster Pump degassing return line
222 152 502 14in 150 Oil Outlet Line
222 152 502 14in 150 Second Oil Outlet Line
222 152 502 6in 150 Separator Drain to Sump Tank
222 152 502 3in 150 Outlet Line Hydrocarbon Drain (1 of 5)

UPPER ZAKUM POM: 8
7.4.3 Separator 223-V-001A Opening and Aeration
On completion of the mechanical isolation, the separator may be opened and

aerated.
An air blower may be installed at the top of a vessel/tank either to force air to
the bottom through ducting with other top openings used for gas release or by
forcing air in and providing other top openings with suspended ducts.
A further method is to install a blower in a bottom shell opening and vent

through a top opening. The installation of equipment in the openings of
vessels/tanks to be gas freed must be carried out with great care and may
require the use of breathing apparatus, with wetting down to minimise the risk
of accidental sparking or ignition of Pyrophoric scale.
When an eductor or air mover is used, it should be situated in a top opening

with flexible ducting extended to near the bottom of the vessel and preferably
another top openings used for air entry.
An air blower must be electrically bonded and earth-connected to any ducting

used and to the vessel or tank to be ventilated. This is important for the
prevention of accumulation of static electrical charges and an inspection and
test of all bonding and earth connections must be made. Particular attention is
to be paid to the removal of coatings at earth contact points, and the direction
of rotation checked, before an air blower is put into operation.
The separator can now be opened as follows:
• Check the separator for H2S or hydrocarbons. This can be done by

disconnecting 222- PI-111 on the top of the separator
• Open both of the separator man ways
• Install an air injector at one of the open man ways
• Install an air blower (eductor) to opening on top of separator
• Periodically check the separator for H2S, hydrocarbon and oxygen

content

UPPER ZAKUM POM: 8
Re-check until the separator air content is as follows:
• H2S is Nil
• Hydrocarbon content <1% LEL
• Oxygen content between 19.7% and 23%
Vessel entry is now dependant on all conditions and precautions as stated on

the Entry Permit and associated certificates/permits being strictly adhered too.
CAUTION: PYROPHORIC SCALE OR SLUDGE IS A SUBSTANCE

FOUND IN CRUDE OIL VESSELS. WHEN DRY, THE SCALE
HAS A TENDENCY TO AUTO IGNITE WHEN IN CONTACT
WITH AIR. THEREFORE WHEN OPENING ANY CRUDE
OIL VESSEL FOR INSPECTION OR MAINTENANCE, THE
CONTENTS MUST BE KEPT WET, PARTICULARLY WHEN
REMOVED FROM THE VESSEL.
7.4.4 Separator 222-V-001A Re-instatement
Upon completion of the separator final inspection, carry out the following
de-spading and leak test activities:
Step Actions
1 Remove all equipment from inside the separator.
2 Carry out final inspection of the separator to ensure all is in order,
then close man ways.
It is the responsibility of Senior Production person on site to
ensure a final internal inspection is conducted.
3 Re-instate any instruments, bridles or sight glasses that have
been removed for calibration/cleaning.
4 Ensure that all level switches, bridles gauge glasses and all
instruments are lined correctly.
This is to eliminate pockets of oxygen remaining in the system.

UPPER ZAKUM POM: 8
7.4.3 Separator 222-V-001A Re-instatement (cont’d)
Step Actions
5 Connect a Nitrogen (N2) hose to the 2in bridle of 223-LT-4 and
pressurise the Separator to 200psig.
Note: The PSVs are set at 225psig.
6 Using a soap solution, check the manholes and all disturbed
flanges for leaks.
7 Depressurise the separator on successful completion of the
manhole leak test.
8 Pressure purge the separator with nitrogen to 30psig.
Repeat the pressure purge until oxygen content is Nil.
9 Remove blinds and spades from the separator under a slight
nitrogen flow.
10 Using nitrogen pressurise the separator to 200psig and carry out
a leak test.
Rectify any leaks found.
11 Carry out a final oxygen content to confirm that oxygen content is
Nil.
7.5 PLANNED SHUTDOWN BY SYSTEM
Process systems that may be shutdown individually for overhaul, maintenance

or repair are as detailed below. It should be noted that in the event of a
particular system or item of equipment needing to be taken out of service, the
reason for the removal from service is infinitely variable and therefore specific
shutdown and isolation procedures are normally developed in accordance
with the problem.
• Injection water
• Production separator and associated pumps
• Oil lines from wellheads
• Individual instrument air compressor

UPPER ZAKUM POM: 8
• Individual firewater pump
• Individual fuel oil pump
• Chlorine injection system
The following equipment, on the other hand, may not be shutdown on an

individual basis as there is no standby or there is a significant process or
safety risk.
Shutdown may only be performed if total platform shutdown is initiated:
• Flare system
• Hydrocarbon drain tank
• Diesel fire pump
• All air compressors
8 START-UP FROM LEVEL 1 SHUTDOWN
8.1 INTRODUCTION
This procedure provides the necessary information for the re-start of the
process after the 22kV main power supply has been re-established.
Reinstatement of 22kV power supply is part of the Black Start procedure.
Following a Level 1 Shutdown, regardless of electrical isolation, all manual

valves will remain in their normal operating position. All remotely actuated HV
or XCV or control valves will change status to their designated fail-safe
position.
The subsequent re-start procedure is detailed for each system in the

pre-requisite sequence.
This procedure assumes that the gas trunkline is pressurised and fuel gas is
to be imported from the trunkline.

UPPER ZAKUM POM: 8
8.2 FUEL GAS SYSTEM
After a Level 1 Shutdown all process systems will need to be re-pressurised

with fuel gas. The following steps should be taken to re-introduce fuel gas and
re-pressurise the process systems.
Fuel gas may be taken from the separator gas manifold upstream of the
Separator Pressure Control Valves, 222-PCV-116/119/204 or from the gas
trunkline, downstream of the last block valve. For a normal black start, fuel
gas is available from the gas trunkline; this procedure makes this assumption.
If there is no gas in the trunkline this operation is delayed until gas becomes
available from the production separators, 222-V-001A/B/C.
Line up system by manually opening and closing valves as required.
Open 222-HV-80 in fuel gas line from gas trunkline.
Fuel gas is now being supplied through the fuel gas header to the flare system
as normal.
8.3 FLARE SYSTEM
The following steps should be taken to re-instate the flare systems.
• Ensure that the purge rate through 222-FISL-30 is approximately

2900scf/h
• Ensure that the purge rate through 222-FISL-31 is approximately

900scf/h
• Ensure all valves to and from the standby ignition system are open
• Ensure that instrument air is available in flare package air receiver

222-V-017
• Open all manually operated valves within the ignition panel
• Select automatic operation. The panel will not operate until the 'remote
ignition impulse' is sent to the panel from the FCC. This impulse
triggers off the automatic ignition sequence on the panel and the
solenoid valves will open

UPPER ZAKUM POM: 8
• With the solenoid valves open, gas and air are admitted into the
ignition line
• After a delay as set on timer T1 (Note: this will be a long time due to
distance to flare) to allow the igniters line to fill with the gas/air mixture,
a spark is generated in the ignition chamber. This spark will travel
along the ignition lines to light the pilots
• If after the final attempt, the pilot failure condition remains, the pilot
failed lamps and remote ‘pilot failed’ alarms will remain
• The auto-ignition sequence can be re-initiated by pushing the ‘remote

ignition switch’ to give a 48V DC impulse to the panel
Note: If the three-way switch is turned to reset during the auto ignition
sequence, the sequence will be stopped. Restarting the ignition
sequence can only occur by resetting the three-way switch to auto,
then giving an impulse to the panel from the ‘remote ignition switch’
Note: If pilot ignition is not achieved, the previous step is repeated three
times.
Due to the unavailability of the remote ignition facility, the flare is normally lit
using flare ignition cartridges.
8.4 DRAIN SYSTEM
The following steps should be taken to re-instate the drains system.
• Ensure there is a liquid level in the sump tank such that the
non-hazardous area drain inlet is submerged
• Ensure that the system is lined up and respective valves are opened or
closed as required
• Ensure that sump tank loop seal contains water
• Check that the hydrocarbon drain tank vent to flare and the fuel gas
supply to the hydrocarbon drain tank are open

UPPER ZAKUM POM: 8
• Check that sump tank controls attached to 222-LT-16 are energised.

Put the selector switch to the Auto position. The level in the Sump Tank
will be regulated by automatic operation of the sump tank pumps
• Check that hydrocarbon drain tank controls attached to 223-LT-31 are

energised. Put the selector switch to the Auto position. The level in the
hydrocarbon drain tank will be regulated by automatic operation of the
hydrocarbon drain tank pumps
8.5 PRODUCTION SEPARATOR
Instructions for the preparation and operation of the production wells are
detailed in UZ-POM010 – Upper Zakum – Wellhead Platforms – Plant
Operating Manual, Chapter 2.
The following steps provide the necessary details for the reinstatement
Production Separator 223-V-001A.
Ensure that the following valves are open:
• Pig receiver bypass
• Wellhead oil flow line to the selected oil feed manifold
• 222-XCV-11 separator inlet
• Low flow re-cycle to separator
• 222-XCV-154 hydrocarbon drain tank to separator
• 222-HV-208 oil outlet from the separator. (This is a manually operated

valve and needs to be opened prior to the Separator Reset)
• Block valves on 222-PSV-107/108, separator and oil flow lines

222-PSV-102/297/298
• 222-HV-66 gas outlet from the separator
• 222-HV-63 gas outlet from the separator to the flare header
UZ_POM08_C04_R0 Page 60 of 68 Date: 01-01-2004

UPPER ZAKUM POM: 8
Ensure that the following valves are closed:
• Wellhead flow line valve
• Pig receiver inlet and outlet
• Wellhead flow line to non-operational manifold
• Oil manifold drain
• 222-HCV-170, separator Inlet
• Separator drains, vents and purge connections
• Separator relief valve bypass globe valve
• XCV-12, emergency depressurisation valve
• HCV-67, bypass for PCV-116, separator gas to trunkline
• Drains associated with control valve assemblies
• All valves on sample connection assemblies
• The separator gas to fuel gas system is already closed
Set gas to flare Pressure Control Valve, PCV-117 at 100psig in auto mode.
Set Gas Trunkline Pressure Control Valve, 222-PCV-116 in manual mode,

fully closed.
Set Separator Level Control Valve, 222-LCV-4 in manual mode at 25% open.
Energise the platform shutdown systems for the well streams and the
separators.
Ensure that the following shutdown switches are operative:
• PSH Wellhead Oil Flow Line High Pressure
• 222-LSHHH-1A/B, Separator Very High Level
• 222-PSH-106, Separator High Pressure

UPPER ZAKUM POM: 8
Override the following shutdown switches:
• PSL Wellhead Oil Flow Line Low Pressure
• 222-PSL-105, Separator Low Pressure
• 222-LSLLL-5, Separator Very Low Level
The process systems are now ready to receive hydrocarbons from the
Wellhead Platforms. Reinstatement of operations can commence as detailed
in the following steps.
• Check that downstream equipment is ready to receive a flow of oil
• Start oil production from wellheads
• Open 222-HCV-170 on separator inlet
• Open the 2in bypass around 222-HV-1 to pressurise the production

separator and associated pipework
• Check the system for leaks and rectify as necessary
• Open platform inlet shutdown valve on wellhead flow line, close bypass
valve
• Gradually increase the flow from the well by opening additional strings
• As the pressure increases in the separator, slowly open Pressure

Control Valve, 222-PCV-116 and start the gas flow to the gas trunkline
• When the gas trunkline pressure is at 75psig, place 222-PCV-116 in

auto mode with a set point of 75psig.
Note: Although Flare Relief Valve 222-PCV-117 can be used to initially

control the pressure in V-001A until Central Complex is ready to
receive gas, gas flaring shall be kept at an absolute minimum.
When normal operating pressures and levels are achieved all overrides shall
be removed after ensuring that the trip switch is healthy and has been reset
as required.

UPPER ZAKUM POM: 8
Reinstatement of the crude oil booster and transfer pumps can now take place
as described in the following paragraph.
8.6 OIL BOOSTER PUMPS
Crude oil leaves the separator and joins a 20in header that supplies the
booster pump suction manifold. Crude from Separator A is routed via the
manifold to Oil Booster Pumps 222-P-001A/C. The booster pumps discharge
to a common 14in header, which feed the suction of the crude transfer pumps.
Crude Transfer Pumps 222-P-012A/D discharge through 222-LCV-4, to the

18in trunkline manifold before entering the 24in oil trunkline.
If the Crude Transfer Pumps 222-P-012A/D are not on line, the transfer pump
bypass valve must be opened.
When a liquid level develops in 222-V-001A, start one oil booster pump
(assumed P-001A).
Semi Auto mode is the normal operating mode for the SSP.
Semi Auto mode requires that the pumps selected in this mode need to be
started manually but the remainder of the logic is under full sequence control.
8.6.1 Preparation
Line up pump system by opening and closing respective valves as required.
Close breaker on 6.6kV switchboard for selected pumps.
Prepare the oil trunkline for operation.

UPPER ZAKUM POM: 8
8.6.2 Booster Pump Operation From FCC
This procedure assumes that Oil Booster Pump 222-P-001A is to be started

from the FCC.
The FCC will confirm with SSP that:
• Local/remote selector switch 222-HS-98 is in the remote position
• Field selector switches for the suction and discharge valves are in the
remote control position (222-HS-81 and 222-HS-82)
• 3-way selector switch 222-HS-91 in the LOR is in the semi-auto

position
Call up SSP Train 1 Control Mimic display and issue a Start Command for Oil
Booster Pump 222-P-001A and observe:
• Pump suction and discharge valves opening
• Motor running indication is lit
• Increase in discharge pressure (normal pressure range 260-290psig)
Confirm with SSP that Booster Pump Recycle Valve 222-PCV-502, has
opened.
Place Separator Level Control Valve 222-LCV-4 in auto mode with set point
of 50%.
Note: The pump shutdown logic is bypassed when field operation is selected
and the following trips are not operational:
• Low suction pressure
• Low discharge pressure
• High discharge pressure
• Seal failure
Start the second oil booster pump using the same procedure when the oil flow
rate is high enough to warrant it.

UPPER ZAKUM POM: 8
8.7 CRUDE OIL TRANSFER PUMPS
Normal operating levels and pressures have been re-established in Separator

222-V-001A and the oil trunkline from SSP to CSP are available. Start-up and
operation of the transfer pumps can be considered as a simultaneous
operation with the start-up and operation of the trunkline. Reset and opening
of the oil trunkline shutdown valves is detailed in Paragraph 8.8.
For detailed illustration of the start logic for Crude Oil Transfer 222-P-012A
refer to the following illustrations:
SSP-02-02-003 South Satellite Pumps Manual-Auto Start Sequence

SSP-02-02-008 South Satellite Manual and Field Pump Start Typical Pump
Shutdowns Separator Train-A Only
SSP-02-02-009 South Satellite Sequence Valve Action
SSP-02-02-010 South Satellite Instrument and Electrical Control System
For Booster and Transfer Pumps
The following description provides specific details for the start-up and
reinstatement of 222-P-012A in the Semi Auto mode, which is the normal
mode of operation. Further details for pumps start-up and operation can be
found in Chapter 2.
Line up pump system by opening and closing respective valves as required.
Transfer Pump 222-P-012A is the designated pump for Separator A. If it is not

available for operation, Transfer Pump 222-P-012D, which serves as a
common stand by for all three separators, is to be prepared.
The relevant transfer pump is started from the FCC as follows:
Call up SSP Train 1 Control Mimic, display and issue a Start Command for the
selected transfer pump and observe:
• Pump suction and discharge valves opening
• Motor ‘Running’ indication is lit
• Increase in discharge pressure (normal pressure range 400-500

dependent on operating conditions)
The oil starts to flow to the trunkline as soon as the crude transfer pump
discharge valve is opened.

UPPER ZAKUM POM: 8
This procedure details a first time start. Normally the plant is lined up to the
satellite oil manifold at the Central Complex with the exception of the booster
and transfer pumps.
8.8 OIL TRUNKLINE
Reinstatement and line out of the trunkline is carried out in conjunction with
the start-up of the transfer pumps. The following override may need to be
applied in order to be able to complete the reset and start-up.
• Override shutdown switch 222-PSL-190, low pressure in oil trunkline
• Open 222-XCV-35
• Inform Central Complex that SSP is ready to commence oil export
• As soon as the crude oil transfer pump has reached operating speed
and its discharge valve has been opened, open the oil pig launcher
bypass valve gradually, maintaining normal discharge pressure
upstream of the valve. The oil will flow to CSP and the pressure in the
trunkline will begin to increase
• When the sub sea pressure has risen to normal operating pressures
reinstate 222-PSL-190, low pressure in oil trunkline and reset any
related overrides on the platform shutdown system for the oil trunkline
8.9 GAS TRUNKLINE
This procedure assumes that 222-V-001A is put into operation first.
Line up gas trunkline by opening or closing respective isolation valves as

required.
The status of 222-HV-80, fuel gas to flare, should not be changed.
Inform Central Complex that South satellite is ready to start transferring gas.
If active, bypass Gas Trunkline Pressure Switch Low, 222-PSL-147.

UPPER ZAKUM POM: 8
Ensure that the Separator Pressure Control Valve 222-PCV-116 is in auto

mode with a set point of 75psig. 222-PCV-116 bypass valve, 222-HCV-67 can
also be used to control the separator pressure.
Place 222-PCV-117 in auto mode and slowly increase the set point to
100psig, 222-PCV-116 will start to open and 222-PCV-117 will start to close.
Raise the set point of Separator-A, Level Control Valve 222-LCV-4 to the
normal operating level.
When the gas trunkline pressure has risen, normalise gas trunkline Low
Pressure Switch 222-PSL-147.
When gas from the second production separator is transferred to the trunkline,
open block valves and shutdown valves in the second header. Ensure that
222-HCV-73 is closed; increase the set point of 222-PIC-130 slowly, as for the
first stream.
8.10 WATER INJECTION SYSTEM
Detailed instructions for the preparation and operation of the Water Injection
well are contained UZ-POM010 – Upper Zakum – Wellhead Platforms – Plant
Operating Manual, Chapter 3.
The following description assumes that injection water is available from the
Central Complex.
Select first WHPT concerned for injection.
Ensure that the following valves are open:
• Block valves for relief valves 222-PSV-375/378/382
• Flow line isolation valve at manifold
Ensure that the following valves are closed:
• Drain and vent lines overboard, on wellhead flow line
• Sample connection valves
• 222-HV-181, Pig Receiver Inlet

UPPER ZAKUM POM: 8
• Pig receiver outlet
• 222-HV-182, pig receiver bypass
• Bypass valves around 222-HV-181 and 222-HV-182
• Pig receiver vent
The crossover to the oil trunkline is already closed.
Energise FSH, wellhead flow line high flow.
Open the 2in bypass of 222-HV-182, Pig Receiver Bypass, to pressurise the
water injection manifold, then open 222-HV-182.
Slowly open HCV-L, choke valve on wellhead flow line. Vent air, if any is
present, through the 1in line.
When pressure has risen in the wellhead flow line, indicated by PI, open HV
shutdown valve on flow line, and close HCV.
Subsequent wells are put on-stream in a similar manner.

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UPPER ZAKUM POM: 8

SOUTH SATELLITE PLATFORM Chapter: 4

PROCESS SHUTDOWN AND START-UP Revision: 0

1 EMERGENCY SHUTDOWN PROCEDURES .......................................3

UZ_POM08_C04_R0.doc Page 1 of 68 Date: 01-01-2004

PROCESS SHUTDOWN AND START-UP Revision: 0

8 START-UP FROM LEVEL 1 SHUTDOWN .........................................57

UZ_POM08_C04_R0.doc Page 2 of 68 Date: 01-01-2004

PROCESS SHUTDOWN AND START-UP Revision: 0

1 EMERGENCY SHUTDOWN PROCEDURES

An Emergency Shutdown (ESD) is a rapid response to protect personnel,

SSP-04-01-001 South Satellite Level 1 Total Emergency Platform

• Level 1 – Total Emergency Platform Shutdown Depressurised

• Level 2 – Total Process Shutdown Pressurised

• Level 3 – Shutdown Process Sections Pressurised

• Level 4 – Equipment Safety Trips

UZ_POM08_C04_R0.doc Page 3 of 68 Date: 01-01-2004

PROCESS SHUTDOWN AND START-UP Revision: 0

• Certain Zone Fire and Gas Input Signals

• Other input Signals, eg Pushbuttons, FCC Commands, LCR

1.2 EMERGENCY RESPONSE

Specific actions for on site personnel in the event of an emergency situation

On-scene Commander (Senior Operator on site) shall:

• Obtain initial assessment information and request assistance, prior to

• Make the necessary PA announcement indicating specific area of

• Proceed to the emergency scene and start taking corrective actions

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• Request assistance from trades personnel as required

• Assess situation and take necessary actions ie ESD, depressurisation

• Confirm POB, initiate search and rescue when required

• If abandonment is necessary, proceed to muster point and prepare all

The on site Duty Operator shall:

• Proceed to the scene of the emergency and take actions as instructed

• If abandonment is necessary, proceed to muster point

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• Module 10 Battery Room

• Module 9 Emergency Diesel Generator Room (Air Intake and Room)

• Module 9 Essential Services Switch Room (Air Intake and Room)

• Module 9 Battery Room

SSP-04-01-001 South Satellite Level 1 Total Emergency Platform

The Black Start procedure is a sequence of manual operations to ensure each

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2.2 BLACK START RESET

This procedure is structured to give the response team a guideline for

The Black Start reset sequence requires a team comprising of a minimum of

• One Production Supervisor

• One Senior Operator

• One Safety Officer

• One Electrical Supervisor, Senior Authorised Electrical Person (SAEP)

• One HVAC Technician

• One Instrument Technician

Each room or enclosure shall be gas tested in strict rotation by a minimum of

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SSP-04-02-001 South Satellite Black Procedure with Gas Present in

The Black Start sequence is influenced by safety considerations such as

2.2.1 HVAC Start-up

SSP-04-02-002 South Satellite HVAC System Black Start Sequences

Step Operation Comments