Initial Start Up Procedure RevA

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

INTRODUCTION Contents Description

Page

1.0

INTRODUCTION

2

2.0

OBJECTIVE

3

3.0

DEFINITIONS

4

4.0

REFERENCES

4

1

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

1.0

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

INTRODUCTION

This information contained in this manual is intended as an aid to the operation of EOR facilities installed in the following platform:    

Sumandak Selatan Integrated Platform (SUPG-B) Samarang Oil Production Platform SMP-B Samarang Drilling Platform SMDP-B Samarang Jacket Platform SMJT-E

It is provided for the guidance and instruction of the platform operators and other personnel concerned with the design intent of the platform and thus will help to ensure the safety and the proper operation of the platform. Samarang Redevelopment Phase 2 EOR project will be undertaken to extend Samarang field life and is anticipated to increase recoverable reserves by as much as 78 mmstb from 17 mmstb to 95 mmstb within 2026. If implemented and executed as recommended, the field will achieve a state of zero continuous venting within 2015, and result in a remaining oil production rate of 6,000 bopd at 2026. Recovery factors from the field will increase from the pre-FDP forecast of 41%, to 51% in 2026. Phase 2 EOR Detail Design work for identified wells consists of infill, water and gas injection facilities (Gravity Assisted Simultaneous Water and Gas - GASWAG). The work involves platform upgrading at existing Sumandak platform SUPG-B, tie-in on existing Samarang platforms (SMP-B / SMDP-B and SMJT-E), and infill drilling on two existing drilling platforms SMDP-B and SMJT-E. Samarang will be utilizing Sumandak SUPG-B water injection (WI) facilities, with 2 new booster pumps installed in series with the existing water injection pumps to meet Samarang water injection pressure. Whereas, for the gas compression facility, there are originally 3 gas compressor trains installed on SUPG-B. However, compressor train A has been removed due to the reduction in export gas amount and SUPG-B is currently operating on 2X100% mode. A new 2 stages compressor train will be installed in place of the existing compressor, as the existing one has limited pressure to meet the required injection pressure in Samarang. A new 6” flexible pipeline (~13.5 km) is required to export the gas injection from SUPG-B to SMP-B. The gas will be further routed to SMDP-B via bridge link piping and the remaining gas will be routed to SMJT-E via new 4” flexible pipeline (~2.3 km). For water injection, a new 6” flexible pipeline (~13.5 km) will be installed from SUPG-B to SMP-B. And new 4” flexible pipeline (~2.3 km) will be installed to transfer water injection from SMP-B to SMJT-E. Safety Procedures and Operating Procedure bulletins issued by the Owner must be considered in conjunction with these guidelines and incorporated into actual procedures to be implemented. Of particular significance are: i.

Structure of the supervisory management in the operating organization and line of communication within.

2

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

ii.

Experience of Owner’s operator.

iii.

Liaison between Owner’s during initial start-up.

iv.

Detailed operating guidelines for vendor package equipment.

operator and field representatives of equipment manufacturers

The manual is divided into six sections. Each section provides information such as system description, equipment design data, detailed operating sequences and instructions, and equipment / valve location tables, to facilitate proper and safe operation of the facilities. Relevant diagrams are also provided to enhance the understanding of instructions and the operation of Sumandak Selatan Integrated Platform (SUPG-B). Although the manual contains inherent safe operating practices, it is intended to supplement, but not replace, other relevant Carigali approved safety and operating procedures. This manual must be read in conjunction with other relevant Carigali approved safety and operating procedures, including, but not limited to, the following: 1. 2. 3. 4. 5. 6.

Carigali Operating Procedure Bulletins. SUPG-B Emergency Response Procedures Manual(s) and related documentation. Carigali’s approved Vendor/Manufacturer Operating Procedures. Carigali Operations key as-built Drawings (contained within the Blue Books). Carigali HSEMS Manual. Electrical Standing Instructions.

Where applicable, within the operation procedures included in Section 3 and Section 4, for more specific references refer to the Operating Procedure Bulletins and/or to Vendors' / Manufacturers' Operating Procedures. Units of measurement generally conform to the System International (SI) units, followed by the equivalent Imperial units in parentheses e.g. 10 m (32.91 ft).

2. 0 OBJECTIVE The objective of this document to define the scope of work required to re-instate the system and make it ready for Non Hydrocarbon (Water Injection System) and Hydrocarbon (Gas Injection System) introduction. The whole scope of work to be completed in 3 phases;

a) Reinstatement b) System start-up c) System performance monitoring

3

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

3.0

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

DEFINITIONS

COMPANY

: PETRONAS CARIGALI SDN BHD (PCSB)

CONTRACTOR

: PETRA RESOURCES SDN BHD

VENDOR specified

: Party who supplies and manufactures equipment/ materials or services and ordered by CONTRACTOR

SUBCONTRACTOR ordered

: Party who providing subcontracting packages or services specified and by CONTRACTOR

4.0 REFERENCES: PSD-EOR-CO-013-REVB for Start Up, Shut Down and Operating Manual

Attachment List ATTACHMENT 1.0

: Flowchart for Water Injection Black Start

ATTACHMENT 1.1

: Prepare EOR Water Injection Facilities for Black Start-Up

ATTACHMENT 1.2

: USD System

ATTACHMENT 2.0

: Flowchart for Gas Injection Black Start

ATTACHMENT 2.1

: Prepare EOR Gas Injection Facilities for Black Start-Up

ATTACHMENT 2.2 kPag

: Pressurization of Sumandak and Samarang Gas Injection Facility to 7400

ATTACHMENT 2.3

: Start-Up Gas Turbine for Gas Injection Compressor

ATTACHMENT 2.4

: Shutdown of EOR Gas Compression

4

Formatted: Font: (Default) Arial, 10 pt

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

1.0

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Flowchart for Water Injection Black Start

THIS FLOWCHART IS FOR FIRST BLACK START UP ONLY, NOT DESIGNATED FOR POST ABANDON PLATFORM STARTUP.

Prior to introduction of Non Hydrocarbon, PASR and shall be conducted which include pre startup check in order to ensure Platform readiness for RFSU.

STEP   NO. 

1 

2 

3 

4 

PROCEDURE   ACTIVITY 

PROCEDURE INSTRUCTION 

DRAWING   REFERENCE  

Power Supply from 6.6kV SG‐7510     (Existing)  

09‐SUPG‐B‐E‐ 10001‐1  

  Vacuum Circuit Breaker (VCB  204)(Existing) 

  

09‐SUPG‐B‐E‐ 10001‐1  

  Vacuum Circuit Unit (VCU‐214 &  220 spare), 1000KW VCU 214 and  1000KW VCU 220 (Existing)  Ensure that all for  DMC WI  Mechanical (Off Skid + relevant  skids) System and checksheets  and records are complete and  signoff  Prepare PASR  

  

09‐SUPG‐B‐E‐ 10001‐1  

 1.0 

  

5 

5

CHECK (/)   ONCE TASK   IS  COMPLETED  

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

REVISION NO: 0

HOOK-UP AND COMMISSIONING

Prepare and CEM Simulation Test 

 1.1 

09‐SUPG‐B‐I‐ 10001‐01‐1  

Prepare for SAT P‐4085A/B system   1.1 

09‐SUPG‐B‐B‐ 10139‐1‐3 

Prepare and Start P‐4085A/B 

 1.2 

09‐SUPG‐B‐B‐ 10139‐1‐3 

Prepare and USD Test 

 1.3 

09‐SUPG‐B‐I‐ 10001‐01‐1  

Prepare and Endurance Test Pump   1.2  A/B 2 x 72 hours  

09‐SUPG‐B‐B‐ 10139‐1‐3 

Prepare for Dumping at SMP‐B  

 1.2 

09‐SMP‐B‐P‐0031‐1

Prepare for Dumping at SMJT‐E 

 1.2 

09‐SMP‐E‐P‐0022‐ 1‐3 

Stop P‐4085A/B Pump after  endurance test 

 1.2 

09‐SUPG‐B‐B‐ 10139‐1‐3 

Prepare and restart P‐4085A/B 

 1.2 

09‐SUPG‐B‐B‐ 10139‐1‐3 

6 

7 

8 

9 

10 

PSP-CS-SMJT-G-002

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

11 

12 

13 

14 

15 

Prepare for Scaling Inhibitor / Fine   1.2  Stabilizer Injection at SMJT‐E 

09‐SMP‐E‐P‐0022‐ 1‐3 

Prepare for Water Injection to  Wellhead SMJT‐E (SM 74) 

 1.2 

16 

09‐SMP‐E‐P‐0001‐ 1‐3‐4 

Prepare ESD Test (with GI system) 

 1.2 

09‐SUPG‐B‐I‐ 10001‐01‐1  

17 

6

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

18 

Prepare for Scaling Inhibitor / Fine   1.2  Stabilizer Injection at SMDP‐B 

09‐SMDP‐B‐P‐ 0014‐3‐WT  

19 

Prepare for Water Injection to  Wellhead SMDP‐B (SM 50) 

09‐SMDP‐B‐P‐ 0001‐3‐WT  

1.1

 1.2 

Prepare EOR Water Injection Facilities for Black Start-Up

1.1.1 Prepare EOR Water Injection Facilities for Black Start‐Up STEP NO.

CHECK ONCE TASK IS COMPLETED

ACTION

1.

Confirm water injection pipeline from SUPG-B to SMP-B is ready for operation.

2.

Confirm water injection pipeline from SMP-B to SMJT-E is ready for operation.

3.

Confirm communication with Samarang via VSF radio/telephone.

4.

Confirm water injection facility at SMP-B, SMDP-B and SMJT-E ready to receive water injection export from SUPGB.

5.

Ensure that all water injection facility PSVs are online (inlet isolation valves car seal open)

6.

Check that check valve VCH-1111/1112 and restriction orifice RO-4086A/B on pump minimum recycle line are installed correctly.

7.

Ensure that all instrumentations are commissioned and online.

7

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

8.

Ensure chemical injection system on SUPG-B has been filled with the related chemicals – clay stabilizer and scale inhibitor are ready for operation.

9.

Flush pipes between water injection pump (P-4080A/B/C) discharge line to water injection booster pump (P-4805A/B) suction to remove any construction debris prior to "black start-up" of water injection booster pump. Route the flushed water to overboard via water injection booster pump suction drain valve VBA-1187 / 1188 and VBA-1191 / 1192. Close the drain valves once flushing is completed.

10.

Flush water injection booster pump (P-4805A/B) discharge line to water injection export SDV to remove any construction debris prior to “black start-up” of water injection booster pump. Route the flushed water to overboard via water injection booster pump discharge drain valve VBA-1189 / 1190 and VBA-1193 / 1194. Close the drain valves once flushing is completed.

11.

Check water injection booster pump suction strainer to remove any construction debris prior to “black start-up” of water injection booster pump.

12.

13.

Set water injection booster pump discharge pressure controller PICA-4085 @ 21060 kPag by MCP. Place PICA4085 in MANUAL mode and check PCV-4085 is fully closed. Open bypass valves VBA-1004 & VGL-1001 for pressure equalization. Close VBA-1004 & VGL-1001 once the pressure reaches 21060 kPag.

Set water injection booster pump recycle flow controller FIC4087A/B @ 74 m³/hr in AUTO mode.

Apply start-up override for the following instrumentation trip: 14.

Water injection booster pump suction pressure low low PZALL-4085A/B (LL set @ 2260 kPag) Water injection booster pump discharge flow low low FZALL4087A/B (LL set @ 70 m3/h)

8

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

The start-up override bypasses a process value to allow time for the value to reach a state that does not initiate a trip. The start-up override is cleared automatically when pressure/flow restored above low low set point.

15.

Ensure water injection pump P-4080A/B/C is running and water injection supply header at 8000 kPag (PICA-4081).

16.

Ensure SUPG-B water injection header pressure controller PIC-0908 is at 1200 psig (8274 kPag) in AUTO mode. This is to ensure stable suction pressure for water injection booster pump operation.

17.

Ensure SMP-B water injection dump valve HCV-4060 is 50% open prior to starting water injection booster pump at SUPGB. HCV-4060 to be regulated to desired pressure once water injection arrives at SMP-B. During this procedure, ensure VB-2111 and VB-2112 (guard filter inlet isolation valves) is in close position. This is for flushing pipeline purposes before introducing water injection into guard filter.

18.

Ensure SMDP-B water injection dump valve HCV-4089 is 50% open prior to introducing water injection at Riser Guard. HCV-4089 to be regulated to desired pressure once water injection arrives at SMDP-B. During this procedure, ensure DBB-3009 & DBB-3010 is in closed position.

19.

Ensure water quality at water injection supply header meets required water injection quality.

20.

Ensure all spectacle blinds and valves LC/LO/NC as per P&ID.

21.

Line up the valves as shown in the checklist below.

1.1.2 P‐4085A Valve Status Checklist (Water Injection Black Start‐up)  Tag No.

Location/Description

Valve Position

9

Check

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Preparation

Operation

LO

LO

VBA-1001

Discharge header of existing water injection pump

VBA-1141

P-4085A suction isolation valve

Open

Open

XV-4085A

P-4085A suction ON/OFF valve

Open

Open

XV-4086A

P-4085A discharge ON/OFF valve

Open

Open

VBA-1002

P-4085A discharge isolation valve

Open

Open

VBA-1187 / 1188

P-4085A suction drain valves

Open

Close

VBA-1189 / 1190

P-4085A discharge drain valves

Open

Close

VBA-1142

P-4085B suction isolation valve

Close

Open

XV-4085B

P-4085B suction ON/OFF valve

Close

Close

XV-4086B

P-4085B discharge ON/OFF valve

Close

Close

VBA-1003

P-4085B discharge isolation valve

Close

Open

VBA-1191 / 1192

P-4085B suction drain valves

Close

Close

VBA-1193 / 1194

P-4085B discharge drain valves

Close

Close

VBA-1195 / 1196

PCV-4085 inlet isolation valves

Open

Open

VBA-1197 / 1198

PCV-4085 outlet isolation valves

Open

Open

VBA-1004 / VGL-1001

PCV-4085 bypass valves

Open

Close

P

O

1.1.3 P‐4085B Valve Status Checklist (Water Injection Black Start‐up)    Valve Position Tag No.

Check

Location/Description Preparation

10

Operation

P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

VBA-1001

Discharge header of existing water injection pump

VBA-1141

LO

LO

P-4085A suction isolation valve

Close

Open

XV-4085A

P-4085A suction ON/OFF valve

Close

Open

XV-4086A

P-4085A discharge ON/OFF valve

Close

Open

VBA-1002

P-4085A discharge isolation valve

Close

Open

VBA-1187 / 1188

P-4085A suction drain valves

Close

Close

VBA-1189 / 1190

P-4085A discharge drain valves

Close

Close

VBA-1142

P-4085B suction isolation valve

Open

Open

XV-4085B

P-4085B suction ON/OFF valve

Open

Close

XV-4086B

P-4085B discharge ON/OFF valve

Open

Close

VBA-1003

P-4085B discharge isolation valve

Open

Open

VBA-1191 / 1192

P-4085B suction drain valves

Open

Close

VBA-1193 / 1194

P-4085B discharge drain valves

Open

Close

VBA-1195 / 1196

PCV-4085 inlet isolation valves

Open

Open

VBA-1197 / 1198

PCV-4085 outlet isolation valves

Open

Open

VBA-1004 / VGL-1001

PCV-4085 bypass valves

Close

Close

Water Injection Launcher L‐4086 at SUPG‐B  Valve Position Tag No. XV-4089 VBA-

Check

Location/Description Preparation

Operation

Launcher bypass XV

Open

Open

Water injection line valve to SMP-B

Open

Open

11

P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

1011 XV-4087 / 4088

Launcher outlet XV

Close

Close

VGL1014 / VBA1014

Launcher kicker line valves

Close

Close

VBA1008

Launcher balance line valve

Close

Close

VBA1005 / 1006 / 1007 / 1010

Launcher drain valves

Close

Close

VBA1015 / VGL1002

Launcher vent valves

Close

Close

  Water Injection Receiver R‐4060 at SMP‐B   Valve Position Tag No.

Check

Location/Description Preparation

Operation

VB-2025

Incoming water injection supply from SUPG-B

Open

Open

VB-2026 / 2027

Receiver inlet isolation valves

Close

Close

VB-2013 / 2061

Receiver outlet isolation valves

Close

Close

VB-2030

Receiver bypass valve

Open

Open

VB-2028 / VO2014

Receiver bypass pressure equalization valves

Close

Close

VB-2092

Receiver vent valves

Close

Close

12

P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

/ VO2015 VB-2036 / VO2012

Receiver vent valves

Close

Close

VB-2031

Receiver balance line valve

Close

Close

VB-2037 / 2038 / 2039

Receiver drain valves

Close

Close

VB-2105 / 2106

PSV-4060A inlet isolation valves

LO

LO

VB-2107 / 2108

PSV-4060B inlet isolation valves

LC

LC

VB-2109 / 2110

Water injection header dump line isolation valves

Open (Note 1)

Open

VB-2084

Water injection header low point drain

Close

Close

Notes: 1. HCV-4060 (downstream of VB-2109/2110) is 50%-70% open before introduction into guard filter during commissioning or black start.   Water Injection Guard Filter F‐4065 at SMP‐B   Valve Position Tag No.

Check

Location/Description Preparation

Operation

Close (Note 1)

Open

VB-2111 / 2112

Filter inlet isolation valves

VB-2044

Filter bypass valve

Close

Close

VB-2113 / 2114

Filter outlet isolation valves

Open

Open

VB-2041 / 2042

Filter drain valves

Close

Close

VB-2115 / 2116

Water injection supply to SMDP-B isolation valves

Open

Open

13

P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

VB-2117 / 2118

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Water injection supply to SMJT-E isolation valves

Open

Open

Notes: 1. To be open after complete water injection dumping. Estimated 1 hour of dumping duration before opening the valves (for reducing filter clogging due to debris and off spec water).

      Water Injection Launcher L‐4070 at SMP‐B   Valve Position Tag No.

Check

Location/Description Preparation

Operation

VB-2094

Water injection to SMJT-E

Open

Open

VB-2052

Launcher bypass valve

Open

Open

VB-2048 / 2049

Launcher outlet valves

Close

Close

VO2016 / VB-2066

Launcher kicker valves

Close

Close

VB-2047

Launcher balance valve

Close

Close

VB-2046 / 2050 / 2051

Launcher drain valves

Close

Close

VO2017 / VB-2093

Launcher vent valves

Close

Close

P

O

  Water Injection Manifold / Flowline at SMDP‐B   Valve Position Tag No.

Location/Description Preparation

14

Operation

Check P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

DBB-3009

Water injection to injection well

Close (Note 1)

Open

DBB-3010

Water injection to injection well

Close (Note 1)

Open

VB-3015 / 3016

Water injection dump line isolation valves

Open (Note 2)

Open

Notes: 1. To be open once the water injection meets quality. 2. Set opening of HCV-4089 (downstream of VB-3015/3016) at 50%-70%.

Water Injection Wellhead SM‐50 at SMDP‐B   Tag No.

Valve Position

Location/Description

Preparation

Operation

Surface safety valve

Close

Open

Surface controlled subsurface safety valve

Close

Open

Injection choke valve

Close

Open

-

Wing valve

Close

Open

-

Master valve

Close

Open

SSV5051 SCSSV5051 FCV5051

Check P

O

Water Injection Wellhead SM‐49 at SMDP‐B   Valve Position Tag No. SSV4951 SCSSV4951

Location/Description Preparation

Operation

Surface safety valve

Close

Open

Surface controlled subsurface safety valve

Close

Open

15

Check P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

FCV4951

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Injection choke valve

Close

Open

-

Wing valve

Close

Open

-

Master valve

Close

Open

Water Injection Receiver R‐4084 / Manifold at SMJT‐E   Valve Position Tag No.

Preparation

Operation

Open

Open

VB-4019

Incoming water injection supply from SMP-B

VB-4046 / 4047

To water injection wellhead SM-48

Close (Note 1)

Open

Water injection header dump line DBB valves

Open (Note 2)

Open

DBB4026

Check

Location/Description

VB-4017 / 4018

Receiver inlet isolation valves

Close

Close

VB-4033 / VO4022

Receiver outlet isolation valves

Close

Close

VB-4020

Receiver bypass valve

Open

Open

VB-4027 / VO4026

Receiver vent valves

Close

Close

VB-4023

Receiver balance line valve

Close

Close

VB-4024 / 4028 / 4031

Receiver drain valves

Close

Close

Notes: 1. Only open when water injection quality met.

16

P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

2. Set opening of HCV-4084 (downstream of DBB-4026) at 50%-70%. Reduce the opening once quality is met. Water Injection Wellhead SM‐74 at SMJT‐E   Tag No.

Location/Description

SSV-7451 SCSSV7451 FCV-7451

Valve Position

Check

Preparati on

Operation

Surface safety valve

Close

Open

Surface controlled Subsurface safety valve

Close

Open

Injection choke valve

Close

Open

P

O

1.2 Black Start-Up EOR Water Injection Facilities STEP NO.

CHECK ONCE TASK IS COMPLETED

ACTION

1.

Prior to starting water injection booster pump P-4085A, ensure Sumandak Water Injection Facilities are prepared.

2.

Ensure communication between Samarang, are established.

3.

Perform line flushing at SMP-B, SMDP-B and SMJT-E.

4.

Start water injection booster pump P-4085A

5.

Check the water is recycling via pump minimum line via recycle pump flow control valve

6.

Ensure pump discharge flow is about 74 m³/hr via flow measurement at FIC-4087A to prevent pump damage

2

platforms,

7.

17

Sumandak

&

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Observe recycle water temperature via temperature measure at TIA4087A on pump recycle line. Temperature should not exceed 60°C. To reduce the temperature, consider gradually open PCV-4085 bypass valves VBA-1004 & VGL-1001. Close the valves once the temperature is manageable.

8.

Check pressure differential across pump suction strainer via PDA4085A.

9.

Once pump discharge flow is stabilized at about 74 m³/hr, open PCV4085 gradually by 5 – 10% opening.

10.

Set water injection booster pump discharge pressure controller PICA4085 in AUTO mode once FCV-4087A is fully closed.

11.

12.

Remove all inhibited trips once the water injection booster pump discharge pressure and flow has stabilized. Start injecting clay stabilizer and scale inhibitor into SUPG-B water injection export header

Monitor pressure at the following location: Water injection booster pump discharge pressure at 21060 kPag (PICA-4085) Water injection export header to SMP-B at SUPG-B (PIA-4092) 13.

Water injection incoming header from SUPG-B at SMP-B (PI-4060) Differential pressure at SMP-B water injection guard filter F-4065 Water injection export header to SMJT-E at SMP-B (PI-4070) Water injection supply header at SMDP-B (PI-4090) Water injection incoming header from SMP-B at SMJT-E (PI-4086)

14.

15

Prior to injecting to wellhead, perform the SLOPE Test. NOTE: Ensure the water injection guard filter is online before performing the SLOPE Test.

Once required pressure at water injection manifold at SMP-B and

18

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

SMJT-E is achieved, water injection to individual wellhead can proceed.

Water injection to individual wellhead shall be done one wellhead at a time and follows the following sequence: a) Open well SCSSV, manual master valve, manual wing valve and followed by SSV from WHCP unit. b) Manually open injection choke valve at minimum opening and gradually increase as per requirement to introduce water injection into the well.

16.

1.3 Start-Up EOR Water Injection Facilities following USD/PSD/ESD STEP NO.

ACTION

1.

Start-up after USD/PSD/ESD requires operator attendance at the platform

2.

Reason for USD/PSD/ESD has been identified and any correction implemented and conditions cleared.

3.

Ensure all wellhead water injection choke valves and water injection dump valves are closed and confirm pressure in water injection header.

4.

Water injection dump valves shall be open 50% to prevent water hammering during start-up of water injection booster pump and shall be gradually reduce once water injection quality is met.

5.

Confirm pressure in water injection header.

19

CHECK ONCE TASK IS COMPLETED

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Apply start-up override for the following instrumentation trip: Water injection booster pump suction pressure low low PZALL-4085A/B 6.

Water injection booster pump discharge flow low low FZALL-4087A/B The start-up override bypasses a process value to allow time for the value to reach a state that does not initiate a trip. The start-up override is cleared automatically when pressure/flow restored above low low set point.

7.

Follow steps mentioned in section 1.2

1.4 Shutdown EOR Water Injection Facilities CHECK ONCE TASK IS COMPLETED

STEP NO.

ACTION

1.

Monitor pressure at water injection supply header. Open water injection dump valve as necessary to divert the flow overboard.

2.

Slowly reduce water injection supply flow by means of gradually closing wellhead water injection choke valve one by one.

3.

Once all wellhead water injection choke valves are closed, place water injection booster pump discharge pressure controller PICA-4085 in MANUAL mode. Close PCV-4085 gradually by 5% to 10%. By closing of PCV4085 gradually, the water injection flow will be diverted to pump suction via minimum pump recycle line through FCV-4087A.

4.

Close well SSV followed by SCSSV from WHCP unit.

20

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

5.

Stop the clay stabilizer and scale inhibitor injection into water injection export header at SUPG-B.

6.

Monitor water injection booster pump discharge flow via FIC-4087A

7.

Stop the water injection booster pump P-4085A once PCV-4085 is fully closed.

1.5 Instrument Set Points Water Injection Booster Pump at SUPG‐B  Tag No.

Location/Description

Set Point

PZALL-4085A

P-4085A suction pressure low low

2260 kPag

PIAL-4086A

P-4085A suction pressure low

3765 kPag

PIAH-4087A

P-4085A discharge pressure high

22180 kPag

FZALL-4087A

P-4085A discharge flow low low

70 m3/h

FICL-4087A

P-4085A discharge flow low

74 m3/h

TIAH-4087A

P-4085A discharge temperature high

PZALL-4085B

P-4085B suction pressure low low

2260 kPag

PIAL-4086B

P-4085B suction pressure low

3765 kPag

PIAH-4087B

P-4085B discharge pressure high

22180 kPag

FZALL-4087B

P-4085B discharge flow low low

70 m3/h

FICL-4087B

P-4085B discharge flow low

74 m3/h

21

60°C

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

TIAH-4087B

P-4085B discharge temperature high

60°C

PICAH-4085

Water Injection Booster Pump discharge header pressure high

22000 kPag

PICAL-4085

Water Injection Booster Pump discharge header pressure low

10450 kPag

Water Injection Launcher at SUPG‐B   Tag No.

Location/Description

Set Point

PIAH-4092

Water injection to SMP-B pressure high

22000 kPag

PIAL-4092

Water injection to SMP-B pressure low

10450 kPag

Water Injection Receiver at SMP‐B   Tag No. PSV-4060 A/B

Location/Description Water injection to Water Injection Guard Filter pressure safety valves

Set Point 208 barg

Water Injection Guard Filter at SMP‐B   Tag No.

Location/Description

Set Point

PSV-4065

Water Injection Guard Filter pressure safety valve

208 barg

PSV-4066

Water injection line to SMDP-B

208 barg

  Water Injection Wellheads at SMDP‐B   Tag No.

Location/Description

Set Point

PEL-5053

Water injection flowline to wellhead

115.8 barg

PEL-4953

Water injection flowline to wellhead

115.8 barg

  Water Injection Wellhead at SMJT‐E  

22

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

Tag No. PEL-7453

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Location/Description Water injection flowline to wellhead

Set Point 115.8

barg

1.6 SMP-B/SMDP-B The gas from SUPG-B to SMP-B will be further routed to SMDP-B via bridge link piping and injected into two new GI wellheads. Automatic flow control is provided at each gas injection wells. Flow meter will be provided on the common line prior to SMP-B bridge linked to SMDP-B and gas injection export line to SMJT-E, to monitor total gas injection rate. Flow meter is also provided on the line to individual wells. The EOR gas injection facilities at SMP-B consist of: Gas Injection Receiver (R-2940) Item

Specification

Design Pressure

28000 kPag (4060 psig)

Design Temperature

100°C (max) / -20 ºC (min) Diameter: 200 mm / 150 mm

Size (Major Barrel/Minor Barrel)

Length: 1860 mm / 2420 mm

Gas Injection Launcher (L-2950) 1

Item

3

Design Pressure

5

Design Temperature

7

Size (Major Barrel/Minor Barrel)

2 4 6

Specification

28000 kPag (4060 psig) 65 °C (max) / -20 ºC (min)

8

Diameter: 150 mm / 100 mm

9

Length: 1830 mm / 1000 mm

1.6.1 SMJT-E The remaining gas injection from SMP-B will be routed to SMJT-E. New 4” flexible GI pipeline will be installed to transfer injection gas from SMP-B to SMJT-E. Automatic flow control is provided at each gas injection wells.

23

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

There is no additional equipment installed in SMJT-E for gas injection.The EOR gas injection facilities at SMJT-E consist of: Gas Injection Receiver (R-2910) 10 Item 12 Design Pressure 14 Design Temperature 16 Size (Major Barrel/Minor Barrel)

11 Specification 13 28000 kPag (4060 psig) 15 65 °C (max) / -20 ºC (min) 17 Diameter: 150 mm / 100 mm 18 Length: 2040 mm / 1690 mm

24

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Formatted: Font: Bold

2.0 Flowchart for Gas Injection Black Start

Formatted: Font: (Default) Arial, Bold

THIS FLOWCHART IS FOR FIRST BLACK START UP ONLY, NOT DESIGNATED FOR POST ABANDON PLATFORM STARTUP.

Prior to introduction of Hydrocarbon, PIR-04/PASR and shall be conducted which include pre startup check in order to ensure Platform readiness for RFSU.

STEP   NO 

1 

2 

3 

PROCEDURE   ACTIVITY 

PROCEDURE INSTRUCTION 

DRAWING   REFERENCE  

Power Supply from 400V SG SB‐ 7710(Existing)  

  

09‐SUPG‐B‐E‐4012‐1 

  Air Circuit Breaker (ACB  311)(Existing) 

  

09‐SUPG‐B‐E‐4012‐1 

     Vacuum Circuit Unit (VCU‐214 &  220 spare), 1000KW VCU 214 and  1000KW VCU 220 (Existing)  MCC‐7810 (Existing) 184KW    

09‐SUPG‐B‐E‐4012‐1 

09‐SUPG‐B‐E‐4012‐1 

230V AC UPS DB 7814B (Existing) 

  

09‐SUPG‐B‐E‐4012‐1 

IRP 7810 (Existing) 

  

09‐SUPG‐B‐E‐4012‐1 

4 

5 

6 

25

CHECK (/)   ONCE TASK   IS  COMPLETED  

Formatted: Font: (Default) Arial, Bold Formatted: Font: (Default) Arial, Bold

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Ensure that all for  RFC GI  Mechanical (Off Skid + relevant  skids) System and checksheets  and records are complete and  signoff  Prepare PIR‐04 

 2.0 

Prepare PASR 

  

Prepare for CEM Simulation Test 

 2.0 

Prepare for RFSU 

  

Prepare and Pressurization  Pipeline from SUPG‐B to SMJT‐E  at 72 Barg (System Test)  

 2.1 

09‐SUPG‐B‐B‐10119‐ 1‐3 

Prepare for GTC Start Up

 2.2 

09‐SUPG‐B‐B‐10119‐ 1‐3 

Prepare and GTC pressurize 117  Barg to SMJT‐E (System Test) 

 2.2 

14 

09‐SUPG‐B‐B‐10120‐ 1‐3 

  2.2 

15 

Start GTC Ramp Up Pressure to  234 Barg 

09‐SUPG‐B‐B‐10120‐ 1‐3 

Prepare for ESD Test 

  2.4 

09‐SUPG‐B‐I‐10001‐ 01‐1  

Prepare and Restart Up GTC and  Injection to SMJT‐E SM 121 (72  Hours) 

  2.3 

09‐SMJT‐E‐P‐0019‐1‐ 1 

7 

  

8 

9  09‐SUPG‐B‐I‐10001‐ 01‐1  

10 

11 

12 

13 

16 

17 

26

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL

REVISION NO: 0

HOOK-UP AND COMMISSIONING

PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

18 

PSP-CS-SMJT-G-002

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

Prepare for Gas Injection into SM  37 & SM 47 at SMDP‐b 

  2.3 

09‐SMDP‐B‐P‐0009‐ 1‐3‐WT 

Formatted: Font: Bold

2.1 Prepare EOR Gas Injection Facilities for Black

Formatted: Font: (Default) Arial, Bold

STEP NO.

CHECK ONCE TASK IS COMPLETED

ACTION

1.

Confirm gas injection pipeline to SMP-B is ready for operation

2.

Confirm gas injection facility at SMP-B, SMDP-B and SMJT-E ready to receive gas injection export from SUPG-B

3.

Confirm communication with Samarang via VSF radio/telephone

Check the following utility is ready for operation: 4.

Fuel Gas @ 1860-3450 kPag Instrument Air @ HOLD kPag Power supply

5.

Ensure that all gas injection facility PSVs are online (inlet isolation valves car seal open)

6.

Ensure all check valves and restriction orifices are installed correctly

7.

Ensure that all instrumentations are commissioned and online

27

Formatted: Font: (Default) Arial, Bold Formatted: Font: (Default) Arial, Bold Formatted: Font: Bold

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

8.

Ensure gas injection facility piping at SUPG-B, SMP-B, SMDP-B and SMJT-E is already purged and ready prior to hydrocarbon entry. The piping shall be purged and pressurized to 690 kPag with nitrogen.

9.

Ensure gas injection compressor package pre start-up checklist and action item required as stated in Vendor Manual (see vendor doc TPIM 1010) has been completed and complied with.

10.

Verify gas injection compressor casings have been drained.

11.

Set gas injection compressor backpressure controller PICA-2430 @ 23000 kPag and place it in MANUAL mode. Set the controller output to ensure PCV-2430 is fully open.

12.

Set 1st stage compressor suction scrubber level controller LICA2415 on gap control (LCV open @ 650 mm and LCV close @ 400 mm). Place the controller in AUTO mode.

13.

Set 2nd stage compressor suction scrubber level controller LICA2416 on gap control (LCV open @ 650 mm and LCV close @ 400 mm). Place the controller in AUTO mode.

14.

Close all gas injection choke valves via SMQ-A

Apply start-up override for the following instrumentation trip:

15.

1st stage GI compressor scrubber liquid level low low LZALL-2415 1st stage GI compressor suction pressure low low PZALL-2426 1st stage GI compressor suction flow low low FZALL-2425 1st stage GI compressor discharge pressure low low PZAHH-2425 2nd stage GI compressor scrubber liquid level low low LZALL-2416 2nd stage GI compressor suction pressure low low PZALL-2446

28

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

2nd stage GI compressor suction flow low low FZALL-2445 2nd stage GI compressor discharge pressure low low PZAHH-2445 SUPG-B gas injection export header pressure low low PZALL2932A/B/C SMP-B gas injection incoming header pressure low PEL-2940 SMP-B gas injection export header pressure low PEL-2950 SMJT-E gas injection incoming header pressure low PEL-2910 The start-up override bypasses a process value to allow time for the value to reach a state that does not initiate a trip. The start-up override is cleared automatically when pressure/flow restored above low low set point. 16.

Line up the valves as shown in the checklist below.

Gas Injection Preparation Valve Status Checklist

Formatted: Font: (Default) Arial, 11 pt, Bold, English (Malaysia)

Downstream of Gas/Glycol Heat Exchanger at SUPG-B

Formatted: Font: (Default) Arial, 11 pt, Bold, English (Malaysia)

Valve Position Tag No.

Check

Location/Description Prepare

Operation

VDBB1032

Gas supply tie-in DBB

LO

LO

VDBB1033

PSV-2230B inlet DBB

LC

LC

VDBB1034

PSV-2230A inlet DBB

LO

LO

VBA1019

PSV-2230B outlet valve

LO

LO

VBA1017

PSV-2230A outlet valve

LO

LO

P

O

1st Stage Gas Injection Compressor Suction Scrubber V-2415 at SUPG-B Tag No.

Location/Description

Valve Position

29

Check

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Prepare

Operation

VBA1059

Suction scrubber inlet isolation valve

Open

Open

SDV2415

Suction scrubber inlet SDV

Close

Open

SDV2416

Suction scrubber inlet bypass SDV

Close

Close

VBA1175 / 1176

PSV-2415A inlet isolation valves

LO

LO

VBA1177 / 1178

PSV-2415B inlet isolation valves

LC

LC

VBA1077

PSV-2415A outlet isolation valve

LO

LO

VBA1145

PSV-2415B outlet isolation valve

LO

LO

VBA1079

Suction scrubber vent valve

LC

LC

VGL1008

Suction scrubber vent valve

NC

NC

VBA1068 / 1069

Suction scrubber drain valves

NC

NC

VBA1070

Suction scrubber instrument drain valve

NC

NC

SDV2417

Suction scrubber outlet SDV

Close

Open

VBA1071 / 1126

LCV-2415 inlet isolation valves

Open

Open

VBA1127 / 1122

LCV-2415 outlet isolation valves

Open

Open

30

P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Valve Position Tag No. VBA1124 / VGL1015

Check

Location/Description Prepare

Operation

NC

NC

LCV-2415 bypass valves

P

O

1st Stage Gas Injection Compressor K-2425 & After Cooler E-2435 at SUPG-B Valve Position Tag No.

XV-2426

Check

Location/Description Preparation

Operation

Open

Close

Hot gas compressor bypass valve

VDBB-1090

PSV-2425A inlet DBB

LO

LO

VDBB-1091

PSV-2425B inlet DBB

LC

LC

VBA-1084

PSV-2425A outlet isolation valve

LO

LO

VBA-1087

PSV-2425B outlet isolation valve

LO

LO

VBA-1083

Compressor vent valve

LC

LC

VGL-1009

Compressor vent valve

NC

NC

VBA-1081 / 1082

After cooler drain valves

NC

NC

XV-2427

Cold gas compressor bypass valve (HOLD)

Open

P

O

Close

2nd Stage Gas Injection Compressor Suction Scrubber V-2416 at SUPG-B Tag No.

Location/Description

Valve Position

31

Check

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Preparation

Operation

VBA-1183 / 1184

PSV-2416A inlet isolation valves

LO

LO

VBA-1185 / 1186

PSV-2416B inlet isolation valves

LC

LC

VBA-1037

PSV-2416A outlet isolation valve

LO

LO

VBA-1035

PSV-2416B outlet isolation valve

LO

LO

VBA-1104

Suction scrubber vent valve

LC

LC

VGL-1010

Suction scrubber vent valve

NC

NC

Suction scrubber drain valves

NC

NC

VBA-1043

Suction scrubber instrument drain valve

NC

NC

SDV-2420

Suction scrubber liquid outlet SDV

Close

Open

VBA-1040 / 1128

LCV-2416 inlet isolation valves

Open

Open

VBA-1129 / 1150

LCV-2416 outlet isolation valves

Open

Open

VBA-1125 / VGL1016

LCV-2416 bypass valves

NC

NC

VBA-1041 / 1042

P

O

2nd Stage Gas Injection Compressor K-2426 & After Cooler E-2436 at SUPG-B Valve Position Tag No.

XV-2445

Check

Location/Description Hot gas compressor bypass valve

Preparation

Operation

Open

Close

VDBB-1050

PSV-2426A inlet DBB

LO

LO

VDBB-1051

PSV-2426B inlet DBB

LO

LO

VDBB-1099

PSV-2426C inlet DBB

LC

LC

32

P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

VBA-1051

PSV-2426A outlet isolation valve

LO

LO

VBA-1053

PSV-2426B outlet isolation valve

LO

LO

VBA-1144

PSV-2426C outlet isolation valve

LO

LO

VBA-1110

Compressor vent valve

LC

LC

VGL-1011

Compressor vent valve

NC

NC

VBA-1057 / 1056

After cooler drain valves

NC

NC

XV-2446

Cold gas compressor bypass valve (HOLD)

Open

Close

Gas Injection Compression Discharge Header at SUPG-B Valve Position Tag No.

Preparation

Operation Open

SDV-2435

Compressor discharge header SDV

Close

VBA1155/1203SDV2436

Pipeline pressurisation manual valvesCompressor discharge header bypass SDV

Open

Manual blowdown XV to LP flare

Close

Close

LO

LO

loseOpen

Close

XV-2428VBA1202

Check

Location/Description P

Close

VBA-1136

XV-2428 VBA-1202 outlet isolation valve

BDV-2427

Compression discharge header BDV

VBA-1094

BDV-2428 outlet isolation valve

LO

LO

VBA-1090

Compression discharge header isolation valve

Open

Open

Gas Injection Launcher L-2930 and Compressor Seal Gas Supply at SUPG-B Tag No.

Location/Description

Valve Position

33

Check

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Preparation

Operation

Launcher bypass XV

Open

Open

Gas injection line SDV to SMP-B

Open

Open

Launcher outlet XV

Close

Close

VGL1094 / VBA1074

Launcher kicker line valves

Close

Close

VBA1033

Launcher balance line valve

Close

Close

VBA1020 / 1095 / 1034 / 1096 / 1032

Launcher drain valves

Close

Close

VBA1027 / 1098 / 1026

Launcher purging line valves

Close

Close

VBA1021 / 1022

Launcher manual depressurization line valves

Close

Close

BDV2931

Gas injection export header BDV

Close

Close

VBA1030

BDV-2931 outlet isolation valve

LO

LO

VBA1102

BDV-2931 outlet line bleed valve

NC

NC

SDV2932

Gas supply to gas injection turbine compressor seal gas system

Open

Open

VBA-

PCV-2937 inlet isolation valves

Open

Open

XV-2932 SDV2930 XV-2930 / 2931

34

P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

1123 / 1153 VBA1092 / 1155

PCV-2937 outlet isolation valves

Open

Open

VBA1181 / 1182

PSV-2930A inlet isolation valves

LO

LO

VBA1151

PSV-2930A outlet isolation valve

LO

LO

VBA1179 / VBA1181

PSV-2930B inlet isolation valves

LC

LC

VBA1152

PSV-2930B outlet isolation valve

LO

LO

VBA1029 / 1149

Gas injection export pipeline blowdown

Close

Close

Gas Injection Compressor Turbine at SUPG-B Valve Position Tag No.

Preparation

Operation

Compressor turbine utility air supply valve

Open

Open

VBA-1205 / 1206

Compressor turbine instrument air supply valve

Open

Open

VB-24204A

Compressor turbine potable water supply valve

Open

Open

VBA-1210

Engine air inlet duct drain valve

Open

Open

VBA-1207

Lube oil tank drain valve

NC

NC

VBA-1208

Lube oil filter drain-unfiltered valve

NC

NC

VBA-1120

Check

Location/Description

35

P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

VBA-1121

Drip pan oil drain valve

NC

NC

VBA-1209

Engine exhaust collector and combustor drain valve

NC

NC

VBA-1174

Seal gas filter drain valve

Close

Close

LC

LC

Open

Open

VB-59305 / VBA1204

Compressor turbine N2 supply

VBA-1212

TC fuel gas filter inlet

VBA-1211

TC fuel gas filter inlet drain line

NC

NC

VBA-1213

TC fuel gas filter drain point

NC

NC

VBA-1214

TC fuel gas filter depressurisation line

LO

LO

VBA-1216

Potable water supply to high pressure water mist skid

Open

Open

Gas Injection Receiver at SMP-B Valve Position Tag No.

Location/Description Preparation

Operation

ABV-2940

Incoming gas injection supply from SUPG-B

Open

Open

VB-2001 / 2002

Receiver inlet isolation valves

Close

Close

Receiver outlet isolation valves

Close

Close

VB-2007

Receiver bypass valve

Open

Open

VB-2005 / VO-2009

Receiver bypass pressure equalization valves

Close

Close

VB-2009 / 2008

Receiver vent valves

Close

Close

VB-2004

Receiver balance line valve

Close

Close

VBO-2010 / VB-2087

36

Check P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

VB-2101 / 2102

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Receiver purging line valves

Close

Close

Receiver drain valves

Close

Close

VB-2100 / 2099

Future pipeline pressurization line isolation valves

Close

Close

VB-2085

VCH-2001 bypass valve

Close

Close

Gas injection incoming header BDV

Close

Close

LO

LO

VB-2003 / 2010 / 2011

BDV-2941 VB-2012

BDV-2941 outlet isolation valve

DBB-2004

Gas injection to launcher L-2950 DBB valves

Open

Open

DBB-2005

Gas injection to SMDP-B gas injection manifold DBB valves

Open

Open

37

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Gas Injection Launcher at SMP-B Valve Position Tag No.

Location/Description Preparation

Operation

VB-2091

VC-2002 bypass valve

Close

Close

VB-2014

Launcher bypass valve

Open

Open

VB-2020 / 2021

Launcher outlet isolation valves

Close

Close

VB-2024 / 2023

Header vent valves

Close

Close

Open (Note 1)

Open

ABV2950

Gas injection supply to SMJT-E

Check P

O

Notes: 1. Ensure valve is open after ABV-2910 at SMJT-E is fully open during preparation line up.

Gas Injection Manifold at SMDP-B Valve Position Tag No.

Location/Description Preparation

Operation

ABV-2942

Gas injection supply from SMP-B

Open

Open

DBB-3021

Flowline connection for SM-47

Open

Open

DBB-3022

Flowline connection for SM-61

Open

Open

VB-3007 / 3008

Gas injection manifold drain valves

Close

Close

Gas Injection Flowline Wellhead SM-61 at SMDP-B

38

Check P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Valve Position Tag No.

Location/Description Preparation

Operation

VB-3003 / 3004

Flowline vent valves

Close

Close

SSV-6151

Surface safety valve

Close

Open

Surface controlled subsurface safety valve

Close

Open

SCSSV6151

Check P

O

Gas Injection Flowline Wellhead SM-47 at SMDP-B Tag No. VB-3005 / 3006 SSV-4751 SCSSV4751

Valve Position

Location/Description

Preparation

Operation

Flowline vent valves

Close

Close

Surface safety valve

Close

Open

Surface controlled subsurface safety valve

Close

Open

39

Check P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Gas Injection Receiver at SMJT-E Tag No.

Valve Position

Location/Description

Preparation

Operation

ABV-2910

Gas injection supply from SMP-B

Open

Open

VB-4001 / 4002

Receiver inlet isolation valves

Close

Close

VB-4042 / 4043

Future pipeline pressurization line isolation valves

Close

Close

VB-4003

Receiver bypass valve

Open

Open

VB- 4029

Header vent valves

Close

Close

Check P

O

Gas Injection Manifold at SMJT-E (Error! Reference source not found.33) Tag No. VB-4044 / 4045 VB-4013 / 4014

Valve Position

Location/Description

Prepare

Operation

Flowline connection for SM-7448

Open

Open

Gas injection manifold drain valves

Close

Close

Check P

O

Gas Injection Manifold Wellhead at SMJT-E Tag No.

Valve Position

Location/Description

Prepare

Operation

VB-40438 / 40439

Flowline vent valves

Close

Close

SSV121104851

Surface safety valve

Close

Open

SCSSV121104851

Surface controlled subsurface safety valve

Close

Open

40

Check P

O

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

2.2 Pressurization of Sumandak and Samarang Gas Injection Facility to 7400 kPag CHECK ONCE TASK IS COMPLETED

STEP NO.

ACTION

1.

Line up the following valves at respective platform for pipeline pressurization: (The table focuses on the valves involved in pressurization.)

  Downstream of Glycol Heat Exchanger E‐2230 (SUPG‐B)  Valve Position Tag No.

Location/Description

VDBB1032

Gas supply tie-in DBB

VDBB1033

PSV-2230B inlet DBB

VDBB1034

PSV-2230A inlet DBB

41

Pressurization

Operation

LO

LO

LC

LC

LO

LO

Formatted: Font: (Default) Arial, Bold Formatted: Font: Bold, English (Malaysia)

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

VBA-1017

PSV-2230A outlet valve

LO

LO

VBA-1019

PSV-2230B outlet valve

LO

LO

  1st stage Gas Injection Compressor Suction Scrubber V‐2415 (SUPG‐B)  Valve Position Tag No.

Location/Description Pressurization

Operation

VBA-1059

Suction scrubber inlet isolation valve

Close

Open

VBA-1155

Pressurization bypass line isolation valve

Open

LC

        Gas Injection Compression Discharge Header (SUPG‐B)  Valve Position Tag No.

Location/Description Pressurization

Operation

VBA-1203

Pressurization bypass line isolation valve

Open

LC

VBA-1090

Compression discharge header isolation valve

Open

Open

  Gas Injection Launcher (SUPG‐B)  Valve Position Tag No.

Location/Description Pressurization

Operation

PCV-2430

Launcher pressure control valve

Open

Open

VCH-1003

Launcher check valve

Open

Open

XV-2932

Launcher bypass

Open

Open

42

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

SDV-2930

Gas injection line SDV to SMP-B

Open

Open

BDV-2931

Gas injection export header BDV

Open

Open

VBA-1030

BDV-2931 outlet isolation valve

LO

LO

  Gas Injection Receiver (SMP‐B)  Valve Position Tag No. 

Location/Description  Pressurization

Operation

ABV-2940

Incoming gas injection supply from SUPG-B

Open

Open

VB-2005/VO2009

Receiver bypass pressure equalization valves

Open

Close

VCH-2001

Receiver check valve

Open

Open

BDV-2941

Gas injection receiver BDV

Close

Close

DBB-2004

Gas injection to launcher L-2950

Open

Open

DBB-2005

Gas injection to SMDP-B injection manifold via bridge

Open

Open

  Gas Injection Export (SMP‐B)  Valve Position Tag No. 

Location/Description  Pressurization

Operation

VC-2002

Export check valve

Open

Open

VB-2014

Launcher bypass valve

Open

Open

VB-2024/23

Header vent valves

Close

Close

ABV-2950

Gas injection supply to SMJT-E

Open

Open

  Gas Injection Manifold (SMDP‐B)  Tag No. 

Location/Description 

Valve Position

43

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING Pressurization

Operation

ABV-2942

Gas injection supply from SMP-B

Open

Open

DBB-3021

Connection to SM-47

Close

Open

DBB-3022

Connection to SM-61

Close

Open

VB-3007/08

Manifold drain valves

Close

Close

  Gas Injection Receiver (SMJT‐E)  Valve Position Tag No.

Location/Description Pressurization

Operation

ABV-2910

Gas injection supply from SMP-B

Open

Open

VB-4001/02

Receiver inlet isolation valves

Close

Close

VB-4050/51

Future pipeline pressurization line isolation valves

Close

Close

    Gas Injection Manifold (SMJT‐E)  Valve Position Tag No. 

Location/Description  Pressurization

Operation

VB-4044/45

Connection to SM-74

Close

Open

VB-4013/14

Manifold drain valves

Close

Close

(Continue from step no.1)  STEP NO.

2.

CHECK ONCE TASK IS COMPLETED

ACTION

Pressurize the pipeline in 4 stages (each stage accounts for 25% of 7400 kPag): 1850, 3700, 5550, and 7400 kPag. Control the inlet pressure using PCV-2430 in MANUAL mode by setting the control valve to the pressure at each stage. Close VBA-1155 and 1203 to isolate the bypass line at each stage.

44

Formatted: Font: Bold, English (Malaysia)

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

3.

The expected pressure profile is shown in the figure below. A certain time should be reserved for stabilization of pressure and leakage detection upon completion of pressurizing at each stage. Dedicated personnel will be assigned to perform testing (to detect leakage) and remediation at the main valves during pressurization.

4.

Be reminded that the pressure is taken from design value, at discharge of 2nd stage GI compressor. Value may vary during actual pressurization.

5.

Close VBA-1155 and VBA-1203 (LC) when the pressure in the pipeline reaches 74 barg (or the current export pressure). This is to prevent backflow during compressor startup and cause Glycol Contactor C-2220 to overpressure.

6.

Open 1st stage compressor suction scrubber inlet bypass SDV-2416 to start pressurization of gas injection facility to 7400 kPag

7.

Once the pressure is reaches 7400 kPag, place gas injection compressor

45

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

backpressure controller PICA-2430 in AUTO mode (set point: i. 117.0 barg and ii. 234.4 barg). Due to control action, the pressure control valve PCV-2430 will close.

Start cooler fan for 1st stage gas injection compressor after cooler E-2435 and 2nd stage gas injection compressor after cooler E-2436

8.

Line up the following valves for operation prior to compressor start-up: •1st Stage Gas Injection Compressor Suction Scrubber Inlet SDV-2415 •1st Stage Gas Injection Compressor Suction Scrubber Inlet Bypass SDV-2416 •Compressor Discharge Header SDV-2435 •Pipeline pressurisation manual valves VBA-1155 / 1203

9.

Refer to 2.0 for the valve position during operation. NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for detailed sequencing of the valves.

2.3 Start-Up Gas Turbine for Gas Injection Compressor STEP NO.

CHECK ONCE TASK IS COMPLETED

ACTION

NOTE: Refer vendor doc. title Turbomachinery Package Installation Guideline: Compressor and Mechanical Drive Units, doc no. TPIM 1010 for further details 

1.

Check that fuel gas supply is adequately available for the gas injection compressor turbine driver.

2.

Ensure adequate process gas supply is available from glycol  contactor for compressor start up.  NOTE : A restart may be initiated one minute after the turbine engine speed drops to 15 percent. In case of a malfunction shutdown, do not attempt another restart until the cause of the malfunction has been determined and the condition has been corrected. After three attempted starts have been unsuccessful, additional troubleshooting

46

Formatted: Font: Bold, English (Malaysia)

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

3.

4. 5. 6.

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

may be required. Select Maintenance display screen and select onscreen FAIL TO LOAD SHUTDOWN ENABLE button. Verify [Fail to Load Enabled] highlights. Select Unit Valves display screen and select onscreen Seal System Auto button. Verify [Auto] highlights for Seal System Status. From Unit Valves display screen, select onscreen Yard Valves Auto button and verify [Auto] highlights for Yard Valves System Status. Select HPC Surge Control display screen and select onscreen Auto button. Verify [Auto] is highlighted for ANTI-SURGE CONTROL.

7.

Select LPC Surge Control display screen and select onscreen Auto button. Verify [Auto] is highlighted for ANTI-SURGE CONTROL.

8.

Verify Operation display screen is selected to monitor package during start.

9.

Press START Switch (S1010) or select Operation display screen onscreen START button.

 

a. STARTING Light (DS1014) begins flashing and [Starting] is highlighted on Operation display screen. Enclosure vent fan is energized. Backup lube oil pump is tested for operation and pre/post pump starts pre-lubrication cycle. The control system begins a fuel system check. Start system is energized.

 

b. After pre-lube cycle is complete, engine cranking begins. c.

 

     

After starter has cranked engine to 15 percent speed, purge timer provides a preselected period of exhaust system purging via engine air flow. [Purge Crank] is highlighted on Operation display screen. d. After purge cycle is completed, fuel is admitted into combustor chamber where it is mixed with compressed air and ignited. [Ignition] is highlighted on e. Operation display screen. Light off occurs within next few seconds and combustion begins. f. The engine continues to accelerate and engine temperature increases to 400°F (204°C). [Light Off] is highlighted on Operation display screen, fuel ramp is activated, and ignition is de-

47

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

energized. ENGINE HOURS/START COUNTER Meter (M210) registers a successful start.

 

g. Engine speed increases to starter dropout speed. Engine-driven lube oil pump pressure increases and pre/post lube oil pump stops. Start system is de-energized and starter clutch overruns. Engine speed increases to idle speed. ENGINE HOURS/START COUNTER Meter (M210) begins to log engine operating hours. STARTING Light is extinguished and [Running] is highlighted on Operation display screen.

 

h. If engine speed remains at idle speed, manually increase engine speed by pressing INCREASE Switch (S1054) until [Ready to Load] is highlighted on Operation display screen.

NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for detailed sequencing of the valves. NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for detailed sequencing of the valves.

2.3 .1 Start-Up Gas Turbine for Gas Injection Compressor STEP NO.

CHECK ONCE TASK IS COMPLETED

ACTION

1.

Confirm that gas injection compressor is in stable operation

2.

Monitor flow, pressure and temperature at the following location: 1st stage GI compressor suction pressure (PIA-2425) via GI compressor TCP 1st stage GI compressor discharge pressure (PIA-2426) via GI

48

Formatted: Font: Bold, English (Malaysia)

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

compressor TCP 1st stage GI compressor discharge temperature (TIA-2426) via GI compressor TCP 2nd stage GI compressor suction pressure (PIA-2445) via GI compressor TCP 2nd stage GI compressor discharge pressure (PIA-2448) via GI compressor TCP 2nd stage GI compressor discharge temperature (TIA-2446) via GI compressor TCP 2nd stage GI compressor after cooler outlet temperature (TIA-2457) GI injection export header flow (FQI-2435)

3.

4.

5.

With closed PCV-2430 due controller action, 2nd stage GI compressor discharge pressure is expected to build up to 23000 kPag. Upon reaching this pressure, PCV-2430 will start to open to pressurize the pipeline further from 74 barg to reach required operating landing pressure at SMP-B and SMJT-E depending on GI injection well consumption.

Once required pressure at gas injection manifold at SMP-B and SMJT-E is achieved, gas injection to individual wellhead can proceed.

Gas injection to individual wellhead shall be done one wellhead at a time and follows the following sequence: a. Ensure the header valves are fully open. b. Ensure the master and wing valves are fully open. c. Open well SCSSV and followed by SSV from WHCP unit. d. Open injection choke valve to introduce gas injection into the well

2.4 Shutdown of EOR Gas Compression 49

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

NOTE: Refer vendor doc. title Turbomachinery Package Installation Guideline: Compressor and Mechanical Drive Unit, doc no. TPIM 1010 for further details This subsection describes the shutdown procedures for the turbine package. There are four types of shutdown procedures; normal stop, pressurized fast stop, emergency stop, and control system stop. Once the turbine is shutdown, operator at SMG-A to stop gas injection at SMDP-B and SMJT-E as necessary by closing the wellhead gas injection choke valves. Close injector well SSV followed by SCSSV from well control-o-maticWHCP unit.

2.4.1 NORMAL STOP NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for more details.

This subsection describes the procedures to initiate a normal stop from the control console. A normal stop shutdown sequence includes a cooldown period, which allows the engine to run with no load for a preset period before the engine is stopped. 1. Press NORMAL STOP Switch (S1011) or select Operation display screen onscreen STOP button. The following events occur: a. COOLDOWN Light (DS1013) illuminates, surge control valve is opened, and [Cooldown] highlights on Operation display screen. b. Engine slows to idle speed and continues to run for a preset cooldown cycle. NOTE : Engine may be restarted during cooldown cycle by pressing ACKNOWLEDGE Switch, RESET Switch, and then START Switch or by selecting Operation display screen onscreen RESET and START buttons. c.

After preset cooldown cycle, fuel system valves close, combustion ceases, and engine begins to decelerate. COOLDOWN Light (DS1013) extinguishes and [Cooldown] indication reverts to normal video. d. When engine speed decreases below 25%, Slow Roll Time counts down under TIME REMAINING on Operation display screen.

NOTE : The Variable Frequency Drive (VFD) commands the starter motor to a speed of ~2 to 3.5% NGP. As the engine speed continues to slow from 25%, the overrunning clutch continues to overrun until the engine speed matches the starter speed. The clutch engages and the starter maintains the commanded speed until the slow roll timer times out.

50

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

e. After preset slow roll cycle, start motor is de-energized. STOPPING Light (DS1011) illuminates, and [Stopping] highlights on Operation display screen. f. Gas compressors suction valves and discharge valves close and vent valves remains closed to maintain pressure in gas compressors and process piping for a preselected pressurization hold time period. g. [Running] indication reverts to normal video. ENGINE HOURS/START COUNTER Meter (M210) stops logging operating time. h. After engine coasts to a stop and rundown timer expires, a preset post lubrication cycle will be initiated. i. After preselected pressurization hold time period ends, vent valves open to depressurize compressors and process piping and seal system is de- energized.

2.4.2 PRESSURIZED FAST STOP NOTE: Refer vendor doc. title Unit-Control Balance of Plant Functional Specification, doc no. 3Y041-149008 for further details A pressurized fast stop causes the unit to stop with the compressors pressurized, and vent valves and blowdown valves remain closed. To initiate a pressurized fast stop, press the customerfurnished FAST STOP (REMOTE) Switch (S513). The following events occur: 1. Compressor suction valves close, discharge valves close, vent valves, and blowdown valves remain closed to maintain pressure in gas compressors and process piping for a preselected pressurization hold time period. 2. Engine shuts down immediately with no cooldown cycle. Slow roll cycle is bypassed, STOPPING Light (DS1011) illuminates, and [Stopping] highlights on Operation display screen. 3. ENGINE HOURS/START COUNTER Meter (M210) stops logging operating time. 4. After engine coasts to a stop and rundown timer expires, a preset post lubrication cycle will be initiated. 5. After pre-selected pressurization hold time period ends, vent valves and blowdown valves open to depressurize compressors and process piping and seal system is de-energized.

2.4.2 EMERGENCY STOP NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for more details. An emergency stop does not include a cool down period, which allows the engine to run with no load for a preset period before the engine is stopped. The emergency stop shutdown should only be used when plant conditions require an immediate shutdown.

51

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

An emergency stop prevents package operation until the emergency stop shutdown is acknowledged and reset by pressing the local ACKNOWLEDGE and RESET switches and the backup relay system is reset. NOTE : In the following procedures, display screen indications that highlight in (reverse video) are shown in brackets [ ]. To initiate an emergency stop, press either the EMERGENCY STOP Switch (S1012) located on the turbine control panel or the EMERGENCY STOP Switch (S312) located on the enclosure twin control station. The following events occur: 1. Pressurized hold sequence is bypassed. Compressor suction valves close, discharge valves close, and vent valves open. 2. Engine shuts down immediately with no cool down cycle. Slow roll cycle is bypassed, STOPPING Light (DS1011) illuminates, and [Stopping] highlights on Operation display screen. 3. ENGINE HOURS/START COUNTER Meter (M210) stops logging operating time. 4. After engine coasts to a stop and rundown timer expires, a preset post lubrication cycle will be initiated.

2.4.3 CONTROL SYSTEM STOP NOTE: Refer to Solar Turbines document title Unit-Control Balance of Plant Functional Specification, doc. no. 3Y041-149007 for more details. There are two types of control system stops; cool down stop and fast stop. If an unsafe operating condition is detected by the control system, the control system will initiate a shutdown. Depending upon the severity of the shutdown, the control system will initiate either a cool down stop or a fast stop. If the control system stop was initiated due to a condition that is self-correcting, the engine can be restarted after the condition returns to normal. If the control system stop was initiated due to a condition that is not self-correcting, contact maintenance personnel to perform corrective actions.

Cooldown Stop If a cooldown stop has been initiated, the compressors are unloaded and the engine is shut down in the same manner as a normal stop. There are two types of cooldown stops; cooldown lockout and cooldown nonlockout.

52

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)





PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Cooldown Nonlockout (CN) - Cooldown nonlockout shutdowns reduce engine speed to idle for a preset cooldown period before initiating a shutdown. Cooldown nonlockout shutdowns include operator initiated normal stops, operating conditions that reached a shutdown limit because maintenance was not performed, a momentary disruption that causes an out-oflimits condition, and operating conditions that exceed alarm levels but are not serious enough to cause any immediate damage. Cooldown nonlockout shutdowns can be reset after corrective action has been taken or operating conditions revert to normal using either the local or remote acknowledge and reset switches. Cooldown Lockout (CL) - Cooldown lockout shutdowns reduce engine speed to idle for a preset cooldown period before initiating a shutdown. Cooldown lockout shutdowns typically result from a component failure and not because operating conditions have exceeded alarm or shutdown levels. Cooldown lockout shutdowns may not present immediate danger, but corrective action must be taken to avoid damage resulting from a component failure. Cooldown lockout shutdowns prevent package operation until the shutdown is acknowledged and reset using the local acknowledge and reset switches.

NOTE : Remote acknowledge and reset switches cannot acknowledge or reset cooldown lockout shutdowns. Fast Stop If a fast stop has been initiated, the compressors are unloaded and the engine is shut down in the same manner as an emergency stop. There are two types of fast stops; fast stop lockout and fast stop non lockout. WARNING : When a fast stop shutdown has been initiated due to fire detection, the postlube oil pump will remain energized for a preset rundown period. After the preset rundown period expires, the postlube oil pump will be deenergized for 20 minutes. After the 20 minute time period expires, the postlube pump will cycle on and off for a preset postlube period. If unsafe conditions still exist, the operator must manually abort the post lube cycle by opening the facility contactors for the postlube and backup lube oil pumps. 



Fast Stop Nonlockout (FN) - Fast stop nonlockout shutdowns initiate an immediate shutdown of the engine. Fast stop nonlockout shutdowns typically result from a disruption in operation due to abnormal operating conditions and may not require corrective action. Fast stop nonlockout shutdowns can be reset when operating conditions revert to normal using either the local or remote acknowledge and reset switches. Fast Stop Lockout (FL) - Fast stop lockout shutdowns initiate an immediate shutdown of the engine. Fast stop lockout shutdowns prevent package operation until the shutdown is acknowledged and reset using the local acknowledge and reset switches. In addition to using the local acknowledge and reset switches, fast stop lockout shutdowns initiated due to a microprocessor failure, fire detection, backup overspeed, or pressing of emergency stop switch will require the backup relay system to be reset. Fast stop lockout shutdowns

53

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

are the most severe shutdown types and require corrective action before the package can be restarted. NOTE : Remote acknowledge and reset switches cannot acknowledge or reset fast stop lockout shutdowns. Shutdown Initiators Any of the following process abnormality signals will result an export compressor USD. 1st stage GI compressor scrubber liquid level high high LZAHH-2415 1st stage GI compressor suction pressure low low PZALL-2426 1st stage GI compressor suction flow low low FZALL-2425 1st stage GI compressor discharge pressure high high PZAHH-2427 1st stage GI compressor discharge pressure low low PZAHH-2425 1st stage GI compressor after cooler inlet temperature high high TZAHH-2427A/B 1st stage GI compressor after cooler outlet temperature high high TZAHH-2436 2nd stage GI compressor scrubber liquid level high high LZAHH-2416 2nd stage GI compressor suction pressure low low PZALL-2446 2nd stage GI compressor suction flow low low FZALL-2445 2nd stage GI compressor discharge pressure high high PZAHH-2447 2nd stage GI compressor discharge pressure low low PZAHH-2445 2nd stage GI compressor after cooler inlet temperature high high TZAHH-2447A/B 2nd stage GI compressor after cooler outlet temperature high high TZAHH-2456 PSD ESD In addition to this a number of machine related signals can give a USD. For details on this refer to vendors operation and maintenance manuals. In the event of crash shutdown is initiated check the following actions occur. 1. Check lube oil supply from run down tank is maintained during speed down. 2. Check that fuel gas SABDV has closed. 3. Check that compressor inlet, outlet valves have closed and compressor has been depressurised.

54

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Check lube oil pumps and air coolers are shutdown and isolate all motor breakers.

55

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

2.42.5 Instrument Set Points Downstream of Gas/Glycol Heat Exchanger at SUPG-B Tag No. TIAH-2230

PSV-2230 A/B

Location/Description

Set Point

Downstream of Gas/Glycol Heat Exchanger temperature high Gas/Glycol Heat Exchanger pressure safety valves

65°C 8740 kPag (1267 psig)

1st Stage Gas Injection Compressor Suction Scrubber V-2415 at SUPG-B Tag No.

Location/Description

Set Point

LZAHH-2415

1st Stage Gas Injection Compressor Suction Scrubber level high high

800mm from vessel bottom tangent line

LZALL-2415

1st Stage Gas Injection Compressor Suction Scrubber level low low

250mm from vessel bottom tangent line

LICAH-2415

1st Stage Gas Injection Compressor Suction Scrubber level high

700mm from vessel bottom tangent line

LICAL-2415

1st Stage Gas Injection Compressor Suction Scrubber level low

350mm from vessel bottom tangent line

PSV-2415 A/B

1st Stage Gas Injection Compressor Suction Scrubber pressure safety valves

13700 kPag (1986.5 psig)

1st Stage Gas Injection Compressor K-2425 & After Cooler E-2435 at SUPG-B Tag No. PZALL-2426

Location/Description 1st Stage Gas Injection Compressor suction pressure low low

56

Set Point 5250 kPag (761 psig)

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

Tag No.

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Location/Description

Set Point

FZALL-2425

1st Stage Gas Injection Compressor suction flow low low

PZALL-2425

1st Stage Gas Injection Compressor discharge pressure low low

8870 kPag (1286 psig)

PZAHH-2427

1st Stage Gas Injection Compressor discharge pressure high high

13500 kPag (1975.6 psig)

TZAHH-2427A

1st Stage Gas Injection Compressor discharge temperature high high

115°C

TZAHH-2427B

1st Stage Gas Injection Compressor discharge temperature high high

115°C

TZAHH-2436

1st Stage Gas Injection Compressor After Cooler outlet temperature high high

60°C

PSV-2425 A/B

1st Stage Gas Injection Compressor pressure safety valves

HOLD

15000 kPag (2175 psig)

Gas Injection Launcher L-2930 and Compressor Seal Gas Supply at SUPG-B Tag No.

Location/Description

Set Point

PZAHH-2932

Seal gas pressure high high

17080 kPag (2477 psig)

PSV-2930 A/B

Seal gas line pressure safety valves

18200 kPag (2639 psig)

2nd Stage Gas Injection Compressor Suction Scrubber V-2416 at SUPG-B Tag No.

Location/Description

57

Set Point

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

LZAHH-2416

2nd Stage Gas Injection Compressor Suction Scrubber level high high

800mm from vessel bottom tangent line

LZALL-2416

2nd Stage Gas Injection Compressor Suction Scrubber level low low

250mm from vessel bottom tangent line

LICAH-2416

2nd Stage Gas Injection Compressor Suction Scrubber level high

700mm from vessel bottom tangent line

LICAL-2416

2nd Stage Gas Injection Compressor Suction Scrubber level low

350mm from vessel bottom tangent line

PSV-2416 A/B

2nd Stage Gas Injection Compressor Suction Scrubber pressure safety valves

17350 kPag (2516 psig)

58

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

2nd Stage Gas Injection Compressor K-2426 & After Cooler E-2436 at SUPG-B Tag No.

Location/Description

Set Point

PZALL-2446

2nd Stage Gas Injection Compressor suction pressure low low

6600 kPag (960 psig)

FZALL-2445

2nd Stage Gas Injection Compressor suction flow low low

PZALL-2445

2nd Stage Gas Injection Compressor discharge pressure low low

20000 kPag (2900 psig)

PZAHH-2447

2nd Stage Gas Injection Compressor discharge pressure high high

25200 kPag (3654 psig)

TZAHH-2447A

2nd Stage Gas Injection Compressor discharge temperature high high

123°C

TZAHH-2447B

2nd Stage Gas Injection Compressor discharge temperature high high

123°C

PSV-2426 A/C

2nd Stage Gas Injection Compressor pressure safety valves

28000 kPag (4060 psig)

PSV-2426 B

2nd Stage Gas Injection Compressor pressure safety valve

29400 kPag (4264 psig)

TZAHH-2456

2nd Stage Gas Injection Compressor After Cooler outlet temperature high high

80°C

TIAH-2457

2nd Stage Gas Injection Compressor After Cooler outlet temperature high

75°C

HOLD

Gas Injection Launcher L-2930 and Compressor Seal Gas Supply at SUPG-B Tag No.

Location/Description

Set Point

PICAH-2430

Gas injection compression discharge header pressure high

24150 kPag (3503 psig)

PICAL-2430

Gas injection compression discharge header pressure low

21850 kPag (3170 psig)

Gas injection to SMP-B pressure low

18952 kPag (2720 psig)

PIAL-2931

59

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

Tag No.

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Location/Description

Set Point

PZALL-2932 A/B/C

Gas injection to SMP-B pressure low low

16408 kPag (2380 psig)

PZAHH-2932

Gas supply to compressor turbine seal gas system

17080 kPag (2477 psig)

Gas Injection Receiver at SMP-B Tag No.

Location/Description

Set Point

PEL-2940

Pressure Alarm Low for Gas Injection from SUPG-B

148 barg (2146.6 psig)

Gas Injection Launcher at SMP-B Tag No. PEL-2950

Location/Description Pressure Alarm Low for Gas Injection to SMJT-E

Set Point 148 barg (2146.6 psig)

Gas Injection Manifold at SMDP-B Tag No.

Location/Description

Set Point

PEL-6151

Pressure Alarm Low for Gas Injection to SMDP-B

144.8 barg

PEL-4751

Pressure Alarm Low for Gas Injection to SMDP-B

144.8 barg

Gas Injection Receiver at SMJT-E Tag No. PEL-2910

Location/Description Pressure Alarm Low for Gas Injection from SMP-B

Gas Injection Manifold at SMJT-E

60

Set Point 145.6 barg (2111.8 psig)

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

Tag No. PEL-1214853

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-018 REVISION NO : A

HOOK-UP AND COMMISSIONING

Location/Description Pressure Alarm Low for Gas Injection at SMJT-E

61

Set Point 144.8

barg

PROCEDURE NO:

START UP, SHUT DOWN AND OPERATING MANUAL PETRA RESOURCES SDN BHD (172962-D)

PETRA RESOURCES SDN BHD (172962-D)

HOOK-UP AND COMMISSIONING

62

PSP-CS-SMJT-G-002 REVISION NO: 0

PROCEDURE NO : PSP-EOR-CO-013 REVISION NO : A