V12 Waterflood System

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SHELL NIGERIA EXPLORATION AND PRODUCTIONCOMPANY Ltd.

Bonga FPSOPlant Operating Procedures Manual

Volume 12WATERFLOOD SYSTEM

OPRM 2003 0312

Version: 2.1

Thi s document is not confidential.

The Copyright of this document is vested in Shell NigeriaExploration and Production Company Limited. All rights reserved.Neither the whole nor any part of this document may bereproduced, stored in any retrieval system or transmitted in anyform or by any means (electronic, mechanical, reprographic,recording or otherwise) without the prior written consent of thecopyright owner.



Shell Nigeria E & P Company Ltd. Unrestricted

Document Status Information

1.0. DOCUMENT CONTROL

1.1. Change History

Date Version AuthorRef

IndicatorChange Description

31/08/05 2.0 ODL – Amendments to Part 1Section 1 Paragraphs 1.0,2.0 and 3.2.3. Changes toFigure 1.2.

Amendments to Part 1

Section 2:• Paragraphs 1.0, 2.1, 2.2,

2.3, 2.4, 2.5, 2.6, 2.7, 2.8,2.9, 2.11, 3.3.1, 3.4.1,3.4.2, 3.4.6, 3.4.7, 3.4.9,3.6.1, 3.6.2, 3.6.3, 3.6.4,3.6.5, 3.6.6, 3.6.7, 3.6.8,3.6.9, 3.6.10, 3.6.11,3.6.12, 3.6.14, 3.7.1,3.7.2, 3.7.3, 3.8, 3.9.1,

3.9.2, 3.9.3, 3.9.7, 3.9.11,3.10.1

• Changes to Tables 2.13,2.17, 2.18, 2.19, 2.23,2.37, 2.38

• Changes to Figures 2.7and 2.10

• New Paragraphs 2.12,2.13 and 3.12 added

• New Figures 2.16 and2.17 added

Amendments to Part 2Section 1 ProcedureNo 1/001:• Changes to Prestart

Checks and Procedure(Pages 21, 22, 27, 30, 31and 32)

OPRM-2003-0312 Page ii of xiii 30-April-2006






2.0 PURPOSE

The purpose of this document is to provide guidance on the safe, efficientand environmentally aware operation of the Waterflood System.

It is one Volume within an overall suite of Volumes, which comprise the

Bonga FPSO Plant Operating Procedures Manual (POPM). The full listing ofVolumes isas follows:

Volume 1 Field and Facilities OverviewVolume 2A Subsea Production SystemVolume 2B Subsea Waterflood SystemVolume 2C Subsea Control SystemVolume 2D Flow Assurance GuidelinesVolume 3 Oil Separation and TreatmentVolume 4 Oil Storage, Handling and Ballast Systems

Volume 5 Oil Metering and Export SystemVolume 6 Vapour Recovery Compression SystemVolume 7 Field Gas Compression SystemVolume 8 Gas Dehydration/Glycol Regeneration SystemsVolume 9 Gas Export/Import/Lift SystemsVolume 10 Flare and Vent SystemsVolume 11 Produced Water Treatment SystemsVolume 12 Waterflood SystemVolume 13 Chemical Injection and Methanol Injection SystemVolume 14 Fuel Gas System

Volume 15 Heating Medium SystemVolume 16 Drainage SystemsVolume 17 Sewage Treatment SystemsVolume 18 Bilge and Oily Water Separation SystemsVolume 19 Inert Gas SystemVolume 20 Nitrogen Generation SystemVolume 21 Seawater SystemVolume 22 Fresh and Potable Water SystemsVolume 23 Diesel Fuel System and IncineratorVolume 24 Aviation Fuel SystemVolume 25 Instrument and Utility Air SystemVolume 26 Deck Hydraulic SystemsVolume 27 Fire Protection Systems and EquipmentVolume 28 Safety and Lifesaving EquipmentVolume 29 PSCS and ESSVolume 30 Power Generation and Distribution SystemsVolume 31 Black Start ProceduresVolume 32 HVAC SystemsVolume 33 Deck Machinery and Mechanical Handling Systems (Cranes, etc)Volume 34 TelecommunicationsVolume 35 Ancillary Living Quarters (ALQ)

OPRM-2003-0312 Page iv of xiii 30-April-2006




3.0 SCOPE

This document provides a detailed description of the plant and equipment,which comprise the Waterflood System, and includes step-by-step guidanceon the operation of the system and its equipment, under both normal and

abnormal operation.

4.0 TARGET READERSHIP

All SNEPCO staff, contractors and other third-party personnel who may beinvolved in the operation of the Waterflood System onboard the Bonga FPSO.

5.0 SPECIAL NOTE

Not applicable.

6.0 ABBREVIATIONSThe abbreviations used within this document are listed at the end of theseintroductory pages.

7.0 REFERENCE INFORMATION/SUPPORTING DOCUMENTATION

The primary reference/supporting documents, which have been either usedor referred to in the development of this manual, are listed at the end ofthese introductory pages. These are part of the available OperationalDocumentation, which SNEPCO Offshore Operations (OO) has in place to

support its day-to-day operations. These and many other documents areavailable within the SNEPCO Livelink System. Where appropriate, thesedocuments have been cross-referenced within this document.

OPRM-2003-0312 Page v of xiii 30-April-2006




Abbreviations

AC Alternating Current

BIT Backwash Interval TimerBPCS Basic Process Control SystemBWPD Barrel of Water per Day

CCR Central Control RoomCO 2 Carbon Dioxide

DC Direct CurrentDCS Distributed Control SystemDE Drive End

DI DeionisedDP Differential Pressure

ESD Emergency ShutdownESR 1 Process ShutdownESR 2 Surface Process ShutdownESR 3 Total FPSO ShutdownESS Emergency Shutdown SystemESS Emergency Support System

FPSO Floating Production, Storage and OffloadingFZA Flow Safety Alarm

HMI Human/Machine InterfaceHSE Health, Safety and Environment

IGV Inlet Guide Vane

LP Low PressureLV Low VoltageLZA Level Safety Alarm

MAWP Maximum Allowable Working PressureMCC Motor Control CentreMGS Minimum Governor SpeedMSDS Material Safety Data Sheets

NDE Non-drive EndNgp Gas Producer Speed

OAL Operator Access Level

OPRM-2003-0312 Page vi of xiii 30-April-2006




PLC Programmable Logic ControllerPPE Personnel Protective Equipmentppm Parts Per MillionPSCS Process Control and Safety SystemPSV Pressure Safety Valve

PTW Permit to WorkPZA Process Safety Alarm

SCSSV Surface Controlled Subsea Safety ValveSCU Subsea Control UnitSDV Shutdown ValveSSDS Safety Shutdown System

TDS Total Dissolved Solids

TRIC Toolbox Risk Identification CardTZA Temperature Safety Alarm

UCP Unit Control Panel

WFP Waterflood Pump

OPRM-2003-0312 Page vii of xiii 30-April-2006






HAZOP Actions

ActionNumber/

NodeCause

ODL Response toHAZOP

Operation ProcedureSection/Procedure

11/6.07Filter AidInjection

Loss of filteraid throughempty tank orfailure ofpump

Procedure detailsthe requirement foroperator checks toensure continuousfilter aid injection

Part 2 Section 1 ProcedureNo 1/003

23/6.08WaterfloodCartridge

Filters

PartialBlockage ofWaterfloodCartridgeFilters

Note added for filterelements to bechanged outperiodically

Part 1 Section 2 EquipmentDescription. Comment addedto Paragraph 2.4

19/6.08WaterfloodCartridge

Filters

WaterfloodCartridgeFiltersIsolationValveIntegrity

Note added forvalves to beinspected annually

Part 1 Section 2 EquipmentDescription. Comment addedto Paragraph 2.4

22/6.08Waterflood

CartridgeFilters

WaterfloodCartridge

FiltersPartialBlockage

Note added forvalves to be

inspected annually

Part 1 Section 2 EquipmentDescription. Comment added

to Paragraph 2.4

128/6.06Hypochlorite

Generator

Air FilterScreenBlockage

Hydrogendisengagement tankvent screen to becleaned on a regularbasis

Part 1 Section 2 EquipmentDescription Paragraph 2.10.1

Part 2 Section 2 ProcedureNo 1/003

HEMP SHEET 1 of 2 Actions

No Description Control Measure ODL Action

4 Operator vents waterflood

facility prior to start-up to

Ensure air venting

requirement activity

Steps added to Part 2

Section 1 Procedure

OPRM-2003-0312 Page ix of xiii 30-April-2006




eliminate air and preventwater hammer. Also, incertain areas, gas cancollect in high points duringnormal operations andrequires venting.

description andpotential hazardsare included in theoperatingprocedures for allphases ofstart-up.

Nos 1/001 and 1/003

5 Monitoring the performanceof the hypochloritegenerator at highconcentration point.Fluid sampling leads tooperator exposure of thehypochlorinated water.

Ensure activitydescription andpotential hazardsare included in theoperating

procedures.

Caution added to Part1 Section 1 ProcedureNos 1/001 and 1/002

6 Inspection and minormaintenance in MinoxBlower housing (oil levelcheck, seal gas check). Thisis occurring duringoperation exposure to hotequipment.

Nitrogen gas purge presentin enclosure.

Poorly designed accessmakes inspection awkward.

Ensure activitydescription andpotential hazardsare included in theoperatingprocedures.

Note and Cautionadded to Part 1 Section1 Procedure No 1/003

OPRM-2003-0312 Page x of xiii 30-April-2006






1 ‘ Caution’ text annotationsin the POPM document arenot highly visible.

Highlight the cautionstatement using theyellow/black cautionnotice.

Caution text in allprocedures modified tobe more visible.

2 There is no writtenprocedure for charge pumpssuction strainer changeout.

Refer to OCOPmechanical isolationsection.

Write specificprocedure forstrainer changeout.

Confirm oil gasket isinspected forintegrity before re-use. Replace withnew gasket ifrequired.

Part 2 Section 3Procedure No 3/002added.

(Procedure commonwith injection pumpsuction strainerchangeout.)

3 There is no writtenprocedure for injectionpumps suction strainerchangeout.


Write specificprocedure forstrainer changeout.


(Procedure commonwith charge pumpsuction strainerchangeout.)

6 There is no writtenprocedure for lube oil filterschangeout/changeover.


Write specificprocedure for filterchangeout.


7 Operator access into turbineenclosure during normaloperation.

Write andincorporateprocedure foroperator/maintenance access to solarturbine enclosureduring operation.


OPRM-2003-0312 Page xi of xiii 30-April-2006






8 Operator access into turbineenclosure immediately aftera fire/emergency trip.

Write andincorporateprocedure foroperator/maintenance access to solarturbine enclosureimmediately after afire/emergency tripin compliance withsolar fire logic.


9 No written procedure for

when the injection pumpsare stopped, say at start-up,but the charge pumps aredischarging water throughthe injection pumps into theinjection risers.

Detailed procedure

to be writtenrequiring theinjection pumps lubeoil system to be onso the ‘ Lomakin’effect can come intoplace to preventpumpbearingdamage.

Sub-procedure for

‘ Waterflood RiserVacuum Breaking’ isincluded in Part 2Section 1 ProcedureNos 1/001 and1/002. In theseprocedures theinjection pump lube oilsystems are run whenthe charge pumps arestarted to fill therisers.

Main Table of Contents

OPRM-2003-0312 Page xii of xiii 30-April-2006




OPRM-2003-0312 Page xiii of xiii 30-April-2006

Document Status Information

Abbreviations

Reference Information/Supporting Documentation

Part 1 – System Description

Section 1 System Overview

Section 2 Detailed Description

Part 2 – Operating Procedures

Section 1 System Operating Procedures

Section 2 Equipment Operating Procedures

Section 3 Supplementary Operating Procedures



Shell Nigeria E&P Company Ltd Unrestricted

PART 1

TECHNICAL DESCRIPTION

Section 1 System Overview

Section 2 Detailed Description

Part 1 Technical DescriptionOPRM-2003-0312 Page 1 of 1 30-April-2006




Part 1Technical Description

Section 1System Overview

Table of Contents

1.0 INTRODUCTION.............................................................................................................2

1.1 General Overview................................................................................................2

2.0 PROCESS DESCRIPTION.............................................................................................3

3.0 HEALTH, SAFETY AND ENVIRONMENT (HSE) .......................... ............................. ... 5

3.1 General................................................................................................................5

3.2 Specific Hazards..................................................................................................6

3.3 Environmental Issues ........................... ............................ ............................. ...... 6

FIGURES

Figure 1.1 – Waterflood System Overview (1 of 2) .......................... ............................. .......... 8

Figure 1.2 – Waterflood System Overview (2 of 2) .......................... ............................. .......... 9

Part 1 Section 1 System Overview

OPRM-2003-0312 Page 1 of 9 30-April-2006




1.0 INTRODUCTION

1.1 General Overview

The Waterflood System is designed to maintain reservoir pressure by the injection of1988m 3/h (300,000BWPD) of treated seawater via up to 16 subsea waterflood wells,at an injection pump discharge pressure of approximately 210barg.

Seawater is filtered, deoxygenated and then treated with scale inhibitor to reducescaling of system pipework, and potential plugging of the water injection wells.Biocide is also injected to prevent biological fouling of the system pipework.

Waterflood is utilised to maintain well pressure and improve well fluid recovery.The Waterflood System comprises the following major equipment:• P-4040A/B Waterflood Source Pumps• S-4040A/B Seawater Strainers• A-4051 Hypochlorite Generation• S-4041A/B/C/D/E/F Waterflood Multimedia Filters• S-4042A/B/C Waterflood Cartridge Filters• K-4040 Waterflood Air Scour Blower• A-4041A/B Waterflood Deoxygenators• P-4043A to F Sulphate Removal Feed Pumps (Future)• A-4043A to F Sulphate Removal Membrane Packages (Future)• T-4045 Injection Water Tank• P-4045A/B Injection Charge Pumps• P-4046A/B Waterflood Injection Pumps• PT-4040A/B Water Injection Pump Turbine Drivers• T-4202 Calcium Nitrate Hull Tank• P-4201C/D Calcium Nitrate Transfer Pumps• T-4254 Calcium Nitrate Day Tank• P-4254A/B Calcium Nitrate Injection Pumps

• A-4255 Waterflood Chemical Injection Package• A-4259 Oxygen Scavenger Skid• A-4256 Waterflood Deoxygenator Chemical Injection Package

Note: Subsea waterflood operations are not covered in this volume. For details ofwater injection well operations, refer to Volume 2B Subsea WaterfloodSystem (OPRM-2003-0302B).






2.0 PROCESS DESCRIPTION

Refer to Figures 1.1 and 1.2.

Water for the system is provided by two vertical electrically driven Source Pumps

P-4040A/B, which draw seawater from individual caissons below the vessel keel anddischarge it into the waterflood system.

The discharge from P-4040A/B is routed to Seawater Strainers S-4040A/B, whereparticles greater than 100 microns are removed. A small flow of seawater is takenfrom downstream of the strainers to supply the hypochlorite generators.

The water then passes to the Waterflood Multimedia Filters S-4041A/B/C/D/E/F,where the water is treated to remove 98% of particles greater than 5 microns.

From the multimedia filters the water passes through the Waterflood CartridgeFilters S-4042A/B/C before passing to the Waterflood Deoxygenators A-4041A/B.

The Minox deoxygenating process is based on the principle of using nitrogen to stripoxygen from the seawater in two separate stages of gas/water separation. The gasstripping action takes place in the static mixer at the inlet to each gas/waterseparator. A blower is used to blow nitrogen into the first-stage static mixerupstream of the first-stage gas/water separator. The nitrogen/oxygen mix passesfrom the first-stage gas-water separator to the heat exchanger and into deoxydiserfor regeneration. The blower subsequently draws the nitrogen/oxygen mix from thesecond-stage gas/water separator, together with fresh nitrogen make-up, tocontinue the process in the first-stage vessel.

The oxygen in the nitrogen/oxygen mix from the first-stage gas/water separationrequires to be extracted before being re-used in the second-stage oxygen removalprocess. Removal of the oxygen from the mix is carried out by an exothermic

catalytic reaction between the oxygen and a fuel in a reactor tank, the deoxydiser.The catalyst is palladium coated Al 2O3 sphere balls, with methanol as the fuelelement. The regenerated nitrogen is reintroduced to the seawater feed in the staticmixer upstream of the second-stage gas/water separator.

The catalyst is guaranteed to last 6 years, as long as the recommendedmaintenance procedures are followed. In practical plant operation the consumptionof methanol is approximately 18 litres/1000m 3 of seawater treated. The reaction isexothermic and the generated energy is re-used in the heat exchanger to preheatthe incoming stripping gas to the deoxydiser.

This continuous process removes the oxygen from the seawater providing a residualoxygen level of less than 10ppb, without the need of oxygen scavenger.

The deoxygenated water leaves the deoxygenators and passes into Injection WaterTank T-4045.

Injection Water Tank T-4045 provides suction for the Injection Charge PumpsP-4045A/B, which in turn supply the Waterflood Injection Pumps P-4046A/B.

In early field life the injection requirement may be below the minimum flow for asingle water injection pump, 575m 3/h, requiring the pump minimum flow recyclevalve to be open. To avoid this mode of operation, a 6in line has been provided fromeach of the topside water injection flowlines down stream of the flow meters40-FE-646/656, to allow excess water above that required for injection, to bediverted to the overboard dump controlled by an orifice and a globe valve. The lines

can also be used to depressurise the respective risers.






The Hypochlorite Generation Package A-4051 generates sodium hypochlorite at aconcentration of 1100ppm at the outlet of the package.

The discharge flow from the package combines with the main seawater flowdownstream of the Seawater Strainers S-4040A/B to achieve a concentration of1 to 3ppm. Sodium hypochlorite from A-4051 is also dosed into the suction of thesource pumps.

The system start-up is carried out in the following sequence:

(1) Source pumps.

(2) Seawater strainers.

(3) Multimedia filters.

(4) Deoxygenation package.

(5) Hypochlorite generator.

(6) Injection water tank.(7) Injection charge pumps.

(8) Injection pumps.

(9) Calcium nitrate injection pumps.

This order allows the various package minimum flowrate requirements to besatisfied as each component is brought on line.

The flow of water through the system varies as each item is brought on line. Thereare four main overboard discharge lines on the forward flow through the systemas follows:• Source pump minimum flow discharge• Deoxygenation package outlet• Charge pump discharge minimum flow• Injection pump minimum flow discharge

Backwash outflows are also routed overboard from the seawater strainers andmultimedia filters.

At start-up, the source pumps initially discharge overboard via the minimumflow line. Forward flowrate through the seawater strainers, multimedia filters andwaterflood cartridge filters depends upon the outflow rate from the deoxygenation

package, which is achieved by dumping overboard until a minimum number of filtershave been brought on line.

Flow to the injection water tank can be established when the oxygen content ofthe deoxygenation outflow is below the minimum alarm value, thus allowing theinjection charge pumps to be started and any possible vacuum in the riser to besafely broken. This is then followed by start-up of the injection pumps.

A vacuum can develop in the waterflood riser at some stages of field life if thereservoir pressure is not great enough to support the column of water in the riserfollowing shutdown. During early field life, the pressure in every reservoir is sufficientto support a column of water to the surface however, later in the field life somereservoir pressures will drop below the point of supporting a column of water.






Rapid start-up into a riser under vacuum would cause water hammer, which in turncould damage the riser.

For this reason, the vacuum will be counteracted by initially slowly adding water tothe riser using the charge pumps, with the injection pumps shut down.

Chemical injection to the system can then commence and the hypochlorite packagemay be started.

The Waterflood Chemical Injection Skid A-4255 consists of two pump assembliesP-4255A/B/C and P-4255D/E/F, each consisting of a motor and three pump heads,configured as follows:• P-4255A – Biocide Injection Pump• P-4255B – Filter Aid Injection Pump• P-4255C – Oxygen Scavenger Pump•

P-4255D – Antiscale Injection Pump• P-4255E – Corrosion Inhibitor Injection Pump• P-4255F – Scale Inhibitor Injection Pump

The Oxygen Scavenger Skid A-4259 comprises a two-ganged oxygen scavengerpump assembly P-4259A/B, and the single oxygen scavenger pump assemblyP-4259C. A single motor drives each assembly.

The Methanol/Antifoam Skid A-4256 consists of three pump assemblies, P-4256A/B,P4256C/D and P4256E/F, each consisting of a motor and two pump headsconfigured as follows:•

P-4256A, C and E are for methanol• P-4256B, D and F are for antifoam

The Calcium Nitrate Injection System consists of a Day Tank T-4254 and injectionPumps P-4254A/B.

3.0 HEALTH, SAFETY AND ENVIRONMENT (HSE)

3.1 General

The Waterflood System is located on the topsides and as such forms part of thetopsides process systems.

All personnel in the area must have received training in, and be fully conversantwith, the following:• Location and use of fire and safety equipment in the area• Recognition and response to all of the vessel’s visual and audible alarms• Muster and evacuation procedures• Escape routes• Location and use of lifesaving equipment






3.2 Specific Hazards

3.2.1 High Pressure

The Waterflood System handles water at high pressure.

All personnel must wear the appropriate protective clothing (overalls, safety helmet,gloves, goggles etc) when in the area and hearing protection if noise levels in thearea are high.

The Waterflood Treatment System employs various items of rotating equipment,which must have all moving parts securely guarded at all times.

3.2.2 Chemical Hazards

The specific hazards associated with the operation of the Waterflood System arethose associated with handling operations related to the chemicals used in thesystem.

Operators must be fully aware of the chemical properties of all the chemicals used inthe system.

Appropriate Personel Protective Equipment (PPE) (gauntlets, aprons and full-facevisors) must be worn when handling chemicals.

For any specific hazards and special precautions, reference must be made to theMaterial Safety Data Sheet (MSDS) for the chemical.

3.2.3 Calcium Nitrate

Calcium nitrate in its powder form, which may accumulate from a leak of thesolution, presents the following unique hazards:• Will accelerate burning if involved in a fire• May explode on heating when subjected to a shock or heating by friction• May react explosively when contacting hydrocarbons• May ignite combustibles such as wood, paper clothing etc, upon contact

3.2.4 Nitrogen

Nitrogen is used within the Minox System. Nitrogen is an asphyxiant, and iscolourless and odourless. Rapid and unsignalled loss of consciousness can occur inpersons exposed to a nitrogen-enriched atmosphere. When using nitrogen, care

should be taken to ensure that nitrogen escapes are dispersed and not allowed tocollect in enclosed areas.

3.3 Environmental Issues

3.3.1 Consumables

The Minox Deoxygenation System is an environmentally friendly process and theonly potential sources of pollution are accidental leaks or spillage of consumableproducts such as ethanol and catalyst.

The palladium catalyst used in the deoxydisers is not classified as hazardous tothe environment. It is insoluble in water and insignificantly biologically degradable,however, care should be taken to avoid any spillage.






Used catalyst should be recirculated if facilities are available or returned to thesystem vendors for regeneration.

When catalyst is removed it can become very hot upon exposure to the atmosphere.

To dispose of used catalyst it should be submerged in water within a suitablesealed metal container for transportation to an approved waste disposal ortreatment facility.

Refer to the relevant MSDSs for the safe handling of all chemicals. Approvedrespirators must be worn whilst dealing with palladium to avoid ingestion of vapours.





Shell Nigeria E&P Company Limited

DERIVED FROM P&ID BON-AME-3GN-B-21192-013-C02

FI

FI

FC

40FIC495

TT

FC FC

FI

PC

FC FC

S-4041AWATERFLOOD

MEDIA FILTERS

OXYGENSCAVENGER

FILTER AID

BIOCIDE

TO OVERBOARDHEADER

FILTERED WATER

BACKWASH DRAIN

TO OVERBOARDHEADER

42-FIC-370(FIG 1.2)

42-FIC-370(FIG 1.2)

42-FIC-370(FIG 1.2)

42-FIC-370(FIG 1.2)

42-FIC-370(FIG 1.2)

40-FCV495

40XV362

40XV376

40RV385

40-XV492

40-RV503

40-RV508

40-PCV366

40-XV491

40XV396

40RV405

40RV425

40RV445

40RV465

40XV379

40XV377

40XV399

40XV397

40XV417

40XV437

40XV433

40XV453

40XV416

40XV436

40XV456

40XV380

40XV319

40XV339

40XV373

40XV

381

40XV

401

40XV372

40XV392

40XV39340

FCV371

40FCV391

40XV400

40XV420

40XV440

40XV

401

40RV

491

40

RV492

40XV

419

40XV

439

40XV

432

40XV

452

40XV

441

40XV

461

40XV412

40XV41340

FCV411

40FCV431

40FCV451

VENT

BACKWASH SUPPLY HEADER

FLUFF AIR

S-4041BWATERFLOOD

MEDIA FILTERS

S-4041CWATERFLOOD

MEDIA FILTERS

S-4040BSEAWATER STRAINER

S-4040ASEAWATER STRAINERS

P-4040AWATERFLOODSOURCE PUMP

P-4040BWATERFLOODSOURCE PUMP

S-4041DWATERFLOOD

MEDIA FILTERS

S-4041EWATERFLOOD

MEDIA FILTERS

S-4042AWATERFLOOD

CARTRIDGE FILTER

S-4042BWATERFLOOD

CARTRIDGE FILTER

O VE RB OA RD O VE RB OA RD

A-4051HYPOCHLORITE

GENERATOR

STATIC MIXER


OPRM-2003-0312 Page 8 of 9



Shell Nigeria E&P Company Limited


OPRM-2003-0312 Page 9 of 9

DERIVED FROM P&ID BON-AME-3GN-B-21192-014-C02

FO

PC

FIC

LC

AE

TC

LC

TC

AE

AE40LIC581

SC

PC

FC

FCSC

FC

FC

FC

FROM WATERFLOODCARTRIDGE FILTERSFROM (FIG 1.1)

NITROGEN

OVERBOARDHEADER

SULPHATE REFACILITIES (F

OVERBOARDHEADER

INSTRUMENT AIR

MULTIMEDIA FILTERS(FIG 2.1)

NITROGEN

LOCALVENT

40PV

585

40-RV587

40-RV586

40FCV598

40RV604

40RV624

40RV608

40RV628

40-BUV230

40-FIC598

40-BUV232

40-BUV235

40-BLV201

40-PCV629

40-SDV633

40-PCV609

40-SDV613

40-PV-594

40-FCV-602 40-FCV-622

OVERBOARD

TO OVERBOARDHEADER

TO OVERBOARDHEADER

TO OVERBOARDHEADER

CORROSIONINHIBITOR

CALCIUMNITRATE

A-4041BDEOXYGENATOR

SKID B

A-4041ADEOXYGENATOR

SKID A

BLOWERA-4041-K-01

GAS/WATERSEPARATORA-4041-V-02

DEOXYDISERA-4041A-V-03

HEATERA-4041A-V-03

GAS/WATERSEPARATORA-4041-V-01

SCALEINHIBITOR BIOCIDE

OXYGENSCAVENGER

A-4255WATERFLOOD CHEMICAL INJECTION SKID

FILTERAND/

WATERCLARIFIE

T-4045INJECTION WATER

TANK

P-4045AINJECTIONCHARGEPUMPS

P-4045BINJECTIONCHARGEPUMPS

P-4046AWATERFLOOD

INJECTION PUMP

PT-4046A PT-4046BP-4046B

WATERFLOODINJECTION PUMP

ANTISCALANT

LOCALVENT

LOCALVENT

LOCALVENT

METHANOLANTIFOAM

40-XV520

40-PV521

40RV555

40XV

536

40TCV539

40RV527

40PV532 40-RV

531

40-PV522

40-XV-526

40-XV-546

40-XV-576

40-FCV-547

40-FCV-577

40-LCV-530 40-LCV-535

40-LCV-565

40-XV-542

40-XV-549

40-XV-579

40-XV-572

40-XV-545

40-SDV-544

40

FIC370

40-BUV261

L C

40-BUV260

LC BF




PART 2

OPERATING PROCEDURES

Section 1 System Operating Procedures

Section 2 Equipment Operating Procedures

Section 3 Supplementary Operating Procedures

Part 2 Operating Procedures





Part 2Operating Procedures

Section 1System Operating Procedures

ProcedureNumber

WATERFLOOD SYSTEM OPERATING PROCEDURES

PROCEDURE NO 1/001: COLD START-UP

PROCEDURE NO 1/002: HOT START-UP

PROCEDURE NO 1/003: NORMAL OPERATION

PROCEDURE NO 1/004: PLANNED SHUTDOWN

PROCEDURE NO 1/005: PROCESS AND EMERGENCY SHUTDOWN

Part 2 Section 1 System Operating Procedures





SYSTEM/EQUIPMENT: WATERFLOOD SYSTEM

PROCEDURE NO 1/001: COLD START-UP

THE WHOLE OF THIS PROCEDURE MUST BE READ THROUGH ANDFULLY UNDERSTOOD BEFORE CARRYING OUT ANY OF THE

FOLLOWING ACTIONS.

INTRODUCTION

This procedure details the cold start-up of the Waterflood System. The procedure assumesthat all vessels in the system are empty and require to be filled.

This procedure does not include water injection wellhead procedures, as these are detailedin POPM Volume 2B Subsea Waterflood System (OPRM-2003-0302B).

Operational Note: Developing a vacuum in the waterflood riser is possible at some stagesof field life, due to the reservoir pressure not being sufficient to supportthe water column in the riser following shutdown. Initially the pressure inevery reservoir is sufficient to support the column of water, but later in thefield life some reservoir pressures will drop below the point of supportingthe column. For this reason, the risers are rated for vacuum service.

If a water injection wellhead on such a reservoir remains open after

topsides shutdown, the riser will partially drain into the reservoir, resultingin a vacuum in the riser. Rapid start-up into a riser under vacuum wouldcause a surge (water hammer), which could damage the riser.

It is assumed that the water injection wellheads will be closed prior tostart-up. If this is not the case, the well will continue to pull water duringthis operation and riser vacuum breaking will be more difficult.

The vacuum will be counteracted initially by slowly adding water to theriser using the charge pumps. Refer to Steps 65 to 74.

PRECONDITIONS

Supporting Drawings

The Waterflood System utilises the following P&IDs:• BON-AME-3-SP-B-21640-001-C06 Waterflood Source Pumps• BON-AME-3-SP-B-21640-002-C06 Hypochlorite Generator and Seawater Strainers• BON-AME-3-SP-B-21640-003-C06 Waterflood Multimedia Filters• BON-AME-3-SP-B-21640-004-C06 Waterflood Multimedia Filters• BON-AME-3-SP-B-21640-005-C06 Waterflood Cartridge Filters

• BON-AME-3-SP-B-21640-006-C06 Waterflood Cartridge Filters






• BON-AME-3-SP-B-21640-007-C06 Waterflood Deoxygenation• BON-AME-3-SP-B-21640-008-C06 Waterflood Deoxygenation• BON-AME-3-SP-B-21640-009-C06 Waterflood Deoxygenation• BON-AME-3-SP-B-21640-023-C06 Injection Water Tank and Charge Pumps• BON-AME-3-SP-B-21640-024-C06 Waterflood Injection Pump• BON-AME-3-SP-B-21640-025-C06 Waterflood Injection Pump• BON-AME-3-WF-B-21540-001-C06 Waterflood Injection Pump No 1• BON-AME-3-WF-B-21540-002-C06 Waterflood Injection Pump No 2• BON-AME-3-SP-B-21640-026-C06 Waterflood Injection Launcher/Receivers• P0001-M037-KVER-019-001-001 Minox Deoxygenation Skid A•

P0001-M037-KVER-019-001-002 Minox Deoxygenation Skid A• P-238-K-001 Electrochlorination Generation Package

Interface Systems

The following systems are required to be operational for the start-up of the WaterfloodSystem:• Subsea Waterflood System. Refer to POPM Volume 2B (OPRM-2003-0302B)• Drainage Systems. Refer to POPM Volume 16 (OPRM-2003-0316)• Nitrogen System. Refer to POPM Volume 20 (OPRM-2003-0320)

• Instrument and Utility Air System. Refer to POPM Volume 25 (OPRM-2003-0325)• Power Generation and Distribution. Refer to POPM Volume 30 (OPRM-2003-0330)

Pre-requisites• No Permits to Work are in force that may prohibit start-up of the Waterflood System.

After completion of all maintenance activities, all workscope documentation must becompleted and signed off by the relevant authorities before the start-up can commence

• All spades and spectacle blinds are in their correct positions, as per the WaterfloodSystem P&IDs listed in Supporting Drawings

• All disturbed flanges and fittings in the system have been nitrogen leak/pressure testedas appropriate, and any leak test certificate signed off

• All system pipework drain, vent, purge and sample point valves are closed• All system equipment drain and vent valves are closed• All instrument isolation valves are open• All level bridle vent and drain valves are closed• The DCS, SSDS, ESS and SCU control and shutdown facilities are operational

and healthy• Toolbox talks have been held with all directly and indirectly concerned parties outlining

the workscope and procedure






• TRIC completed• Communications are established between all personnel involved in this procedure

PLANT STATUS• Waterflood is required for reservoir pressure maintenance

Note: Subsea waterflood operations are not covered in this volume. For details of waterinjection well operations, refer to POPM Volume 2B Subsea Waterflood System(OPRM-2003-0302B).

• The following facilities within the Waterflood System are prepared for start-up:− Waterflood Source Pumps P-4040A/B− Seawater Strainers S-4040A/B− Hypochlorite Generation package A-4051− Waterflood Multimedia Filters S-4041A/B/C/D/E/F− Waterflood Cartridge Filters S-4042A/B/C− K-4040 Waterflood Air Scour Blower− Waterflood Deoxygenators A-4041A/B− Injection Water Tank T-4045− Injection Charge Pumps P-4045A/B− Waterflood Injection Pumps P-4046A/B, including the turbine drivers− A-4255 Waterflood Chemical Injection Package− A-4259 Oxygen Scavenger Skid− A-4256 Waterflood Deoxygenator Chemical Injection Package

• The Fuel Gas System is operational and fuel gas is available for Water Injection PumpTurbine Drivers PT-4040A/B

• The Nitrogen System is operational and nitrogen is available for blanket gas in InjectionWater Tank T-4045, Waterflood Deoxygenators A-4041A/B and Deoxygenator MethanolStorage Tank V-4256

• The system isolation valves are positioned as indicated in Valve Checklist No 1Waterflood System






VALVE CHECKLIST NO 1: WATERFLOOD SYSTEM

Tag No Function Setting Checked

Waterflood Source PumpsRefer to P&ID BON-AME-3-SP-B-21640-001-C06

40-BUV-201 P-4040A Discharge Valve CAR SEALOPEN

40-BUV-202 P-4040B Discharge Valve CAR SEALOPEN

40-BUV-236 Overboard Discharge Valve u/s of 40-PCV-366 OPEN

40-BUV-237 Overboard Discharge Valve d/s of 40-PCV-366 OPEN

40-XV-319 P-4040A Overboard Dump Valve AUTO

40-XV-339 P-4040B Overboard Dump Valve AUTO

40-GBV-218 Sodium Hypochlorite to P-4040A OPEN

40-GBV-219 Sodium Hypochlorite to P-4040B OPEN

40-GBV-288 Utility Water Supply Valve CLOSED

Hypochlorite Generator and Seawater StrainersRefer to P&ID BON-AME-3-SP-B-21640-002-C06

40-BUV-203 S-4040A Inlet Valve OPEN

40-BUV-204 S-4040A Outlet Valve OPEN

40-BUV-238 S-4040A Drain Valve CLOSED

40-BUV-205 S-4040B Inlet Valve OPEN

40-BUV-206 S-4040B Outlet Valve OPEN

40-BUV-239 S-4040B Drain Valve CLOSED

40-BLV-241 Multimedia Filter Backwash Supply u/s 40-FCV-495 OPEN

40-BLV-242 Multimedia Filter Backwash Supply d/s 40-FCV-495 OPEN

40-BUV-240 Seawater Supply to Hypochlorite Generators CLOSED

47-BUV-200 Hypochlorite Generator Drain Valve CLOSED

40-GTV-210 Hypochlorite Supply to Waterflood Pump Suctions CLOSED

40-BLV-234 Biocide to Multimedia Filters CLOSED

40-BLV-278 Oxygen Scavenger to Multimedia Filters OPEN

40-BLV-279 Filter Aid to Multimedia Filters OPEN

Waterflood Multimedia Filters Sheet 1 of 2Refer to P&ID BON-AME-3-SP-B-21640-003-C06

40-BUV-207 S-4041A Manual Inlet Valve OPEN

40-XV-372 S-4041A Actuated Inlet Valve AUTO

40-BUV-208 S-4041A Manual Outlet Valve OPEN






VALVE CHECKLIST NO 1: WATERFLOOD SYSTEM (cont’d)


40-XV-380 S-4041A Actuated Outlet Valve AUTO

40-BUV-243 S-4041A Manual Backwash Inlet Valve OPEN

40-XV-379 S-4041A Actuated Backwash Inlet Valve AUTO

48-BUV-200 S-4041A Manual Backwash Outlet Valve OPEN

40-XV-373 S-4041A Actuated Backwash Outlet Valve AUTO

40-XV-381 S-4041A Actuated Drain Down Valve AUTO

40-BUV-249 K-4040 Air Scour Blower Manual Outlet Valve OPEN

40-GTV-201 S-4041A Air Scour Manual Inlet Valve OPEN

40-XV-377 S-4041A Actuated Air Scour Inlet Valve AUTO

40-XV-376 S-4041A Actuated Air Scour Outlet Valve AUTO

48-NEV-203 1/2in Needle Valve u/s Air Scour Outlet Valve CLOSED

40-BUV-209 S-4041B Manual Inlet Valve OPEN

40-XV-392 S-4041B Actuated Inlet Valve AUTO

40-BUV-210 S-4041B Manual Outlet Valve OPEN

40-XV-400 S-4041B Actuated Outlet Valve AUTO

40-BUV-244 S-4041B Manual Backwash Inlet Valve OPEN

40-XV-399 S-4041B Actuated Backwash Inlet Valve AUTO

48-BUV-201 S-4041B Manual Backwash Outlet Valve OPEN40-XV-393 S-4041B Actuated Backwash Outlet Valve AUTO

40-XV-401 S-4041B Actuated Drain Down Valve AUTO

40-GTV-202 S-4041B Air Scour Manual Inlet Valve OPEN

40-XV-397 S-4041B Actuated Air Scour Inlet Valve AUTO

40-XV-396 S-4041B Actuated Air Scour Outlet Valve AUTO


40-BUV-211 S-4041C Manual Inlet Valve OPEN

40-XV-412 S-4041C Actuated Inlet Valve AUTO40-BUV-212 S-4041C Manual Outlet Valve OPEN

40-XV-420 S-4041C Actuated Outlet Valve AUTO

40-BUV-245 S-4041C Manual Backwash Inlet Valve OPEN

40-XV-419 S-4041C Actuated Backwash Inlet Valve AUTO

48-BUV-202 S-4041C Manual Backwash Outlet Valve OPEN

40-XV-413 S-4041C Actuated Backwash Outlet Valve AUTO

40-XV-421 S-4041C Actuated Drain Down Valve AUTO

40-GTV-203 S-4041C Manual Air Scour Inlet Valve OPEN

40-XV-417 S-4041C Actuated Air Scour Inlet Valve AUTO








40-XV-416 S-4041C Actuated Air Scour Outlet Valve AUTO


40-XV-365 Backwash Header to Overboard Actuated Valve AUTO

Waterflood Multimedia Filters Sheet 2 of 2Refer to P&ID BON-AME-3-SP-B-21640-004-C06

40-BUV-213 S-4041D Manual Inlet Valve OPEN

40-XV-432 S-4041D Actuated Inlet Valve AUTO

40-BUV-214 S-4041D Manual Outlet Valve OPEN

40-XV-440 S-4041D Actuated Outlet Valve AUTO

40-BUV-246 S-4041D Manual Backwash Inlet Valve OPEN40-XV-439 S-4041D Actuated Backwash Inlet Valve AUTO

48-BUV-203 S-4041D Manual Backwash Outlet OPEN

40-XV-433 S-4041D Actuated Backwash Outlet Valve AUTO

40-XV-441 S-4041D Actuated Drain Down Valve AUTO

40-GTV-204 S-4041D Air Scour Manual Inlet Valve OPEN

40-XV-437 S-4041D Actuated Air Scour Inlet Valve AUTO

40-XV-436 S-4041D Actuated Air Scour Outlet Valve AUTO


40-BUV-215 S-4041E Manual Inlet Valve OPEN

40-XV-452 S-4041E Actuated Inlet Valve AUTO

40-BUV-216 S-4041E Manual Outlet Valve OPEN

40-XV-460 S-4041E Actuated Outlet Valve AUTO

40-BUV-247 S-4041E Manual Backwash Inlet Valve OPEN

40-XV-459 S-4041E Actuated Backwash Inlet Valve AUTO

48-BUV-204 S-4041E Manual Backwash Outlet OPEN

40-XV-453 S-4041E Actuated Backwash Outlet Valve AUTO

40-XV-461 S-4041E Actuated Drain Down Valve AUTO

40-GTV-205 S-4041E Air Scour Inlet Valve OPEN

40-XV-457 S-4041E Actuated Air Scour Inlet Valve AUTO

40-XV-456 S-4041E Actuated Air Scour Outlet Valve AUTO


40-BUV-217 S-4041F Manual Inlet Valve OPEN

40-XV-472 S-4041F Actuated Inlet Valve AUTO

40-BUV-218 S-4041F Manual Outlet Valve OPEN








40-XV-480 S-4041F Actuated Outlet Valve AUTO

40-BUV-248 S-4041F Manual Backwash Inlet Valve OPEN

40-XV-479 S-4041F Actuated Backwash Inlet Valve AUTO

48-BUV-205 S-4041F Manual Backwash Outlet OPEN

40-XV-473 S-4041F Actuated Backwash Outlet Valve AUTO

40-XV-481 S-4041F Actuated Drain Down Valve AUTO

40-GTV-206 S-4041F Air Scour Manual Inlet Valve OPEN

40-XV-477 S-4041F Actuated Air Scour Inlet Valve AUTO

40-XV-476 S-4041F Actuated Air Scour Outlet Valve AUTO


Waterflood Cartridge Filters Sheet 1 of 2Refer to P&ID BON-AME-3-SP-B-21640-005-C06

40-BUV-219 S-4042A Inlet Valve OPEN

40-BUV-220 S-4042A Outlet Valve OPEN

40-BUV-256 S-4042A Drain Valve CLOSED

40-BUV-221 S-4042B Inlet Valve OPEN

40-BUV-222 S-4042B Outlet Valve OPEN

40-BUV-257 S-4042B Drain Valve CLOSED

Waterflood Cartridge Filters Sheet 2 of 2Refer to P&ID BON-AME-3-SP-B-21640-006-C06

40-BUV-223 S-4042C Inlet Valve OPEN

40-BUV-224 S-4042C Outlet Valve OPEN

40-BUV-258 S-4042C Drain Valve CLOSED

Waterflood Deoxygenation Sheet 1 of 3Refer to P&ID BON-AME-3-SP-B-21640-007-C06

40-XV-546 Deoxygenation Skid A Actuated Inlet Valve AUTO

40-XV-542 Deoxygenation Skid A Actuated Outlet Valve AUTO40-XV-549 Deoxygenation Skid A Overboard Header

Actuated Valve AUTO

40-GBV-210 Deoxygenation Skid A outlet to Open Drains CLOSED


40-XV-576 Deoxygenation Skid B Actuated Inlet Valve AUTO

40-XV-572 Deoxygenation Skid B Actuated Outlet Valve AUTO

40-XV-579 Deoxygenation Skid B Overboard Header Actuated Valve

AUTO

40-GBV-217 Deoxygenation Skid B outlet to Open Drains CLOSED








Minox Deoxygenator Skid A Vendor P&IDRefer to P&ID P0001-M037-KVER-019-001-001

XV-546 Deoxygenation Skid A Seawater Inlet Actuated Valve AUTO

XV-542 Deoxygenation Skid A Seawater Outlet Actuated Valve AUTO

XV-549 Deoxygenation Skid A Seawater Dump Actuated Valve AUTO

V-1011 Deoxygenation Skid A Instrument Air SupplyManual Valve

OPEN

V-1013 Deoxygenation Skid A Instrument Air SupplyManual Valve

OPEN

XV-520 Deoxygenation Skid A Instrument Air Supply

Actuated Valve

AUTO

XV-536 Deoxygenation Skid A Separator Tower V-02 StrippingGas Inlet Actuated Valve

AUTO

XV-545 Deoxygenation Skid A Separator Tower V-02 StrippingGas Outlet Actuated Valve

AUTO

XV-526 Deoxygenation Skid A Separator Tower V-01 StrippingGas Inlet Actuated Valve

AUTO

SDV-544 Methanol Inlet to Deoxygenation Train A AUTO

V-1014 Deoxygenation Skid A Seawater Drain Valve CLOSED



V1025 Deoxygenation Skid A Seawater Drain Valve CLOSED

V-1023 Deoxygenation Skid A Gas Bleed-off ManualIsolation Valve

LOCKEDOPEN

V-1021 Deoxygenation Skid A Nitrogen Purging Isolation Valve OPEN

V-1039 Deoxygenation Skid A Antifoam Manual Isolation Valve OPEN

V-1016 Deoxygenation Skid A Methanol Manual IsolationValve

OPEN

V-1002 Deoxygenation Skid A LG-530 Top Isolation Valve OPEN

V-1003 Deoxygenation Skid A LG-530 Bottom Isolation Valve OPEN

V-1007 Deoxygenation Skid A LG-535 Top Isolation Valve OPEN

V-1008 Deoxygenation Skid A LG-535 Bottom Isolation Valve OPEN








Minox Deoxygenator Skid B Vendor P&IDRefer to P&ID P0001-M037-KVER-019-001-002

XV-576 Deoxygenation Skid B Seawater Inlet Actuated Valve AUTO

XV-572 Deoxygenation Skid B Seawater Outlet Actuated Valve AUTO

XV-579 Deoxygenation Skid B Seawater Dump Actuated Valve AUTO

V-1061 Deoxygenation Skid B Instrument Air Supply OPEN

V-1063 Deoxygenation Skid B Instrument Air Supply OPEN

XV-550 Deoxygenation Skid B Instrument Air Supply Actuated Valve

AUTO

XV-566 Deoxygenation Skid B Separator Tower V-02 StrippingGas Inlet Actuated Valve

AUTO

XV-575 Deoxygenation Skid B Separator Tower V-02 StrippingGas Outlet Actuated Valve

AUTO

XV-556 Deoxygenation Skid B Separator Tower V-01 StrippingGas Inlet Actuated Valve

AUTO

SDV-574 Methanol Inlet to Deoxygenation Train B AUTO

V-1064 Deoxygenation Skid B Seawater Drain Valve CLOSED



V1075 Deoxygenation Skid B Seawater Drain Valve CLOSED

V-1073 Deoxygenation Skid B Gas Bleed-off ManualIsolation Valve

LOCKEDOPEN

V-1071 Deoxygenation Skid B Nitrogen Purging Isolation Valve OPEN

V-1089 Deoxygenation Skid B Antifoam Manual Isolation Valve OPEN

V-1066 Deoxygenation Skid B Methanol Manual IsolationValve

OPEN

V-1052 Deoxygenation Skid B LG-530 Top Isolation Valve OPEN

V-1053 Deoxygenation Skid B LG-530 Bottom Isolation Valve OPEN

V-1057 Deoxygenation Skid B LG-535 Top Isolation Valve OPEN

V-1058 Deoxygenation Skid B LG-535 Bottom Isolation Valve OPEN


40-BUV-228 Deoxygenation outlet to Injection Water Tank LOCKEDOPEN

40-BUV-260 Deoxygenation outlet to Sulphate Removal Pumps LOCKEDCLOSED








Injection Water Tank and Charge PumpsRefer to P&ID BON-AME-3-SP-B-21640-023-C06

40-BUV-261 Sulphate Removal Membrane to Injection Water Tank LOCKEDCLOSED

40-BUV-229 Injection Water Tank Inlet Valve LOCKEDOPEN

40-BLV-282 40-LZT-582A/40-LG-582A Top Bridle Isolation Valve OPEN

40-BLV-283 40-LZT-582A/40-LG-582A Bottom Bridle IsolationValve

OPEN

40-BLV-284 40-LZT-582B/40-LG-582B Top Bridle Isolation Valve OPEN

40-BLV-285 40-LZT-582B/40-LG-582B Bottom Bridle IsolationValve OPEN

40-BLV-286 40-LIT-581 Top Isolation Valve OPEN

40-BLV-287 40-LIT-581 Bottom Isolation Valve OPEN

50-BLV-688 40-PV-585 u/s Isolation Valve LOCKEDOPEN

50-BLV-689 40-PV-585 d/s Isolation Valve LOCKEDOPEN

40-BUV-230 P-4045A Suction Valve CAR SEALOPEN

40-BUV-231 P-4045A Discharge Valve CAR SEALOPEN

40-BUV-219 P-4045A Suction Strainer Drain Valve CLOSED

40-BUV-273 P-4045A Casing Drain Valve CLOSED

40-BUV-232 P-4045B Suction Valve CAR SEALOPEN

40-BUV-233 P-4045B Discharge Valve CAR SEALOPEN

40-BUV-220 P-4045B Suction Strainer Drain Valve CLOSED

40-BUV-274 P-4045B Casing Drain Valve CLOSED40-BLV-221 Biocide to Injection Pumps CLOSED

40-BLV-222 Corrosion Inhibitor to Injection Pumps OPEN

40-BLV-223 Scale Inhibitor to Injection Pumps OPEN

Waterflood Injection Pump Sheet 1 of 2Refer to P&ID BON-AME-3-SP-B-21640-024-C06

40-BLV-224 Suction Strainer Drain Valve CLOSED

40-BLV-289 Suction Strainer Vent Valve CLOSED

40-BUV-234 P-4046A Suction Valve LOCKED

OPEN








40-BLV-225 40-PCV-609 u/s Isolation Valve OPEN

40-BLV-227 40-PCV-609 d/s Isolation Valve OPEN

40-SDV-613 P-4046A Discharge Shutdown Valve CLOSED

Waterflood Injection Pump Sheet 2 of 2Refer to P&ID BON-AME-3-SP-B-21640-025-C06

40-BLV-229 Suction Strainer Drain Valve CLOSED

40-BLV-290 Suction Strainer Vent Valve CLOSED

40-BUV-235 P-4046B Suction Valve LOCKEDOPEN

40-BLV-201 40-PCV-629 u/s Isolation Valve OPEN

40-BLV-232 40-PCV-629 d/s Isolation Valve OPEN

40-SDV-633 P-4046B Discharge Shutdown Valve CLOSED

Refer to P&ID BON-AME-3WF-21540-001-C06Waterflood Injection Pump No 1 – Turbine Utilities

44-BLV-366 Fuel gas supply manual isolation valve OPEN


44-BLV-367 Vent Valve between 44-BLV-366 and 44-BLV-368 CLOSED


44-SDV-482 Fuel gas supply shutdown isolation valve AUTO44-XV-481 Fuel gas supply blowdown valve AUTO

V0F-301 Fuel gas supply vent line ‘globe’ valve LOCKED INPOSITION

44-BLV-365 Fuel gas supply vent line ‘vent’ valve (future tie-in forSolonox Coalescing Filter)

CLOSED

40-SDV-616 WFP Skid Lube Oil Supply Shutdown Valve AUTO

48-BLV-256 WFP Skid Lube Oil Tank Drain Valve CLOSED

47-BLV-249 WFP Engine Air Inlet Duct Drain Valve LOCKEDOPEN

47-BLV-250 WFP Engine Exhaust Collector and Combustion Drain LOCKEDOPEN

51-BLV-508 WFP Engine Air Water Wash Valve CLOSED

50-BLV-567 WFP Engine Pneumatic Valve Air Inlet LOCKEDOPEN

50-BLV-566 WFP Engine Air Supply Valve to Bearing SealsIsolation Valve

OPEN

48-GTV-200 WFP Engine Mechanical Seal Quench OutletIsolation Valve

LOCKEDOPEN

40-BLV-270 Lube Oil from Cooler Isolation Valve CAR SEALEDOPEN








40-BLV-269 Lube Oil to Cooler Isolation Valve CAR SEALEDOPEN

40-BLV-276 Vent from Lube Oil Cooler Isolation Valve CAR SEALEDOPEN

40-BLV-280 Lube oil storage tank bridle upper isolation valve OPEN

40-BLV-281 Lube oil storage tank bridle lower isolation valve OPEN

40-BLV-267 Lube Oil outlet isolation valve to skids OPEN

40-SDV-616 Lube Oil inlet shutdown isolation valve to WFPskid reservoir

AUTO

40-BLV-268 Lube Oil Storage Tank 2in drain valve CLOSED

40-BLV-265 Lube Oil transfer pump 3in suction valve CLOSED40-BLV-266 Lube Oil transfer pump suction strainer drain valve CLOSED/

PLUGGED

Refer to Figure 2.11 or to Solar P&ID 70333-E149293 Rev DWaterflood Injection Pump P-4046A Turbine Lube Oil System

VH-908-2 Lube Oil to Conditioning Unit CLOSED

VH-908-3 Lube Oil from Conditioning Unit CLOSED

VH-909-6 Lube Oil Sample Point CLOSED




44-BLV-371 Vent Valve between 44-BLV-370 and 44-BLV-372 CLOSED


44-SDV-492 Fuel gas supply shutdown isolation valve AUTO

44-XV-491 Fuel gas supply blowdown valve AUTO

44-GBV-208 Fuel gas supply vent line ‘globe’ valve LOCKED INPOSITION

44-BLV-369 Fuel gas supply vent line ‘vent’ valve (future tie-in forSolonox Coalescing Filter)

CLOSED

40-SDV-636 WFP Skid Lube Oil Supply Shutdown Valve AUTO

48-BLV-257 WFP Skid Lube Oil Tank Drain Valve CLOSED

47-BLV-251 WFP Engine Air Inlet Duct Drain Valve LOCKEDOPEN

47-BLV-252 WFP Engine Exhaust Collector and Combustion Drain LOCKEDOPEN

51-BLV-509 WFP Engine Air Water Wash Valve CLOSED








50-BLV-568 WFP Engine Pneumatic Valve Air Inlet LOCKEDOPEN

50-BLV-569 WFP Engine Air Supply Valve to Bearing SealsIsolation Valve

OPEN

48-GTV-201 WFP Engine Mechanical Seal Quench OutletIsolation Valve

LOCKEDOPEN

40-BLV-271 Lube Oil to Cooler Isolation Valve CAR SEALEDOPEN

40-BLV-272 Lube Oil from Cooler Isolation Valve CAR SEALEDOPEN

40-BLV-277 Vent from Lube Oil Cooler Isolation Valve CAR SEALED

OPENRefer to Figure 2.11 or to Solar P&ID 70333-E149293 Rev DWaterflood Injection Pump P-4046B Turbine Lube Oil System

VH-908-2 Lube Oil to Conditioning Unit CLOSED

VH-908-3 Lube Oil from Conditioning Unit CLOSED

VH-909-6 Lube Oil Sample Point CLOSED

Waterflood Injection Launcher/ReceiverRefer to P&ID BON-AME-3-SP-B-21940-026-C06

40-HV-640 P-4046A/4046B Crossover Valve LOCKEDCLOSED

40-BL-235 Riser 01 u/s Isolation Valve OPEN

40-HV-647 Riser 01 Manual Choke Valve OPEN

40-BL-236 Riser 01 d/s Isolation Valve OPEN

40-SDV-643 Riser 01 Shutdown Valve OPEN

40-MOV-641 Riser 03 Shutdown Valve OPEN

40-BL-237 Riser 03 u/s Isolation Valve OPEN

40-HV-657 Riser 03 Manual Choke Valve OPEN

40-BL-238 Riser 03 d/s Isolation Valve OPEN

40-SDV-653 Riser 03 Shutdown Valve OPEN

40-MOV-651 Riser 03 Shutdown Valve OPEN

Waterflood Chemical Tanks and PumpsRefer to P&ID BON-AME-3-GN-B-21642-001-C06

42-BLV-1349 Filter Aid/Clarifier Tote Tank T-4255A Isolation Valve OPEN

42-BLV-1350 Filter Aid/Clarifier Tote Tank T-4255A Isolation Valve OPEN

42-BLV-1355 Oxygen Scavenger Tote Tank T-4255B Isolation Valve OPEN

42-BLV-1356 Oxygen Scavenger Tote Tank T-4255B Isolation Valve OPEN

42-BLV-1357 Oxygen Scavenger Tote Tank T-4255C Isolation Valve OPEN

42-BLV-1358 Oxygen Scavenger Tote Tank T-4255C Isolation Valve OPEN








42-BLV-1359 Oxygen Scavenger Tote Tank T-4255D Isolation Valve OPEN

42-BLV-1360 Oxygen Scavenger Tote Tank T-4255D Isolation Valve OPEN

42-BLV-1372 P-4259A Suction Valve OPEN

42-GTV-970 P-4259A Bleed Valve CLOSED

42-BLV-1373 P-4259A Discharge Valve OPEN

42-BLV-1376 P-4259B Suction Valve OPEN

42-GTV-971 P-4259B Bleed Valve CLOSED

42-BLV-1377 P-4259B Discharge Valve OPEN

42-BLV-1380 P-4259C Suction Valve OPEN

42-GTV-972 P-4259C Bleed Valve CLOSED

42-BLV-1381 P-4259C Discharge Valve OPEN



42-BLV-1138 P-4255A Discharge Valve OPEN



42-BLV-1354 P-4255B Discharge Valve OPEN

42-BLV-1361 P-4255C Suction Valve OPEN42-GTV-968 P-4255C Bleed Valve CLOSED


42-BLV-1366 P-4255D Suction Valve OPEN

42-GTV-969 P-4255D Bleed Valve CLOSED

42-BLV-1369 P-4255D Discharge Valve OPEN

42-BLV-1275 P-4255E Suction Valve OPEN

42-GTV-882 P-4255E Bleed Valve CLOSED

42-BLV-1278 P-4255E Discharge Valve OPEN42-BLV-1271 P-4255F Suction Valve OPEN

42-GTV-881 P-4255F Bleed Valve CLOSED

42-BLV-1274 P-4255F Discharge Valve OPEN

42-XV-414 Biocide to Injection Pumps AUTO

42-XV-415 Biocide to Multimedia Filters AUTO

Chemical System Tanks and PumpsRefer to P&ID BON-AME-3GN-B-21642-002-C06

42-SDV-480 Supply from Methanol Filters S-4240A/B OPEN

42-BLV-944 42-LCV-481 u/s isolation Valve OPEN






VALVE CHECKLIST NO 1: WATERFLOOD SYSTEM COLD START-UP


42-HV-481 42-LCV-481 Bypass Valve LOCKEDCLOSED

42-BLV-947 42-LCV-481 d/s isolation Valve OPEN

42-BLV-1393 42-LG-482/42-LZT-482 Top Bridle Isolation v/v OPEN

42-BLV-1394 42-LG-482/42-LZT-482 Bottom Bridle Isolation Valve OPEN

42-BLV-1395 42-LT-481 Top Bridle Isolation Valve OPEN

42-BLV-1396 42-LT-481 Bottom Bridle Isolation Valve OPEN

42-BLV-992 42-PV-485 u/s isolation Valve OPEN

42-BLV-995 42-PV-485 d/s isolation Valve OPEN

42-GBV-802 42-PV-485 Bypass Valve CLOSED42-BLV-991 42-PV-486 u/s isolation Valve OPEN

42-BLV-988 42-PV-486 d/s isolation Valve OPEN

42-HV-485 42-PV-486 Bypass Valve LOCKEDCLOSED

42-BLV-984 Antifoam Tank T-4256A Isolation Valve CLOSED

42-BLV-985 Antifoam Tank T-4256B Isolation Valve OPEN

42-BLV-965 Antifoam Suction Isolation Valve OPEN



42-BLV-953 P-4256A Discharge Valve (Align to Minox Skid B) OPEN



42-BLV-969 P-4256B Discharge Valve (Align to Minox Skid B) OPEN

42-BLV-954 P-4256C Suction Valve OPEN

42-GTV-801 P-4256C Bleed Valve CLOSED


42-BLV-980 P-4256C Crossover Valve CLOSED


42-BLV-970 P-4256D Suction Valve OPEN

42-GTV-805 P-4256D Bleed Valve CLOSED

42-BLV-973 P-4256D Discharge Valve OPEN



42-BLV-958 P-4256E Suction Valve OPEN

42-GTV-802 P-4256E Bleed Valve CLOSED






VALVE CHECKLIST NO 1: WATERFLOOD SYSTEM COLD START-UP (cont’d)


42-BLV-961 P-4256E Discharge Valve (Align to Minox Skid A) OPEN

42-BLV-974 P-4256F Suction Valve OPEN

42-GTV-806 P-4256F Bleed Valve CLOSED

42-BLV-977 P-4256F Discharge Valve (Align to Minox Skid A) OPEN

Hypochlorite Generator Vendor P&IDRefer to P&ID P-238-K-001

40-XV-680 A-4051-A-01A/B Actuated Inlet Valve AUTO

VB-002 Cell A Manual Inlet Valve OPEN

VD-006 Cell A Manual Outlet Valve OPEN

VB-003 Cell B Manual Inlet Valve OPENVD-007 Cell B Manual Outlet Valve OPEN

VB-010 P-01 Minimum Flow Isolation Valve LOCKEDOPEN

VB-011 P-01 Suction Valve OPEN

VB-013 P-01 Discharge Valve OPEN






PRESTART CHECKS AND CONDITIONS

Step Action

1 ENSURE that the wellhead water injection facilities are available and ready toreceive water.

2 ENSURE electrical power is available for the Waterflood Source Pumps P-4040A/Bdrive motors and the pumps are ready for use.

3 ENSURE that there are adequate levels in the chemical injection storage tanks.

4 ENSURE that the chemical injection facilities are ready and primed to point ofinjection at the required injection points.

5 ENSURE that Deoxygenator Methanol Storage Tank V-4256 is at its normal workinglevel and nitrogen blanketed. ENSURE also that the methanol injection facilities to

Deoxygenation Skids A and B are ready and primed to point of injection at therequired injection points.

6 ENSURE electrical power is available for the multimedia air scour blower.

7 ENSURE that electrical power is available for Injection Charge Pumps P-4045A/Bmain drives.

8 ENSURE that the pump casing drain valve is CLOSED on Waterflood InjectionPumps P-4046A and B.

9 ENSURE that electrical power is available for the Seawater Strainer MotorsS-4040A/B.

10 SET the level, pressure and temperature controllers listed below in the followingmode, setpoint and position:• Waterflood Source Pumps P-4040A/B/C Pressure Indicator Controller

23-PIC-366 in AUTO with a setpoint of 13.53barg• Multimedia Filters S-4041A to F Total Flow Controller 40-FIC-370 set as below:

− With 0 or 1 deoxy unit on line (set automatically by the application and alsois dependent on the level in the Injection Water Tank T-4045):

– Multimedia Filters Total Flow Controller 40-FIC-370 (High Limit)1325m 3/h

– Multimedia Filters Total Flow Controller 40-FIC-370 (Low Limit) 750m 3/h− With two deoxy units on line (set automatically by the application and also is

dependent on the level in the Injection Water Tank T-4045):

– Multimedia Filters Total Flow Controller 40-FIC-370 (High Limit)2650m 3/h

– Multimedia Filters Total Flow Controller 40-FIC-370 (Low Limit)1500m 3/h

Note: The output of 40-LIC-581B cascades to 40-FIC-370, refer to Water InjectionTank below.






Step Action

• Deoxygenator Package A-4041A:− Flow Controller 40-FIC-547 in AUTO with a setpoint of 750m 3/h− Pressure Controller 40-PIC-549 in AUTO with a setpoint of 3barg− Gas/Water Separator V-01 Level Controller 40-LIC-530 in AUTO under

application control

− Gas/Water Separator V-02 Level Controller 40-LIC-535 in AUTO underapplication control

− Deoxydiser V-03 Temperature Controller 40-TIC-539 in AUTO underapplication control

−

Deoxydiser Start-up Heater VH-03 Temperature Controller 40-TIC-540 in AUTO under application control• Deoxygenator Package A-4041B:

− Pressure Controller 40-PIC-579 in AUTO with a setpoint of 3barg− Gas/Water Separator V-01 Level Controller 40-LIC-560 in AUTO under

application control− Gas/Water Separator V-02 Level Controller 40-LIC-565 in AUTO under

application control− Deoxydiser V-03 Temperature Controller 40-TIC-569 in AUTO under

application control− Deoxydiser Start-up Heater VH-03 Temperature Controller 40-TIC-570 in

AUTO under application control• Injection Water Tank T-4045:

− Level Indicator Controller 40-LIC-581A, no control setpoint. Alarm setpointsopen/close Deoxygenator Package A and B Dumps Valves via 40-HS-543and 40-HS-573 respectively

− Level Indicator Controller 40-LIC-581B in Auto, setpoint 4200mm (79.6%)− Level Indicator Controller 40-LIC-581C in Auto, setpoint 2261mm (40%)

− Level Indicator Controller 40-LIC-581D in Auto, setpoint 2261mm (40%)• Injection Charge Pumps P-4045A/B:

− Minimum Flow Controller 40-FIC-598 (one pump running) in Auto, with asetpoint 400m 3/h

− Minimum Flow Controller 40-FIC-598 (two pumps running) in Auto, with asetpoint 800m 3/h

• Waterflood Injection Pump P-4046A Flow Controller 40-FIC-602, set on Auto,with a setpoint of 750m 3/h






Step Action

• Waterflood Injection Pump P-4046A Minimum Backpressure Controller40-PIC-609A on Auto, set by the application to the initial start start-up pressure,will be set to the operating point

• Waterflood Injection Pump P-4046A Minimum Backpressure Controller40-PIC-609B on Auto, set by the application to the initial start start-up pressure,will be set to the operating point

Note: Flow Controller 40-FIC-602 and Pressure Controller 40-PIC-609A can bemanually adjusted by the operator to achieve the injection conditionsrequired.

• Waterflood Injection Pump P-4046B Flow Controller 40-FIC-622, set on Auto,with a setpoint of 750m 3/h

• Waterflood Injection Pump P-4046B Minimum Backpressure Controller40-PIC-629A, on Auto, set by the application to the initial start start-up pressure,will be set to the operating point

• Waterflood Injection Pump P-4046B Minimum Backpressure Controller40-PIC-629B, on Auto, set by the application to the initial start start-up pressure,will be set to the operating point







COLD START PROCEDURE

Step Action

Waterflood Source Pumps P-4040A/B

1 START Source Pump P-4040A from CCR.

2 ENSURE that the Overboard Dump Valve, 40-XV-319, closes after 10 seconds andthe overboard flow is being controlled by 40-PCV-366.

3 If required, START Source Pump P-4040B from the CCR.


Seawater from the waterflood source pumps is now available to fill SeawaterStrainers S-4040A/B and the Multimedia Filters S-4041A to F, as far as the inlet toDeoxygenator Packages A-4041A/B.

Note: One or both pumps may be run to provide the required flowrate.

Seawater Strainers S-4040A/B

5 ENSURE that the following chemical injection manual valves are closed:• Oxygen Scavenger 40-BLV-278• Filter Aid 40-BLV-279• Biocide 40-BLV-234

Note: Chemical injection should not take place whilst overboard dumping is taking

place, to avoid unnecessary chemical pollution of the sea.6 CONFIRM the following on the DCS:

• Waterflood Source Pumps P-4040A/B are running and VERIFY the seawaterinlet flowrate on 40-FI-490

• Seawater Strainers S-4040A/B are selected to the ‘On’ position in the CCR• Sequence fail has been reset• S4040A and S4040B are selected ‘On’.

Note: The backwash cycle timer is unaffected by operator backwash requests orbackwashes triggered by high differential pressure. These will be acceptedas a scheduled backwash if they occur within 30 minutes of scheduled time.

7 CONFIRM that the backwash cycle has been activated.

8 CONFIRM that 40-XV-491 is open.

9 CONFIRM that Strainer Motor S-4040A is running.

10 CONFIRM at the DCS that ‘Backwashing’ is displayed for S-4040A.

11 On completion of the backwash cycle, CONFIRM at the DCS that Strainer MotorS-4040A has stopped and 40-XV-491 has closed.

12 CONFIRM the backwash cycle on S-4040B has been activated, 40-XV-492 is openand 40-HS-492A is running.






Step Action

13 CONFIRM at the DCS that ‘Backwashing’ is displayed for S-4040B.

14 On completion of the backwash cycle, CONFIRM at the DCS that Strainer MotorS-4040A has stopped and 40-XY-492 has closed.

15 VENT any air from the seawater strainers via an appropriate high point vent tominimise any water hammer.

Multimedia Filters S-4041A/F

16 CONFIRM at the DCS that at least one waterflood source pump is running andVERIFY the seawater flowrate on 40-FI-490.

17 CONFIRM that the Multimedia Filters S-4041A/F are in the Off state.

18 When all the multimedia filters are confirmed as fuIl of water, INITIATE a backwashvia the DCS. An application display is available to indicate status of thebackwashing sequence. The application limits the automatic backwashing to onefilter at a time and will queue additional requests for backwashing.

Note: Any valve which fails to open/close causes the sequence to pause.

19 VENT any air from the multimedia filters via an appropriate high point vent tominimise any water hammer.

20 CONFIRM Master Flow Controller 40-FIC-370 is in manual with the output set to100m 3/h to limit flow through the multimedia filters.

Waterflood Cartridge Filters S-4042A/B/C

21 VERIFY the seawater flowrate on 40-FI-490 and CONFIRM that there is flowthrough Cartridge Filters S-4042A/B/C.

22 CONFIRM that the DP across S-4042A/B/C is within alarm limits.

23 VENT any air from the cartridge filters via an appropriate high point vent to minimiseany water hammer.

Waterflood Deoxygenators A-4041A/B

24 With filtered seawater available, CONFIRM Deoxygenation Skids start-up interlocksand permissives are healthy.

25 At the UCPs, SELECT Waterflood Deoxygenators A-4041A and B to REMOTE.

26 At the CCR HMI, SELECT the Deoxygenators Control Graphic (DE02-STRT-DD)and CONFIRM Waterflood Deoxygenators A-4041A and B are set to REMOTE.

27 CONFIRM the start permissives are healthy then START Skids A and B.

Operational Note: The application is designed for normal operation, ie starting andrunning Oxygenation Skids A and B together. Manual operatorintervention is required only if the skids are to be runindependently. In this procedure, starting both skids together forflow to the injection water tank is the intent. However, for clarityof reading the procedure, the respective start-ups are separatedinto Skid A (Steps 28 to 30) followed in text by Skid B(Steps 31 to 33).






Step Action

28 To follow the start sequence for Deoxygenator Skid A at the CCR HMI, SELECT theSequence Page Skid A Graphic (DE02-STRTA-DD).

29 CONFIRM the start interlocks for Skid A, including:• Waterflood Source Pump P4040A or P-4040B is running• At least three multimedia filters are on line• Methanol/Antifoam Pumps P-4256E/F or C/D are available and selected for duty

for A-4041A• A-4041A Methanol Inlet Valve 40-SDV-544 is closed• SSDS trip healthy (40-HZ-580A/B)

• Instrument Air Alarms 50-PIT-006 H and L are healthy30 With all start permissives healthy and the skid selected to REMOTE the control

application starts Skid A in the following sequence and in the following order:• Disable the following shutdown control loops:

− Gas/Water Separator A-4041A-V-01 Pressure Protection 40-PZIT-529− Gas/Water Separator A-4041A-V-02 Pressure Protection 40-PZIT-533− Gas/Water Separator A-4041A-V-01 Level Protection 40-LZIT-528− Gas/Water Separator A-4041A-V-02 Level Protection 40-LZIT-534

− Deoxydiser A-4041A-V-03 Temperature Protection 40-TZIT-541− Blower A-4041A-K-01 Inlet Pressure Protection 40-PZIT-537

• The application opens Inlet Flow Control Valve 40-FCV-547 to 20% andthen opens Gas/Water Separator Level Controllers 40-LIC-530 and 40-LIC-535to 100%

• The application then closes Seawater Outlet Valve 40-XV-542 and SeawaterDump Valve 40-XV-549

• The application waits for Seawater Outlet 40-XV-542 and Seawater Dump Valve40-XV-549 to close, and sets 40-TIC-539 to 100% open

• The application then opens Seawater Inlet Valve 40-XV-546 and allows bothgas/water separators to start filling

• The application waits for Seawater Inlet Valve 40-XV-546 to open and the levelin Gas/Water Separators A-4041A-V-01/02 to rise >5% before activatingDeoxydiser Temperature Control Loop 40-TIC-539 and starting Blower

A-4041A-K-01• The application confirms that the blower is running (40-XL-524), the lube oil

motor is running and that the following valves are open:− Blower Inlet 40-XV-526 to Gas/Water Separator A-4041A-V-01− Blower Inlet 40-XV-545 from Gas/Water Separator A-4041A-V-02− Blower Inlet 40-XV-536 to Gas/Water Separator A-4041A-V-02






Step Action

• The application activates Preheater Temperature Controller 40-TIC-540 andBlower Inlet Controller 40-PIC-537, then opens Top-up Air Valve 40-XV-520

• The application activates Control Loop 13 (Minox logic) then closes Inlet FlowValve 40-FCV-547 and Gas/Water Separator V-01 Level Valve 40-LCV-530

• The application sets 1st Stage Preheat Deoxydiser to 70 ° C (prior to startingmethanol injection)

• The application waits for 1st Stage Preheat Deoxydiser to attain 70 ° C thenstarts methanol injection at a rate of 15 litres/hour (40-XS-527B)

• The application sets 2nd Stage Preheat Deoxydiser to attain 95 ° C thenreopens Seawater Inlet Flow Control Valve 40-FCV-547

• The application sets Gas/Water Separator A-4041A-V-01 Level Controller40-LIC-530 to a set point > the low limit and the Overboard Dump Valve40-XV-549 is opened

• The application activates the following control loops:− Gas/Water Separation A-4041A-V01 Level Controller 40-LIC-530− Gas/Water Separation A-4041A-V02 Level Controller 40-LIC-535− Methanol dosing pump control− Antifoam chemical dosing pump control−

Control Loop 12 (Minox logic)• The application checks that Gas/Water Separator A-4041A-V-01 Pressure

Protection 40-PZIT-529 is healthy then activates the following shutdowncontrol loops:− Gas/Water Separator A-4041A-V-01 Pressure Protection 40-PZIT-529− Gas/Water Separator A-4041A-V-02 Pressure Protection 40-PZIT-533

• After a time period to establish steady-state conditions in Skid A, the applicationactivates all the shutdown control loops

• Skid A is now running and deoxygenating the seawater. When the oxygencontent reaches 10ppb the application opens Outlet Valve 40-XV-542 andcloses Dump Valve 40-XV-549.

Note: To reduce the concentration of dissolved oxygen below 10ppb, oxygenscavenger should be injected.






Step Action

31 To follow the start sequence for Deoxygenator Skid B at the CCR HMI, SELECT theSequence Page Skid B Graphic (DE02-STRTB-DD).

32 CONFIRM the start interlocks for Skid B, including:• Waterflood Source Pump P4040A or P-4040B is running• At least three multimedia filters areon line• Methanol/Antifoam Pumps P-4256A/B or C/D are available and selected for duty

for A-4041B• A-4041B Methanol Inlet Valve 40-SDV-574 is closed• SSDS trip healthy (40-HZ-580A/B)

• Instrument Air Alarms 50-PIT-006 H and L are healthy33 With all start permissives healthy and the skid selected to REMOTE, the control

application starts Skid B in the following sequence order:• Disable the following shutdown control loops:

− Gas/Water Separator A-4041B-V-01 Pressure Protection 40-PZIT-559− Gas/Water Separator A-4041B-V-02 Pressure Protection 40-PZIT-563− Gas/Water Separator A-4041B-V-01 Level Protection 40-LZIT-558− Gas/Water Separator A-4041B-V-02 Level Protection 40-LZIT-564

− Deoxydiser A-4041B-V-03 Temperature Protection 40-TZIT-571− Blower A-4041B-K-01 Inlet Pressure Protection 40-PZIT-567

• The application opens Inlet Flow Control Valve 40-FCV-577 to 20% and thenopens Gas/Water Separator Level Controllers 40-LIC-560 and 40-LIC-565to 100%

• The application then closes Seawater Outlet Valve 40-XV-572 and SeawaterDump Valve 40-XV-579

• The application waits for Seawater Outlet 40-XV-572 and Seawater Dump Valve40-XV-579 to close and sets 40-TIC-569 to 100% open

• The application then opens Seawater Inlet Valve 40-XV-576 and allows bothgas/water separators to start filling

• The application waits for Seawater Inlet Valve 40-XV-576 to open and thelevel in Gas/Water Separators A-4041B-V-01/02 to rise > 5% before activatingDeoxydiser Temperature Control Loop 40-TIC-569 and starting Blower

A-4041B-K-01• The application confirms that the blower is running (40-XL-554), the lube oil

motor is running and that the following valves are open:− Blower Inlet 40-XV-556 to Gas/Water Separator A-4041B-V-01− Blower Inlet 40-XV-575 from Gas/Water Separator A-4041B-V-02− Blower Inlet 40-XV-566 to Gas/Water Separator A-4041B-V-02






Step Action

• The application activates Preheater Temperature Controller 40-TIC-570 andBlower Inlet Controller 40-PIC-567, then opens Top-up Air Valve 40-XV-550

• The application activates Control Loop 13 (Minox logic), then closes Inlet FlowValve 40-FCV-557 and Gas/Water Separator V-01 Level Valve 40-LCV-560

• The application sets 1st stage preheat deoxydiser to 70 ° C (prior to startingmethanol injection)

• The application waits for 1st stage preheat deoxydiser to attain 70 ° C then startsmethanol injection at a rate of 15 litres/hour (40-XS-557B)

• The application sets 2nd stage preheat deoxydiser to attain 95 ° C thenreopens Seawater Inlet Flow Control Valve 40-FCV-577

• The application sets Gas/Water Separator A-4041B-V-01 Level Controller40-LIC-560 to a setpoint > the low limit and the Overboard Dump Valve40-XV-579 is opened

• The application activates the following control loops:− Gas/Water Separation A-4041B-V01 Level Controller 40-LIC-560− Gas/Water Separation A-4041B-V02 Level Controller 40-LIC-565− Methanol dosing pump control− Antifoam chemical dosing pump control−

Control Loop 12 (Minox logic)• The application checks that Gas/Water Separator A-4041B-V-01 Pressure

Protection 40-PZIT-559 is healthy then activates the following shutdown controlloops:− Gas/Water Separator A-4041B-V-01 Pressure Protection 40-PZIT-559− Gas/Water Separator A-4041B-V-02 Pressure Protection 40-PZIT-563

• After a time period to establish steady-state conditions in Skid B, the applicationactivates all the shutdown control loops

• Skid B is now running and deoxygenating the seawater. When the oxygencontent reaches 10ppb the application opens Outlet Valve 40-XV-572 andcloses Dump Valve 40-XV-579

Note: To reduce the concentration of dissolved oxygen below 10ppb, oxygenscavenger should be injected.

With Deoxygenator Skids A and B on line, the Hypochlorite Generator A-4051 canbe started.






Step Action

Hypochlorite Generator A-4051

34 OPEN Hypochlorite Generator A-4051 Inlet Isolation Valve 40-BUV-240.

35 OPEN Hypochlorite Generator A-4051 Outlet Valve 40-BUV-210 to waterfloodsource pump suctions and 40-BLV-234 to multimedia filter inlet supply header.

36 If the package was shut down from a trip or emergency shutdown, RESET thepackage and then SELECT ‘Remote’ operation at the UCP using 40-HS-698B.

37 INITIATE a DCS package start using 40-HS-693A.

38 The application will check the following conditions:• ‘Remote’ is selected on 40-HS-693B at the UCP•

40-LAHH-683 is healthy• Cell A Low Low Flow 40-FALL-681A and 40-FALL 682A• Cell B Low Low Flow 40-FALL-681B and 40-FALL-682B• Blower Duct Low Low Flow 40-FALL-688• Inlet Valve 40-XV-680 is closed• Outlet Valve 40-LCV-684 is closed• Hypochlorite Pump P-01 is stopped and available• Hydrogen Blower K-01A is stopped and available• Hydrogen Blower K-01B is stopped and available• Motors are available, 40-XA-694 and either 40-XA-695 or 40-XA-696 are inactive• SSDS trip 40-XS-693 is healthy• UCP trip 40-XA-690 is healthy• UCP common fault 40-XA-691 is healthy• At least one waterflood source pump is running and the overboard dump valve

is closed

Note: If any of the above conditions are not met, a status fault alarm is initiated at

the UCP and a common alarm is generated on the DCS. When the fault hasbeen rectified, the package reset must be activated via 40-HS-698B on theUCP and DCS.

39 ENSURE that package running indication 40-XL-692 is illuminated.

40 The package is STARTED in the following sequence:• Start the duty blower• The blower running signal from the LV Switchboard 40-XL-695/696 is inhibited

for 2 seconds and the Blower Duct Low Low Flow and Low Flow Alarms40-FALL-688 and 40-FAL-687 are inhibited for 10 seconds






Step Action

• If the blower running signal is received within 2 seconds, the blower continuesto run

• If the blower running signal is not received within 2 seconds, the blowerduty/standby changeover is activated

• If airflow is established within 10 seconds, ie 40-FAL-687 and 40-FALL-688 arenot activated, the blower continues to run

• If the airflow signal is not received within 10 seconds, the blower duty/standbychangeover is activated

• Failure of the standby blower activates a package trip• If the hydrogen disengagement tank level is below the set point of 40-LALL-683,

the alarm is inhibited for 10 minutes and Level Control Valve 40-LCV-684remains closed• Prior to opening Seawater Inlet Valve 40-XV-680, Low Low Flow Alarms

40-FALL-681A/682A and 40-FALL-681B/682B for cells A and B respectively,are inhibited for 20 seconds

• Inlet Valve 40-XV-680 is opened and the respective low low flow alarms aremonitored

• If flow is established within 20 seconds, the procedure moves to the next step.If the flow is not established in this time, the low low flow alarms arereactivated

•

When seawater flow is established, the level in the hydrogen disengagementtank rises and the level is monitored• When the tank level is above 40-LALL-683 setpoint, the 10-minute alarm timer

alarm is inhibited and the tank filling continues• If the hydrogen engagement tank level is not above 40-LALL-683 within

10 minutes, the alarm is activated, the start procedure is aborted, a package tripis illuminated and Package Running 40-XL-692 is extinguished

• When the hydrogen engagement tank level is above 40-LALL-683 setpoint,the selected cell is energised via a run cell signal from the UCP to thetransformer/rectifier panels

•

The relevant Seacell On Lamps 40-XL-697A or 40-XL-697B on the transformerrectifier panels are illuminated• When the hydrogen engagement tank level is above 40-LAL-684 setpoint,

the hypochlorite pump starts via 40-XS-694A and Level Control Valve40-LCV-684 opens and modulates to maintain a normal operating level

41 MONITOR the sodium hypochlorite concentration by fluid sampling.






Step Action

APPROPRIATE PROTECTIVE EQUIPMENT MUST BE WORN DURINGSAMPLING AS HYPOCHLORITE IS A SKIN AND EYE IRRITANT.

42 INCREASE or DECREASE the sea cell currents to achieve the correctconcentration levels.

Hypochlorite Generator A-4051 is now on line.

Injection Water Tank T-4045

43 ENSURE that the nitrogen blanket is on the injection water tank.

44 When oxygen alarms 40-AIH-543 and 40-AIH-543 are healthy, OPENDeoxygenation Skid Outlet Valves 40-XV-542 and 40-XV-572.

45 ENSURE Overboard Dump Valves 40-XV-549 and 40-XV-579 close.

46 CONFIRM that the application automatically sets Total Flow Controller 40-FIC-370to cascade mode taking its signal from Injection Water Tank Level Controller40-LIC-581B.

47 CONFIRM that Injection Water Tank T-4045 is filling.

48 MONITOR the rising level on the DCS at 40-LIT-581.

49 CONFIRM at the SSDS that Low Level Trip 40-LZL-582A resets as the level in thetank rises.

50 CONFIRM at the DCS that 40-LAL-581A resets as the level in the tank rises.

51 CONTROL of the injection tank level and flow through the multifilters is by TotalFlow Controller 40-FIC-370 in cascade mode taking its signal from Injection WaterTank Level Controller 40-LIC-581B.

52 CONFIRM that 40-LIC-581A takes control of Deoxygenation Skids A-4041A and BOverboard Dump Valves 40-XV-549 and 40-XV-579, opening the valves as requiredto dump water overboard.

53 When the normal working level in Injection Water Tank T-4045 is achieved, start theinjection charge pumps as described below.

Injection Charge Pumps P-4045A/B

54 CONFIRM that P-4045A and B are lined up for running, and that the pumpsare primed.

55 CONFIRM Charge Pumps P-4045A and B are available to start.

56 The application will prevent the operator from starting the injection charge pumpsfrom the CCR until the following conditions are satisfied:• At least one waterflood source pump is running (P-4040A or B) and the

Overboard Dump Valve 40-PCV-366 is closed






Step Action

• The level in Injection Water Tank T-4045 is above the low level alarm point of40-LIC-581B

• At least one deoxygenation skid is on line and discharging to the injection watertank via respective skid Outlet Valve 40-XV-542 or 40-XV-572

Note: The procedure assumes that P-4045A is to be started.

57 SELECT P-4045A to Manual at the DCS.

58 START P-4045A via the pump overlay on the DCS.

59 CONFIRM the pump running indication then SELECT P-4045A to Auto via the DCS.

60 CONFIRM that the common Minimum Flow Controller 40-FIC-598 adjusts in relationto the number of charge pumps running.

61 ENSURE that an injection charge pump is operating on minimum flow control anddumping overboard via 40-FCV-598.

62 At the turbine driver UCP, SELECT the lube oil pump start control switchto HAND.

63 Start the Waterflood Injection Pump P-4046A or B lube oil system.


64 Proceed to injection pump start-up below. ENSURE that 40-SDV-613 is closed andSET in AUTO.

Waterflood Injection Pumps P-4046A/B

Note: This procedure assumes that P-4046A is to be started.

65 At the CCR HMI, SELECT the start sequence graphic for PT-4040A(STRTINJ-PMPA-1-AD) and FOLLOW the automatic sequence below:• ENSURE that the following prestart requirements have been met prior to Water

Injection Pump P-4046A start-up:− ESS Permissives, 8351-XS-BW2-421 and 422, to the UCP are healthy− ESS Fire Stop 8351-XS -BW2-420 to UCP is healthy− UCP Permissives, 8351-XB-BW2-420 and 421 and 422 to the ESS are healthy− DCS Permissive 40-XS-704A to the UCP is healthy

Note: This includes the fuel gas supply to turbine being healthy, at least oneWaterflood Charge Pump P4045A/B running and minimum suction

pressure established.− UCP Permissive 40-XS-704B to DCS is healthy− SSDS minimum flow bypassed (40-FZIT-603)

Note: This is automatically carried out by the SSDS when the pumpis stopped.

− Injection Pump Discharge Valve 40-SDV-613 open− DCS stop 40-HS-701 has been reset






Step Action

− Turbine cooldown non-lockout has been reset via PT1-XB-894L− UCP control mode in REMOTE

66 CHECK and CONFIRM that the manual valve in the quench water to mechanicalseal line is open.

67 ISSUE a start command from the DCS via 40-HS-703, when Local/Remote SwitchPT1-XB-932 on the UCP is set to ‘Remote’ and the prestart conditions above aresatisfied.

68 On receipt of a DCS start command or a local start from the UCP, the UCP carriesout internal checks and ISSUES ‘Unit Starting’ signal 40-XS-727 to the DCS.• The following actions are INITIATED by the DCS on receipt of this signal:

− INITIATE the fuel gas purge− SET Minimum Flow Controller 40-FIC-602 to manual with output set to valve

predefined position− SET Discharge Pressure Controller 40-PIC-609A to automatic mode with

tracking set point to initial start-up pressure− SET Backpressure Controller 40-PIC-609B to automatic mode and setpoint

at predefined minimum backpressure− SET Manual Loader 40-HIC-609B output to 0% ie valve closed

• Following receipt of the unit starting signal, the application issues a DCSpermissive 40-XS-728, CONFIRMING to the UCP that the following conditionsare satisfied:− Injection Pump Discharge Shutdown Valve 40-SDV-613 open− Minimum Flow Controller 40-FIC-602 is set to manual with the output set to

valve predefined configurable position− Discharge Pressure Controller 40-PIC-609A is set to automatic mode with

tracking set point to initial start-up pressure− Backpressure Controller 40-PIC-609B set to automatic mode with a setpoint

at predefined minimum backpressure− Fuel gas temperature is correct− Quench water valve confirmed open

• The UCP CARRIES OUT the ignition sequence and when ignition is detectedvia PT1-XB-882, the application automatically closes Fuel Gas Vent Valve44-XV-481

• The UCP continues its start-up sequence and RAMPS the turbine up to MGS






Step Action

Notes:

(1) MGS is hardwired to the DCS via 40-XS-729 as is the Turbine Speed Signal40-SIT-611.

(2) As the turbine runs up to speed, the start-up override on Minimum Flow Trip40-FZIT-603 is automatically removed in accordance with the SSDSautomatic start-up override philosophy.

• On receipt of MGS the application carries out the following actions:− 40-FIC-602 is automatically SET to auto mode with setpoint equalling the

minimum pump flow of 750m 3/h− Discharge Pressure Controller 40-PIC-609A takes control of turbine speed.

The set point will no longer track the pressure• The injection pump is now RUNNING at minimum speed, with minimum flow to

the overboard dump line• The DCS controllers and valves are RELEASED to the operator

Waterflood Riser Vacuum Breaking and Commencement of Injection

Note: The following Waterflood Riser Vacuum Breaking Procedure should befollowed for every start-up, even if vacuum is not suspected.

69 ENSURE that all valves from the injection charge pump through the waterfloodinjection pump to the riser are open, with the exception of 40-PCV-609

(40-PCV-629).70 Slowly OPEN 40-PCV-609 (40-PCV-629) to approximately 10% using manual

controller 40-HIC-609(629).

71 MONITOR to ensure that water is flowing into the riser as measured on the strap-onultrasonic flow indicator on respective flowline. Indications that the riser is takingwater may include partial closure of 40-FCV-598, ie less water going overboard,and flow measurement via 40-FIC-602 (622).

Note: The flow into the riser may be too low to detect via these measurements. It isalso likely that it will be impossible to detect vacuum with the existing

pressure gauges as they are ranged to accurately measure positiveoperating pressures.

72 If the riser is not taking any water or appears to have stopped taking water, PUMPfor 15 minutes after the flow has stopped.

73 If there is no indication of flow into the riser, PUMP for a total of 15 minutes.

74 Slowly OPEN 40-PCV-609 (629) to 25%.

75 SET Discharge Pressure Controller 40-PIC-609A to the normal operating point.

Note: The controller has an operator settable and selectable ramping facility.

76 SET Discharge Pressure Controller 40-PIC-609B to the normal operating point.

Note: The operator has the facility to manually control the discharge valve via

Manual Controller 40-HIC-609B without using the backpressure controller.






Step Action

77 COMMENCE subsea water injection. For details of water injection well operations,refer to POPM Volume 2B Subsea Waterflood System (OPRM-2003-0302B).Notes:

(1) Pressure Controller 40-PIC-609A is manually adjusted to achieve theinjection conditions required.

(2) Speed Control – Level Override 40-LIC-581C/D is configured via low signalselectors with the outputs of 40-PIC-609A/629A. On falling level in theinjection water tank the speed of the injection pumps is automatically reducedto decrease the discharge flowrate and provide a cushion to allow the tanklevel to rise to the design setting. As the level increases 40-PIC-609A/629Aautomatically resumes control.

78 When required, the waterflood injection rate demands START Water InjectionCharge Pump P-4045B following by Water Injection Pump P-4046B, utilising thesteps described for pumps P-4045A and P-4046A, but using the respective tagnumbers for pumps P-4045B and P-4046B.

79 As required, OPEN the following chemical injection valves on the seawater strainersdischarge header when overboard dumping is complete:• Oxygen Scavenger 40-BLV-278• Filter Aid 40-BLV-279• Biocide 40-BLV-234

80 COMMENCE routine sampling of the injection water and start the injection ofoxygen scavenger, filter aid and biocide as appropriate.

The Waterflood System is now on line. Refer to Procedure No 1/003 for normaloperating checks.








• BON-AME-3-SP-B-21640-006-C06 Waterflood Cartridge Filters• BON-AME-3-SP-B-21640-007-C06 Waterflood Deoxygenation• BON-AME-3-SP-B-21640-008-C06 Waterflood Deoxygenation• BON-AME-3-SP-B-21640-009-C06 Waterflood Deoxygenation• BON-AME-3-SP-B-21640-023-C06 Injection Water Tank and Charge Pumps• BON-AME-3-SP-B-21640-024-C06 Waterflood Injection Pump• BON-AME-3-SP-B-21640-025-C06 Waterflood Injection Pump• BON-AME-3-WF-B-21540-001-C06 Waterflood Injection Pump No 1• BON-AME-3-WF-B-21540-002-C06 Waterflood Injection Pump No 2• BON-AME-3-SP-B-21640-026-C06 Waterflood Injection Launcher/Receivers•

P0001-M037-KVER-019-001-001 Minox Deoxygenation Skid A• P0001-M037-KVER-019-001-002 Minox Deoxygenation Skid A• P-238-K-001 Electrochlorination Generation Package

Interface Systems

Before the Waterflood System can be restarted, the following systems are required to beoperational:• Subsea Waterflood System. Refer to POPM Volume 2B (OPRM-2003-0302B)• Drainage Systems. Refer to POPM Volume 16 (OPRM-2003-0316)

• Nitrogen System. Refer to POPM Volume 20 (OPRM-2003-0320)• Instrument and Utility Air System. Refer to POPM Volume 25 (OPRM-2003-0325)• Power Generation and Distribution. Refer to POPM Volume 30 (OPRM-2003-0330)

Pre-requisites• No Permits to Work are in force that may prohibit restart of the Waterflood System• The DCS, SSDS, ESS and SCU control, and shutdown facilities are operational and

healthy• It is assumed that in a short-duration shutdown, it is unlikely that spades or spectacle

blinds would be moved, isolation block valves operated, drain or vent valves opened,unless required to take corrective action on the cause of the shutdown• It is assumed that all shutdown valves are set in their respective positions and all manual

valves have remained in their normal operating positions






PLANT STATUS• Levels, pressures and temperatures throughout the Waterflood System have remained

within normal operating parameters

• Prior to opening any shutdown valves, ensure that controllers and control valves are setin the correct mode for start-up with the correct set point

• The fault, which resulted in the trip has been rectified and the Waterflood System isready to start






VALVE CHECKLIST NO 2: WATERFLOOD SYSTEM HOT START-UP


Waterflood Source PumpsRefer to P&ID BON-AME-3-SP-B-21640-001 C06

40-XV-319 P-4040A Overboard Dump Valve AUTO

40-XV-339 P-4040B Overboard Dump Valve AUTO

Hypochlorite Generator and Seawater StrainersRefer to P&ID BON-AME-3-SP-B-21640-002 C06

40-BLV-234 Biocide to Multimedia Filters CLOSED

40-BLV-278 Oxygen Scavenger to Multimedia Filters CLOSED

40-BLV-279 Filter Aid to Multimedia Filters CLOSED

Waterflood Multimedia Filters Sheet 1 of 2Refer to P&ID BON-AME-3-SP-B-21640-003 C06

40-XV-372 S-4041A Actuated Inlet Valve AUTO

40-XV-380 S-4041A Actuated Outlet Valve AUTO

40-XV-379 S-4041A Actuated Backwash Inlet Valve AUTO

40-XV-373 S-4041A Actuated Backwash Outlet Valve AUTO

40-XV-381 S-4041A Actuated Drain Down Valve AUTO

40-XV-377 S-4041A Actuated Air Scour Inlet Valve AUTO

40-XV-376 S-4041A Actuated Air Scour Outlet Valve AUTO

40-XV-392 S-4041B Actuated Inlet Valve AUTO40-XV-400 S-4041B Actuated Outlet Valve AUTO

40-XV-399 S-4041B Actuated Backwash Inlet Valve AUTO

40-XV-393 S-4041B Actuated Backwash Outlet Valve AUTO

40-XV-401 S-4041B Actuated Drain Down Valve AUTO

40-XV-397 S-4041B Actuated Air Scour Inlet Valve AUTO

40-XV-396 S-4041B Actuated Air Scour Outlet Valve AUTO

40-XV-412 S-4041C Actuated Inlet Valve AUTO

40-XV-420 S-4041C Actuated Outlet Valve AUTO40-XV-419 S-4041C Actuated Backwash Inlet Valve AUTO

40-XV-413 S-4041C Actuated Backwash Outlet Valve AUTO

40-XV-421 S-4041C Actuated Drain Down Valve AUTO

40-XV-417 S-4041C Actuated Air Scour Inlet Valve AUTO

40-XV-416 S-4041C Actuated Air Scour Outlet Valve AUTO

40-XV-365 Backwash Header to Overboard Actuated Valve AUTO






VALVE CHECKLIST NO 2: WATERFLOOD SYSTEM HOT START-UP (cont’d)


Waterflood Multimedia Filters Sheet 2 of 2Refer to P&ID BON-AME-3-SP-B-21640-004 C06

40-XV-432 S-4041D Actuated Inlet Valve AUTO

40-XV-440 S-4041D Actuated Outlet Valve AUTO

40-XV-439 S-4041D Actuated Backwash Inlet Valve AUTO

40-XV-433 S-4041D Actuated Backwash Outlet Valve AUTO

40-XV-441 S-4041D Actuated Drain Down Valve AUTO

40-XV-437 S-4041D Actuated Air Scour Inlet Valve AUTO

40-XV-436 S-4041D Actuated Air Scour Outlet Valve AUTO

40-XV-452 S-4041E Actuated Inlet Valve AUTO40-XV-460 S-4041E Actuated Outlet Valve AUTO

40-XV-459 S-4041E Actuated Backwash Inlet Valve AUTO

40-XV-453 S-4041E Actuated Backwash Outlet Valve AUTO

40-XV-461 S-4041E Actuated Drain Down Valve AUTO

40-XV-457 S-4041E Actuated Air Scour Inlet Valve AUTO

40-XV-456 S-4041E Actuated Air Scour Outlet Valve AUTO

40-XV-472 S-4041F Actuated Inlet Valve AUTO

40-XV-480 S-4041F Actuated Outlet Valve AUTO

40-XV-479 S-4041F Actuated Backwash Inlet Valve AUTO

40-XV-473 S-4041F Actuated Backwash Outlet Valve AUTO

40-XV-481 S-4041F Actuated Drain Down Valve AUTO

40-XV-477 S-4041F Actuated Air Scour Inlet Valve AUTO

40-XV-476 S-4041F Actuated Air Scour Outlet Valve AUTO

Waterflood Deoxygenation Sheet 1 of 3Refer to P&ID BON-AME-3-SP-B-21640-007 C06

40-XV-546 Deoxygenation Skid A Actuated Inlet Valve AUTO

40-XV-542 Deoxygenation Skid A Actuated Outlet Valve AUTO

40-XV-549 Deoxygenation Skid A Overboard Header Actuated Valve

AUTO

Waterflood Deoxygenation Sheet 2 of 3Refer to P&ID BON-AME-3-SP-B-21640-008 C06

40-XV-576 Deoxygenation Skid B Actuated Inlet Valve AUTO

40-XV-572 Deoxygenation Skid B Actuated Outlet Valve AUTO

40-XV-579 Deoxygenation Skid B Overboard Header Actuated Valve

AUTO








Minox System Vendor P&IDRefer to P&ID D02-0405P-01-01 (Minox)

XV-546 Deoxygenation Skid A Seawater Inlet Actuated Valve

AUTO

XV-542 Deoxygenation Skid A Seawater Outlet Actuated Valve

AUTO

XV-549 Deoxygenation Skid A Seawater Dump Actuated Valve

AUTO

XV-520 Deoxygenation Skid A Instrument Air Supply Actuated Valve

AUTO

XV-536 Deoxygenation Skid A Separator Tower V-02Stripping Gas Inlet Actuated Valve

AUTO

XV-545 Deoxygenation Skid A Separator Tower V-02Stripping Gas Outlet Actuated Valve

AUTO

XV-526 Deoxygenation Skid A Separator Tower V-01Stripping Gas Inlet Actuated Valve

AUTO

SDV-544 Methanol Inlet to Deoxygenation Train A AUTO

Minox System Vendor P&IDRefer to P&ID D02-0405P-01-03 (Minox)

XV-576 Deoxygenation Skid B Seawater Inlet Actuated Valve

AUTO

XV-572 Deoxygenation Skid B Seawater Outlet Actuated Valve

AUTO

XV-579 Deoxygenation Skid B Seawater Dump Actuated Valve

AUTO

XV-550 Deoxygenation Skid B Instrument Air Supply Actuated Valve

AUTO

XV-566 Deoxygenation Skid B Separator Tower V-02Stripping Gas Inlet Actuated Valve

AUTO

XV-575 Deoxygenation Skid B Separator Tower V-02Stripping Gas Outlet Actuated Valve

AUTO

XV-556 Deoxygenation Skid B Separator Tower V-01Stripping Gas Inlet Actuated Valve

AUTO

SDV-574 Methanol Inlet to Deoxygenation Train B AUTO

Waterflood Injection Pump Sheet 1 of 2Refer to P&ID BON-AME-3-SP-B-21640-024 C06

40-SDV-613 P-4046A Discharge Shutdown Valve AUTO

Waterflood Injection Pump Sheet 2 of 2Refer to P&ID BON-AME-3-SP-B-21640-025 C06

40-SDV-633 P-4046B Discharge Shutdown Valve AUTO














Waterflood Injection Launcher/ReceiverRefer to P&ID BON-AME-3-SP-B-21640-026 C06

40-SDV-643 Riser 1 Shutdown Valve CLOSED

40-SDV-653 Riser 3 Shutdown Valve CLOSED

Waterflood Chemical Tanks and PumpsRefer to P&ID BON-AME-3-GN-B-21642-001 C06

42-XV-415 Biocide to Multimedia Filters Actuated Valve AUTO

42-XV-414 Biocide to Injection Pumps Actuated Valve AUTO

Hypochlorite Generator Vendor P&IDRefer to P&ID P-238-K-001

40-XV-680 A-4051-A-01A/B Actuated Inlet Valve AUTO







Step Action

1 ENSURE that the wellhead water injection facilities are available and ready toreceive water.

2 ENSURE that fuel gas is available for the water injection pump turbine drivers.

3 ENSURE that all manual valves are still in the correct position for normal operations.

4 ENSURE that all automatic and sequence valves are in the correct positionfor start-up.

5 ENSURE the level, pressure and temperature controllers listed below are in thefollowing mode, setpoint and position:• Waterflood Source Pumps P-4040A/B/C Pressure Indicator Controller 23-PIC-366

in AUTO with a setpoint of 13.53barg• Multimedia Filters S-4041A to F Total Flow Controller 40-FIC-370 set as below:• With 0 or 1 deoxy unit on line (set automatically by the application and also is

dependent on the level in the Injection Water Tank T-4045):− Multimedia Filters Total Flow Controller 40-FIC-370 (High Limit) 1325m 3/h− Multimedia Filters Total Flow Controller 40-FIC-370 (Low Limit) 750m 3/h

• With 2 deoxy unit on line (set automatically by the application and is alsodependent on the level in the Injection Water Tank T-4045):−

Multimedia Filters Total Flow Controller 40-FIC-370 (High Limit) 2650m3

/h− Multimedia Filters Total Flow Controller 40-FIC-370 (Low Limit) 1500m 3/h

Note: The output of 40-LIC-581B cascades to 40-FIC-370, refer to Water InjectionTank below.

• Deoxygenator Package A-4041A:− Flow Controller 40-FIC-547 in AUTO with a setpoint of 750m 3/h− Pressure Controller 40-PIC-549 in AUTO with a Setpoint of 3barg− Gas/Water Separator V-01 Level Controller 40-LIC-530 in AUTO under

application control− Gas/Water Separator V-02 Level Controller 40-LIC-535 in AUTO under

application control− Deoxydiser V-03 Temperature Controller 40-TIC-539 in AUTO under

application control− Deoxydiser Start-up Heater VH-03 Temperature Controller 40-TIC-540 in

AUTO under application control• Deoxygenator Package A-4041B:

− Pressure Controller 40-PIC-579 in AUTO with a setpoint of 3barg−

Gas/Water Separator V-01 Level Controller 40-LIC-560 in AUTO underapplication control






Step Action

− Gas/Water Separator V-02 Level Controller 40-LIC-565 in AUTO underapplication control

− Deoxydiser V-03 Temperature Controller 40-TIC-569 in AUTO underapplication control

− Deoxydiser Start-up Heater VH-03 Temperature Controller 40-TIC-570 in AUTO under application control

• Injection Water Tank T-4045:− Level Indicator Controller 40-LIC-581A, no control setpoint. Alarm setpoints

open/close Deoxygenator Package A and B Dumps Valves via 40-HS-543and 40-HS-573 respectively

− Level Indicator Controller 40-LIC-581B in Auto, setpoint 4200mm (79.6%)− Level Indicator Controller 40-LIC-581C in Auto, setpoint 2261mm (40%)− Level Indicator Controller 40-LIC-581D in Auto, setpoint 2261mm (40%)

• Injection Charge Pumps P-4045A/B:− Minimum Flow Controller 40-FIC-598 (one pump running) in auto with a

setpoint of 400m 3/h− Minimum Flow Controller 40-FIC-598 (two pumps running) in auto with a

setpoint of 800m 3/h•

Waterflood Injection Pump P-4046A Flow Controller 40-FIC-602, set on autowith a setpoint of 750m 3/h• Waterflood Injection Pump P-4046A Minimum Backpressure Controller

40-PIC-609A on auto, set by the application to the initial start start-up pressure,will be set to the operating point

• Waterflood Injection Pump P-4046A Minimum Backpressure Controller40-PIC-609B on auto, set by the application to the initial start start-up pressure,will be set to the operating point


• Waterflood Injection Pump P-4046B Flow Controller 40-FIC-622, set on auto,with a setpoint of 750m 3/h

• Waterflood Injection Pump P-4046B Minimum Backpressure Controller40-PIC-629A, on auto, set by the application to the initial start start-up pressure,will be set to the operating point






Step Action

• Waterflood Injection Pump P-4046B Minimum Backpressure Controller40-PIC-629B, on auto, set by the application to the initial start start-up pressure,will be set to the operating point







HOT START-UP PROCEDURE

Step Action

Waterflood Source Pumps P-4040A/B and Seawater Strainers S-4040A/B

1 START Source Pump P-4040A from the CCR.


3 If required, START Source Pump P-4040B from the CCR.


Note: One or both pumps may be run to provide the required flowrate.

5 ENSURE that the following chemical injection manual valves on the seawaterstrainers are closed:• Oxygen Scavenger 40-BLV-278• Filter Aid 40-BLV-279• Biocide 40-BLV-234

Note: Chemical injection should not take place whilst overboard dumping is in progress, to avoid unnecessary chemical pollution of the sea.

6 CONFIRM the following on the DCS:• Waterflood Pumps P-4040A/B are running• Seawater Strainers S-4040A/B are selected to the ‘On’ position in the CCR• Sequence fail has been reset

Multimedia Filters S-4041A/F

7 CONFIRM that the Multimedia Filters S-4041A/F are in the online state. A minimumof three multimedia filters are required to be online before the Minox units can bestarted.

8 INITIATE or restart the next filter to be backwashed.

Waterflood Cartridge Filters S-4042A/B/C

9 CONFIRM that there is flow through Cartridge Filters S-4042A/B/C.10 CONFIRM that the DP across S-4042A/B/C is within alarm limits.

Waterflood Deoxygenators A-4041A/B

11 START Waterflood Deoxygenators A-4041A and B, as detailed in the WaterfloodCold Start-up Procedure.






Step Action

12 START the Hypochlorite Generator A-4051, as detailed in the Waterflood SystemCold Start Procedure. COMMENCE injection of sodium hypochlorite into thewaterflood source pump suctions and the seawater strainer discharge header.

13 MONITOR the sodium hypochlorite concentration by fluid sampling.

APPROPRIATE PROTECTIVE EQUIPMENT MUST BE WORN DURINGSAMPLING AS HYPOCHLORITE IS A SKIN AND EYE IRRITANT.

Injection Water Tank T-4045

14 START the injection water tank as detailed in Waterflood System Cold StartProcedure.

Injection Charge Pumps P-4045A/B


15 START the Injection Charge Pump P-4045A as detailed in the Waterflood SystemCold Start Procedure.

Waterflood Riser Vacuum Breaking

16 PERFORM the Waterflood Riser Vacuum Breaking Procedure as detailed onSteps 16 to 23.

Note: The Waterflood Riser Vacuum Breaking Procedure should be followed forevery start-up even if vacuum is not suspected.

17 ENSURE that the injection charge pump is operating with all water flowingoverboard on pressure control via 40-FCV-598.

18 START the waterflood injection pump lube oil system on P-4046A or B.

19 Open all valves in path from the injection charge pump through the waterfloodinjection pump to the riser except 40-PCV-609 (629). ENSURE that 40-SDV-643

(40-SDV-653) is open.20 Slowly OPEN 40-PCV-609 (629) to approximately 10%.

21 MONITOR to ensure that water is flowing into the riser. Indications that the riser istaking water may include partial closure of 40-FCV-598, ie less water goingoverboard, and flow measurement via 40-FIC-602 (622).

Note: The flow into the riser may be too low to detect via these measurements. It isalso likely that it will be impossible to detect vacuum with the existing

pressure gauges as they are ranged to accurately measure positiveoperating pressures.

22 If the riser is not taking any water or appears to have stopped taking water,

PUMP for 15 minutes after the flow has stopped.






Step Action

23 If there is no indication of flow into the riser, PUMP for a total of 15 minutes.

24 Slowly OPEN 40-PCV-609 (629) to 25%.

25 Proceed to Waterflood Injection Pump Start-up.

Waterflood Injection Pumps P-4046A/B


26 START the Water Injection Pump P-4046A.

27 ISSUE a start command from the DCS via 40-HS-703 when Local/Remote SwitchPT1-XB-932 on the UCP is on ‘Remote’ and the prestart interlocks are satisfied.

The application carries out the following actions:

• SET Minimum Flow Controller 40-FIC-602 to manual with output set to valvepredefined position (configurable)

• SET Discharge Pressure Controller 40-PIC-609A to automatic mode with OutputTracking Speed Signal 40-ST-611 and setpoint at initial start-up pressure

• SET Backpressure Controller 40-PIC-609B to pressure setpoint tracking

Note: As the Pressure Control Valve 40-PCV-609B may not be fully closed duringthe cooldown period, the hand controller will not be automatically set to 0%.

The application issues the DCS permissive 40-XS-728 to the UCP, CONFIRMINGthat the following conditions are satisfied:

• Minimum Flow Controller 40-FIC-602 is SET to manual with output set to valvepredefined position (configurable)

• Discharge Pressure Controller 40-PIC-609A is SET to automatic mode withOutput Tracking Speed Signal 40-ST-611 and setpoint at initial start-uppressure

• Backpressure Controller 40-PIC-609B is SET to pressure setpoint tracking• Quench water valves CONFIRMED open

The UCP STOPS the cooldown sequence and returns to a start-up sequence toramp the turbine up to MGS.

On receipt of MGS, the application carries out the same actions as during a coldstart as follows:• 40-FIC-602 is automatically SET to auto mode with setpoint equalling the

minimum pump flow of 750m 3/h• Discharge Pressure Controller 40-PIC-609A CONTROLS the turbine speed,

the setpoint will no longer track the pressure

At this point the injection pump is running at minimum speed, with minimum flow tothe overboard dump line. The DCS controllers and valves are RELEASED to theoperator.






Step Action

Note: Throughout the cooldown period the ‘Unit Starting Signal’ is active, fuel gasremains flowing to the unit and the discharge valve remains open. When anormal stop command is issued the UCP raises an alarm ‘TurbineNormal Stop – Remote PT4040A’ PT1-XA -880NR or ‘Turbine NormalStop – Local PT4040A’ PT1-XA-880NL which must be acknowledged viaPT1-XC-852A before the machine can be restarted.

28 SET Discharge Pressure Controller 40-PIC-609A to the normal operating point.

Note: The controller has an operator settable and selectable ramping facility.

29 SET Discharge Pressure Controller 40-PIC-609B to the normal operating point.

Note: The operator has the facility to manually control the discharge valve viaManual Controller 40-HIC-609B without using the backpressure controller.

30 As required RESET and OPEN 40-SDV-613 from the DCS.

Note: The SSDS output to this valve must be reset before the valve can beoperated from the DCS.

31 COMMENCE subsea water injection. For details of the injection well operations,refer to POPM Volume 2B Subsea Waterflood System (OPRM-2003-0302B).

32 As required, OPEN the following chemical injection valves on the seawater strainersdischarge header when overboard dumping is complete:• Oxygen Scavenger 40-BLV-278• Filter Aid 40-BLV-279• Biocide 40-BLV-234

33 COMMENCE routine sampling of the injection water and start the injection ofoxygen scavenger, filter aid and biocide as appropriate.

34 When required, the waterflood injection rate demands START Water InjectionCharge Pump P-4045B following by Water Injection Pump P-4046B, utilising thesteps described for pumps P-4045A and P-4046A, but using the respective tagnumbers for pumps P-4045B and P-4046B.

The Waterflood System is now back on line. Refer to Procedure No 1/003 fornormal operating checks.







PROCEDURE NO 1/003: NORMAL OPERATION


FOLLOWING ACTIONS.

General Operator Routines•

MONITOR the overall operation of the Waterflood System• The Field Operator should regularly walk the system to visually inspect for leaks,

damage and any system abnormality. REPORT any chemical leaks, malfunctions orirregular operating occurrences to the team leader as soon as possible

• The Field Operator should regularly LIAISE with the Control Room Operator so as tocross-check the accuracy of the instrumentation, ie the comparison between the localinstrument and the transmitted level in the DCS

• Visually INSPECT the condition of the system equipment and pipework forcorrosion/deterioration including the security of pipe hangers/fittings

• The Field Operator should regularly vent air from high points in the system, to preventwater hammer and possible damage to equipment

• Off-going shift operators must ENSURE that the oncoming shift operators are fullybriefed as to the status of the plant as detailed in the Shift Operators Logbook.The logbook should contain sufficient detail of the plant status including any deviationfrom the norm and, in particular, any isolation of protection equipment. Both the off-goingand the on-coming shift operators must sign the logbook before responsibility ishanded over

Waterflood Source Pumps P-4040A/B

Waterflood Source Pumps P-4040A/B normally operate without direct operator intervention.However, the following running checks should be carried out periodically so as to ensure thatthe pump is within the normal desired parameters.• CHECK all joints and glands on the pump sets for signs of leakage• CHECK the pump set for unusual noise/excessive noise and vibration and compare

against the normal running parameters previously logged• MONITOR the hypochlorite injection via the local flow gauges• CHECK the pump mechanical seal for leakage and signs of overheating• CHECK the motor current for the duty pump at the MCC and COMPARE against the

normal running amperage previously logged

• CHECK the oil levels in the bearing housings and top up as necessary






Seawater Strainers S-4040A/B/C

Note: Normally, the Seawater Strainers S-4040A/B/C operate without direct operatorintervention.

• MONITOR the differential pressures across the filters.• ENSURE that the filter backwash sequence is operating within required parameters

Waterflood Multimedia Filters S-4041A to F• MONITOR the differential pressures across the filters and ENSURE that they remain

within normal parameters• ENSURE that the backwash sequence is operating normally• CHECK the air scour blower for excessive noise and vibration• CHECK the running amps on the air scour blower at the MCC and COMPARE against

previously taken readingsWaterflood Cartridge Filters S-4042A/B/C• MONITOR the differential pressure across the system and ENSURE that it remains

within normal parameters

Deoxygenation Skid• MONITOR the level in Separator Tower A, ensuring that the level is approximately 50%.

COMPARE the local level with the indication on the DCS• MONITOR the level in Separator Tower B, ensuring that the level is approximately 50%.

COMPARE the local level with the indication on the DCS• MONITOR the local temperature of the start-up heater and COMPARE with the DCS

indication• CHECK methanol and antifoam injection pump flow rates and ENSURE that they remain

within operating parameters• MONITOR the temperature of the deoxydiser via 40-TIC-539 (569) and COMPARE with

the DCS indication• MONITOR the oxygen content of the seawater outlet via the oxygen analyser and

COMPARE with routine samples• CHECK the air blower for excessive noise and vibration• CARRY out inspection and minor maintenance in Minox blower housing, eg oil level, seal

gas check• CHECK the running amps on the air blower at the MCC and compare against previous

readings

CARE SHOULD BE TAKEN WHEN WORKING IN THE MINOX BLOWERHOUSING BECAUSE OF THE POSSIBILITY OF BURNS, ASPHYXIATION AND MUSCULAR STRAINS, DUE TO EXPOSURE TO HOT EQUIPMENT,

PRESENCE OF NITROGEN AND RESTRICTED ACCESS.






Injection Water Tank T-4045• MONITOR the water level and COMPARE with the DCS indication• MONITOR the pressure in the injection water tank via the local pressure gauge

Water Injection Charge Pumps P-4045A/B• CHECK all glands, joints and mechanical seals for leakage• CHECK the pump for excessive noise and vibration• CHECK the running amps at the MCC and compare against previously taken readings

Water Injection Pumps P-4046A/B• CHECK all glands, joints and mechanical seals for leakage• CHECK the pump for excessive noise and vibration

Water Injection Pump Turbine Drivers PT-4046A/B• RECORD engine speeds, pressures, temperatures and vibration levels and COMPARE

with normal operating parameters• MONITOR the turbine system for air, oil or fuel gas leaks• MONITOR the engine bearing drains to ENSURE that oil is draining from the bearings• MONITOR the lube oil temperature via 40-TT-380• MONITOR the lube oil reservoir level•

MONITOR the main lube oil pump pressure via 40-PI-903• MONITOR the lube oil filter differential pressure via 40-PDI-902• MONITOR the lube oil header pressure via 40-PI-901-1• MONITOR the backup post-lube pump pressure via 40-PI-905• MONITOR the lube oil vent separator differential pressure via 40-PDI-903

Electrochlorination Unit• MONITOR the steady operation of unit as outlined in Part 1 Section 2 Paragraph 3.10• Ensure the filter screen on the atmospheric vent from the hydrogen disengagement tank

is cleaned on a regular basis






WATERFLOOD CHEMICAL INJECTION• Waterflood water samples must be routinely taken for analysis in the laboratory. Adjust

the injection of the respective chemicals accordingly to maintain the quality of water

injected and to protect the equipment (oxygen scavenger, methanol, antifoam, filter aid,biocide, anti-scalant and corrosion inhibitor)• MONITOR chemical injection rates on a routine basis• MONITOR the levels in the chemical injection isotainers

Note: The level in Filter Aid/Clarifier Tank T-4255A must be carefully monitored to ensurecontinuous injection of filter aid. Loss of filter aid injection will lead to reduced filtrationefficiency. As the tank is not equipped with a level gauge, the level must be checkedby the operator on a regular basis.







PROCEDURE NO 1/004: PLANNED SHUTDOWN


FOLLOWING ACTIONS.

INTRODUCTION

This procedure provides a safe and efficient means of shutting down the Waterflood System.

It is assumed that the Waterflood System has been running normally and is to be shut downin a controlled manner.

PRECONDITIONS

Supporting Drawings

The Shutdown Procedure makes use of the following P&IDs:• BON-AME-3-SP-B-21640-001-C06 Waterflood Source Pumps• BON-AME-3-SP-B-21640-002-C06 Hypochlorite Generator and Seawater Strainers

• BON-AME-3-SP-B-21640-003-C06 Waterflood Multimedia Filters• BON-AME-3-SP-B-21640-004-C06 Waterflood Multimedia Filters• BON-AME-3-SP-B-21640-005-C06 Waterflood Cartridge Filters• BON-AME-3-SP-B-21640-006-C06 Waterflood Cartridge Filters• BON-AME-3-SP-B-21640-007-C06 Waterflood Deoxygenation• BON-AME-3-SP-B-21640-008-C06 Waterflood Deoxygenation• BON-AME-3-SP-B-21640-009-C06 Waterflood Deoxygenation• BON-AME-3-SP-B-21640-023-C06 Injection Water Tank and Charge Pumps• BON-AME-3-SP-B-21640-024-C06 Waterflood Injection Pump• BON-AME-3-SP-B-21640-025-C06 Waterflood Injection Pump• BON-AME-3-SP-B-21640-026-C06 Waterflood Injection Launcher/Receivers• P0001-M037-KVER-019-001-001 Minox Deoxygenation Skid A• P0001-M037-KVER-019-001-002 Minox Deoxygenation Skid A• P-238-K-001 Electrochlorination Generation Package






Interface Systems• Drainage Systems. Refer to POPM Volume 16 (OPRM-2003-0316)• Nitrogen System. Refer to POPM Volume 20 (OPRM-2003-0320)• Instrument and Utility Air System. Refer to POPM Volume 25 (OPRM-2003-0325)• Power Generation and Distribution. Refer to POPM Volume 30 (OPRM-2003-0330)

Pre-requisites• No Work Permits are in force which will prohibit the shut down of the Waterflood System• There are no further requirements for waterflood• Toolbox talks have been held with all directly and indirectly concerned parties outlining







PLANNED SHUTDOWN PROCEDURE

Step Action

Water Injection Pumps Normal Shutdown

Note: A normal shutdown includes a cooldown period, which allows the engine torun with no load for a preset period before the engine is stopped.

1 A ‘Normal Stop’ for P-4046A can be issued at the UCP (PT1-XA-880NL) or from theDCS (40-HS-701). This is a pulsed signal (5 seconds configurable) and results inthe UCP latching a signal, returning the status ‘Turbine Normal Stop’ – remotePT4040A (PT1-XA-880NR) and carrying out the cooldown sequence withinthe UCP.

2 The DCS application carries out the following actions:•

Pressure Controller 40-PIC-609A is placed in manual and tracks the turbinespeed (the UCP will take over speed control and will ramp down the machine’sspeed)

• As the machine reduces below minimum gas generator speed the FlowController 40-FIC-602 is set to manual mode with the output at the start-upsetting

3 The following actions occur at the UCP following activation of the stop:• Cooldown Light Ds113 ILLUMINATES• Cooldown HIGHLIGHTS on the Operation Summary Screen•

Engine SLOWS to idle speed and continues to run for a preset cooldown cycle• Fuel system valves CLOSE, combustion STOPS and engine DECELERATES• Cooldown Light DS113 EXTINGUISHES• Stopping Light DS111 ILLUMINATES• Stopping HIGHLIGHTS on the Operation Summary Screen• Running indication reverts to ‘normal’ video• Engine Hours/Start Counter M210 STOPS logging run time• Engine coasts to a stop and the rundown timer expires

• Preset post-lubrication cycle INITIATED At the end of the cooldown period, the unit starting signal (40-XS-727) is removedby the UCP and the application carries out the following actions:• Close Discharge Valve 40-SDV-613• Close Fuel Gas Valve 44-SDV-482• Open Fuel Gas Vent valve 44-XV-481

4 CARRY OUT a normal stop of Waterflood Injection Pump P-4046B which follows thesame sequence as for P-4046A above, utilising the tags numbers for P-4046B.

5 Shut down water injection wells in accordance with the relevant procedure detailedin POPM Volume 2B Subsea Waterflood System (OPRM-2003-0302B).






Step Action

6 CLOSE 40-SDV-643 and 40-MOV-641 on Water injection Flowline Riser 01.

7 CLOSE 40-SDV-653 and 40-MOV-651 on Water injection Flowline Riser 03.

8 ENSURE that water is being dumped overboard downstream of the Injection ChargePumps P-4045A/B via 40XV-549/579 and 40-FCV-598.

Water Injection Charge Pump Shutdown

9 SHUT DOWN Injection Charge Pumps P-4045A and B from the CCR.

Deoxygenation Shutdown

10 At the UCPs, SELECT Waterflood Deoxygenators A-4041A and B to REMOTE.

11 At the CCR HMI, SELECT the deoxygenators control graphic and CONFIRM

Waterflood Deoxygenators A-4041A and B are set to REMOTE.12 ACTIVATE stop selector switch for Skids A and B from the HMI screen.

13 The application shuts down Skids A and B in the following sequence (tag numbersfor Skid B are given in parenthesis):• CLOSE Seawater Outlet Valve 40-XV-542 (572), OPEN Dump Valve 40-XV-549

(579)• DEACTIVATE the following control loops:

− Deoxydiser A-4041A-V-03 Temperature Controller 40-TIC-539 (569)− Start-up Heater A-4041A-VH-03 Temperature Controller 40-TIC-540 (570)− Methanol dosing pump control

• OPEN Deoxydiser A-4041A-V-03 Outlet Valve 40-TCV-539 (40-TCV-569)• DEACTIVATE antifoam dosing pump control• CLOSE Seawater Inlet Flow Control Valve 40-FCV-547 (577)• DEACTIVATE blower(s) control loop• DEACTIVATE the following control loops (valves open):

− Gas/Water Separator A-4041A-V-01 Level Controller 40-LIC-530 (560)−

Gas/Water Separator A-4041A-V-02 Level Controller 40-LIC-535 (565)• CLOSE Air Make-up Valve 40-XV-520 (550)• MOVE all valves to FAIL-SAFE position

Note: If an emergency shutdown occurs during a stop sequence, this will overridethe stop sequence and both skids will stop in the following sequence:• STOP the chemical injection pumps• MOVE all valves to FAIL-SAFE position• DEACTIVATE all control loops






Step Action

Multimedia Filters Shutdown

14 SET Multimedia Filters S-4041 A to F to the OFF position via 40-HS-360A to F onthe DCS.

15 ENSURE that seawater is being dumped overboard via 40-PCV-366 on thedischarge of the waterflood source pumps.

Hypochlorite Generator Shutdown

16 SHUT DOWN the Hypochlorite Generator A-4051 (as detailed in Steps 13 to 21).

Note: The hypochlorite generator may be shut down by local or remote initiation.Both methods are detailed in Steps 13 to 20.

17 INITIATE a local package stop via Pushbutton 40-HS-698E at the UCP.

18 The selected cells are DE-ENERGISED by the removal of the run cell signal fromthe UCP to the transformer/rectifier panels. The associated Cell On Indicators40-XL-697A/B will be EXTINGUISHED.

19 A 20-second delay is INITIATED to permit flushing of the cells.

20 At the end of the flushing period, the package is shut down in the followingsequence:

(a) CLOSE Seawater Inlet Valve 40-XV-680.

(b) STOP Hypochlorite Booster Pump P-01 (40-XS-694B).

(c) CLOSE Level Control Valve 40-LCV-684.

(d) START blower run-down period of 10 minutes.

(e) After 10 minutes, Blower K-01A/B is STOPPED via 40-XS-695B or40-XS-696B.

(f) Package Running Indication 40-XI-692 EXTINGUISHED.

21 INITIATE a remote package stop via 40-HS-698A on the DCS.

22 The selected cells are DE-ENERGISED by removing the run cell signal from theUCP to the transformer/rectifier panels. The associated Cell On Indicators40-XL-697A/B will be EXTINGUISHED.

23 A 20-second delay is INITIATED to permit flushing of the cells.

24 At the end of the flushing period, the package is shut down in the followingsequence:

(a) CLOSE Seawater Inlet Valve 40-XV-680.

(b) STOP Hypochlorite Booster Pump P-01 (40-XS-694B).

(c) CLOSE Level Control Valve 40-LCV-684.

(d) START blower run-down period of 10 minutes.

(e) After 10 minutes, STOP Blower K-01A/B via 40-XS-695B or 40-XS-696B.

(f) EXTINGUISH Package Running Indication 40-XL-692.






Step Action

Seawater Strainers Shutdown

25 SELECT Seawater Strainers S-4040A/B to backwash to OFF. On the strainerundergoing a backwash the application will stop the backwash motor, close thebackwash valve and remove the strainer from the backwash sequence.

Waterflood Source Pumps Shutdown

26 SHUT DOWN Waterflood Source Pumps P-4040A/B from the CCR.







PROCEDURE NO 1/005: PROCESS AND EMERGENCY SHUTDOWN


FOLLOWING ACTIONS.

INTRODUCTION

Process and emergency shutdowns for the Waterflood System are initiated by intertrip fromthe ESR System and by activation of one or more of the various SSDS trips, which areclearly indicated on the Cause and Effect Charts.

Supporting Drawings

The process and emergency shutdowns pertinent to the Waterflood System are shown onthe following Bonga Cause and Effect Charts:• BON-AME-3GN-B-25082-010 Z01 Sheet 1 of 2• BON-AME-3GN-B-25082-010 Z01 Sheet 2 of 2

The cause and effect logic attached to each specific trip is illustrated in detail in the Causeand Effect Charts.

SHUTDOWN HIERARCHY

The process and emergency shutdown hierarchy designed for the FPSO is based on acascade system, the highest level of shutdown being ESR 3 (Total FPSO Shutdown).

A shutdown initiated at any particular level automatically initiates all shutdowns associatedwith lower levels, ie an ESR 3 shutdown automatically triggers shutdown actions associatedwith ESR 2, ESR 1 and SSDS trip levels.

A brief explanation of the various FPSO shutdown levels is given below:

ESR 3

Total isolation of the FPSO from external sources of hydrocarbons, shutdown and, whereapplicable, blow down of all process non-essential utility systems, isolation of fuel to theemergency and essential generator break tanks, subsea shutdown and SCSSV closurefollowed by time-delayed depressurising of hydraulic supplies and electrical isolation.

An ESR 3 shutdown is initiated by activation of the following devices:• Manual pushbuttons located at the helideck• Manual pushbuttons located at the lifeboat stations• Manual pushbuttons located in the CCR






Blowdown

Initiates ESR 2 shutdown of all process systems, including subsea production (not closure ofSCSSVs) and blowdown of topsides process systems.

Blowdown is initiated by activation of the following devices:• Manual blowdown pushbutton located in the CCR• Confirmed fire in a hazardous area• Confirmed gas in a process area, subsea module or hull

ESR 2

Shutdown of all process and export systems, including subsea production (not closure ofSCSSVs) followed by time-delayed depressurising of LP hydraulic supplies. The main powergenerator turbines are shut down but the utilities supplied from the emergency and essentialgenerators remain operational with the exception of the diesel supply pumps.

An ESR 2 shutdown is initiated by activation of the following devices:• ESR 3 shutdown• ESR 2 manual pushbuttons• Blowdown• Manual pushbuttons located in the CCR and general areas• Confirmed fire in a hazardous area• Confirmed gas in a process area, subsea module or hull• Total loss of main power generation• Failure of the SSDS (watchdog)• Failure of the Subsea System (watchdog)

ESR 1

Shutdown of all process systems along with the closure of the FPSO boarding valves andsubsea production (not closure of SCSSVs) followed by closure of the oil production, waterinjection and gas lift riser valves and venting of all SDV air supply manifolds.

An ESR 1 shutdown is initiated by activation of the following devices:• ESR 3 shutdown

• ESR 2 shutdown• Manual pushbutton located in the CCR• Confirmed fire in a safe area (equipment space, MCC or hull)• Any blowdown valve failing open








SSDS

Shutdown of individual items of equipment. A unit shutdown does not impair the safeoperation of the remainder of the process.

An SSDS shutdown is initiated by activation of the following devices:• ESR 3 shutdown• ESR 2 shutdown• ESR 1 shutdown• Manual facilities on the HMIs located in the CCR• Process upsets

The cause and effect logic attached to each specific trip is illustrated in detail in the Causeand Effect Charts listed in Supporting Drawings at the beginning of this procedure.

Note: Refer to Procedure No 1/004 for details of the planned shutdown of the WaterfloodSystem.





Section 2Equipment Operating Procedures

ProcedureNumber

WATERFLOOD EQUIPMENT OPERATING PROCEDURES

PROCEDURE NO 2/001: TURBINE COMPRESSOR CLEANING ON-CRANK

PROCEDURE NO 2/002: TURBINE COMPRESSOR CLEANING ONLINE

Part 2 Section 2 Equipment Operating Procedures






PROCEDURE NO 2/001: TURBINE COMPRESSOR CLEANING ON-CRANK


FOLLOWING ACTIONS.

THE SOLAR O&M MANUAL VOLUME II SECTION 8 TAKES PRECEDENCEOVER THIS PROCEDURE AND SHOULD BE FOLLOWED WHEN

PERFORMING THIS TASK.

THERE IS THE POTENTIAL FOR INGRESS OF WATER INTO THETURBINE AND COMBUSTION SECTION. THIS COULD LEAD TO

CATASTROPHIC FAILURE OF THE TURBINE.

WARNING

INTRODUCTION

The turbine engine compressor can be cleaned while the engine is cranking (on-crank mode)or while the engine is operating in the simple cycle mode (online mode).

On-crank engine compressor cleaning is performed when the engine compressor is rotatedby the start system. The engine must be shut down and allowed to cool prior to startingpreparation procedures. On-crank cleaning can be done as often as needed, however,engine cleaning is not recommended below -4°F (-20°C).

The package is equipped with a skid-edge connection routed through two solenoid valveswithin the package – one for online cleaning and one for on-crank cleaning, refer to theschematic on the following page. Each connection is piped to the respective cleaningmanifold with the following components:

• Inlet strainer

• Shut-off solenoid

• Triple cartridge filter

• Three-way hand valve (on-crank only)

Compressor fouling is a combination of water-soluble and non-water-soluble foulants.The unknowns are the degree of each and the rate at which these foulants accumulate in theengine compressor. The waste stream produced by the cleaning procedure is dischargedmainly through the drain ports and can be observed during the cleaning process and usedto gauge the effectiveness and duration of the clean. However, it is important that the

recommended duty cycle for the electric starter system is not exceeded during the on-crankcleaning process.






Gas Turbine Compressor Cleaning Facilities Schematic






On-crank Cleaning Methods and Specifications

CleaningMethod

Cleaning Solution

(Volume in litres)(Note 2)

DeionisedWater toSolution

Ratio

Flow(lt/m)

AirPressure

(barg)(Note 1)

Air Flow(scfm)

Solution 15 4:1 11.4 to15.1 6.2 to 6.9 4.6

Mix 75 N/A 11.4 to15.1 6.2 to 6.9 4.6

Notes:

(1) The optimum pressure at the injectors is between 90 and 100psig (620kPa to 690kPa)measured at the skid edge connection. Optimum pressure may require pressuring thetank higher than specified, but limited to the relief valve setting for the tank.

(2) This is the recommended dosage. The compressor should be rinsed until a cleanwaste stream is noted in the engine drains.

Cleaning Solution and Rinse Water Flow Requirements

CleaningMethod

Cleaning ProductVolume

Rinse WaterVolume

Flowrate forCleaning/Rinsing

On-crank 56.8 to 75.7 litres 75.7 to 151.4 litres 11.4 to 15.1 litre/min

Requirements for Water Used in Ingestive Cleaning of Solar Gas Turbines

Test Method Maximum LimitOn-crank Cleaning

Sodium and Potassium ASTM D1428 105ppmw

Fluorine – 100ppmw

Chlorine ASTM D512 100ppmw

Lead ASTM D3559 2ppmw

Vanadium ASTM D3373 2ppmw

Iron, Tin, Silicon, Aluminium,Copper, Manganese, Phosphorus

ASTM D857, D858,D1068, D1688

10ppmw

Calcium and Magnesium ASTM D3605, D511 100ppmw

Total Dissolved Solids ASTM D1888 350ppmw

pH ASTM D1293 6 to 9






Online turbine cleaning differs from on-crank cleaning in that the turbine is in service duringthe cleaning process. Gas turbine online cleaning requires the use of extremely pureDeionised (DI) water. If the water is not deionised, dissolved materials and salts willprecipitate out as the water flashes to steam at some point in the turbine gas path. The solids

will quickly build up on the rotating and stationary components and can cause foreign-objectdamage and provide an environment for accelerated hot corrosion. Water deionisation is theremoval of ionised minerals and salts from solution by a two-phase ion exchange procedure.Only DI water should be used for online cleaning.

To obtain the required DI water quality, potable water is sent to the locally installed DI watertreatment system (bottle rack). The system includes an array of water treatment bottles thatare life limited and need to be replaced after a certain amount of use. The consumption ratedepends on the quality of the water going into the system. The size of the DI water systemalso dictates the nominal rating on the quantity of water that can be treated beforereplacement of the bottles is required. The online rinse tank used for the turbine washsystem is filled daily with the treated water at the turbine operator manually initiates the rinse

procedure.Operators of online rinse systems should periodically check the purity of the produced DIwater with a suitable conductivity meter – DI water has very low electrical conductivity sincethere is very little dissolved ions resent to conduct an electrical current. It is recommendedthat water quality be checked once a week. The Myron L Company ( www.myronl.com )manufactures several hand-held instruments that are used to spot-check the water quality.The water quality is measured in units of either conductivity (micro-ohms ( µΩ ), same asmicro-Siemens ( µS) or TDS (Total Dissolved Solids, parts per million – ppm)). On a properlyfunctioning DI water system, the treated water can be so pure that it does not register onsome model Myron L conductivity meters typically being used. The standard Myron L EPmeter only starts to read at 0.5 µΩ . The water from a DI system with new bottle should be

below the 0.5 µΩ reading.Do not use the water if the conductivity meter reading is above 1.0 µΩ . When the readingstarts to register on the Myron L meter at 0.5 µΩ , some trending should begin to estimate theremaining life of the DI treatment system and schedule a replacement.

Below are some conversions for the different types of water quality measurement units.

Conductivitymicro-ohms ( µΩ )

Resistivityohms-cm

TDS ppm

2 5,000,000 1.0

1 1,000,000 0.500

0.5 2,000,000 0.250

0.25 4,000,000 0.125



http://www.myronl.com/





PROCEDURE – TESTING MOBILE/STATIONARY TANK CLEANING SYSTEM

Step Action

Before the mobile tank cleaning system can be used it must be flushed to ensure all debrisis removed.

Flush and pressure test the pressure injection tank as follows:

1 CHECK the quality of the water produced by the deionised water unit to ensure thatit meets the Solar specification prior to performing turbine cleaning. (DI waterconductivity to be < 1.0 µΩ .)

2 For mobile tank cleaning system, CONNECT a supply hose between deionised watersource and the tank water inlet.

3 OPEN the tank vent valve and tank water inlet valve.

4 FILL the injection tank with water until it begins to flow out of the tank vent valve.

5 CLOSE the tank water inlet valve and disconnect the supply hose.

6 CLOSE the tank vent valve.

7 CONNECT an air hose between the air source and the air inlet.

8 OPEN the air inlet valve to pressurise the tank to a normal working air pressure of6.9barg then CLOSE the air inlet valve.

9 Leave the tank under PRESSURE for 10 minutes. There should be no pressure dropor leakage at any fittings.

10 Slowly OPEN the drain valve and allow the water to run safely to a drain until tankpressure is zero.

11 CLOSE the drain valve. Remove, clean and replace the filter inserts from the air,water and chemical inlet Y strainers.

12 CHECK the quantity and quality of the water which has passed through the deionisedwater unit to ensure there is sufficient life remaining in the treatment materials(the unit can process 13.25m 3 of deionised water before replacement is required).Trending of DI water quality is to commence at conductivity reading of 0.5 µΩ .Do not use the DI water with conductivity reading of greater or equal to 1.0 µΩ .Replace the DI unit before the DI water conductivity deteriorates to 1.0 µΩ .

13 CONNECT the supply hose between the deionised water source and the tankwater inlet.

14 OPEN the tank water inlet and vent valves.

15 Half FILL the tank with deionised water.

16 MONITOR conductivity of the water at the meter on the outlet of the deionisationpackage (DI water conductivity to be < 1.0 µΩ ).

17 CLOSE the water inlet tank vent valve.

18 DISCONNECT the supply hose.

19 SHUT DOWN the engine normally and allow it to cool to 65 °C.

20 OPEN the air inlet valve to pressurise the tank to 2.07barg.






Step Action

21 CONNECT the supply hose between the tank outlet and the on-crank washmanifold inlet.

22 Slowly OPEN the tank wash fluid outlet valve. Any major connector leaks will beimmediately visible. If leaks are detected, CLOSE the tank outlet valve and TIGHTENthe union fittings.

23 REPEAT this exercise by slowly increasing the pressure until the full workingpressure of 6.9barg is attained with no detected leaks.

24 PRESSURE TEST the atomising nozzles by observing the spray pattern toCONFIRM correct spraying. If any nozzles appear to be blocked or partially blocked,DISCONNECT the nozzle from the manifold and BACKFLUSH the nozzle tip throughthe orifice with a commercial electrical instrument cleaner, followed by high-pressure

air or water.






PROCEDURE – PREPARATION FOR ON-CRANK CLEANING

Step Action

1 ENSURE that the cleaning equipment has been prepared as detailed in ProcedureTesting Mobile/Stationary Tank Cleaning System.

2 CONFIRM that the turbine is shut down and has been allowed to cool to 65 °C in aminimum of 8 hours.

PRIOR TO ENGINE CLEANING, THE ENGINE MUST BE SHUT DOWNAND ALLOWED TO COOL (ENGINE CASE TEMPERATURE SHOULD

NOT EXCEED 65°C). A MINIMUM OF 8 HOURS IS REQUIRED TO ALLOWTHE ENGINE TO COOL SUFFICIENTLY PRIOR TO PERFORMING THE

CLEANING PROCEDURE. QUICKER COOLING MAY BE OBTAINEDBY CRANKING THE ENGINE.

3 REMOVE the bracket holding the eleventh stage bleed lines together under theengine.

4 LOOSEN the eleventh stage bleed line bolts at the diffuser case bosses andREMOVE the bolts from the compressor case bosses.

5 SLIDE the bleed lines away from the compressor case.

6 INSTALL blanking plates FT30222-1 between the bleed line flanges and compressorcase bosses.

7 RETIGHTEN the bolts on all bleed line bosses.

8 DISCONNECT the compressor discharge pressure line to the fuel control (if applicable).

9 DISCONNECT the torch drain line, REMOVE the torch drain plug from the torch body.

10 REMOVE the fuel line flex hose split flange clamps and bolts at gas fuel manifolds.

11 INSTALL blanking plate FT30222-2 on the gas manifold.

12 DISCONNECT the combustor, exhaust collector and air inlet duct drain lines at thecheck valve connections.

13 CONNECT a flexible drain hose and container to each of the drain lines.

14 SET the off/local/remote key switch to local.

15 REMOVE the air inlet assembly side panels.

16 PREPARE the engine for the test crank cycle by VERIFYING that all appropriatecircuit breakers are closed.

17 At either the turbine control junction box or the turbine control panel momentarilyPRESS Reset Switch. If there are no system malfunctions, the shutdown and alarmsummary lights will be extinguished, and there will be no annunciation messages on

the display screen.






Step Action

18 CLOSE all valves on the pressure injection tank.

19 CONNECT a supply hose to the deionised water source and tank water inlet valveconnection.


21 FILL the tank with the required amount of deionised water (45.44 to 60.56 litres).

Note: The cleaning liquid required for on-crank cleaning is between 56.8 and75.7 litres and is made up from 4 parts deionised water to 1 part cleaningconcentrate.

22 MONITOR conductivity of the water < 1.0 µΩ .

23 CLOSE the tank water inlet valve.


25 CONNECT the supply hose between the chemical source and the tank chemical inlet.

26 OPEN the tank chemical inlet valve and fill the tank with the required amount ofcleaning concentrate (11.36 to 15.14 litres).

Note: Chemical feed to the injection tank should be pumped through the chemicaltransfer hose. Positive pressure from source is required to overcomerestrictions in inlet fittings.

27 CLOSE the tank chemical inlet valve.


29 CONNECT the air hose between the compressed air source and the tank air inlet.

30 ENSURE that the regulator at the on-crank air inlet is set within the specified range6.2 to 6.9barg.

31 CONNECT a supply hose between the tank wash fluid outlet connection and theon-crank/water wash manifold inlet, located on the skid.


33 OPEN the tank air inlet valve and pressurise the tank to the normal working pressure(6.2 to 6.9barg). Leave the tank air inlet valve open for the duration of the on-crankcleaning to maintain a steady injection pressure and flow.






Step Action

CHECK THE ENGINE COMPRESSOR SECTION CASING TEMPERATURE;IT SHOULD NOT EXCEED 65°C. ENGINE FAILURE WILL RESULT IF

PREPARATION PROCEDURES ARE NOT COMPLETED.

1 VERIFY that the preparation procedures are completed before undertaking on-crankfluid cleaning.

2 CHECK the inlet plenum temperature on the UCP or DCS HMI.

FOR INLET PLENUM TEMPERATURES BELOW -4°F (-20°C),ENGINE CLEANING SHOULD NOT BE UNDERTAKEN.

3 REMOVE the screen around the inlet, clean the throat of the engine and the IGVsusing the solution wand selected at the valve V2P990-1 adjacent to the on-crankconnection at the air intake. Reinstall the screen.

4 To CRANK the engine, ACCESS the operation summary display screen and PRESSthe appropriate ‘Crank-on’ function key.

5 VERIFY that the pre-lube oil pressure reaches the preset value of 0.55barg.

6 VERIFY that the engine has increased to a maximum cranking speed ofapproximately 20 to 25% Ngp.

7 OPEN the tank fluid outlet valve and INITIATE engine cleaning from the control panel.

8 When the cleaning tank is empty, STOP cranking the engine by ACCESSING theoperation summary display screen and PRESSING the appropriate ‘Crank-off’function key. Leave the on-crank air inlet valve open for 2 to 3 minutes to allow airpurge from the line.

9 CLOSE the tank air inlet valve, keep the tank fluid outlet valve open and allow thetank pressure to drop to between 0.69 and 1.38barg.

10 CLOSE the tank fluid outlet valve.

11 Slowly OPEN the tank vent valve and VENT the tank to atmospheric pressure.






Step Action

Note: Based on the recommended volume of cleaning solution and rinse water,it should take approximately 5 to 15 minutes (dependent on volume and flow)to complete each on-crank cleaning cycle (chemical solution injection or rinsewater injection) at a steady injection pressure. If it takes longer, check the tankoutlet filter or injection nozzles for possible blockage. If it takes less time,check all connections for possible leaks.

12 ALLOW the cleaning product to soak for a period of 20 minutes.

13 CARRY OUT a water rinse 15 to 30 minutes after completion of on-crank chemicalcleaning, as follows:

14 RECONNECT the supply hose between the deionised water source and the tankwater inlet valve.

15 OPEN the tank water inlet valve and tank vent valve. FILL the tank with the requiredamount of deionised water (75.7 to 151.4 litres).

16 MONITOR conductivity of the water at the meter on the outlet of the deionisationpackage < 1.0 µΩ .

17 CLOSE the tank water inlet valve and tank vent valve. DISCONNECT the supply hose.

18 OPEN the tank air inlet valve and pressurise the tank to the normal working pressure.Leave the tank air inlet valve open for the duration of the on-crank rinsing to maintaina steady injection pressure and flow.

19 CRANK the engine, ACCESS the operation summary display screen and PRESS theappropriate crank-on function key.

20 VERIFY that the pre-lube oil pressure reaches the preset value.

21 VERIFY that the engine has increased to a maximum cranking speed ofapproximately 20 to 25% Ngp.

22 OPEN the tank fluid outlet valve and INITIATE on-crank engine cleaning from thecontrol panel.

23 CONTINUE until clean water runs from the drains or the cleaning tank is empty.

24 STOP cranking the engine by ACCESSING the operation summary display screenand PRESSING the appropriate crank-off function key. Leave the on-crank air inletvalve open for 2 to 3 minutes to allow air purge from the line.

25 DISCONNECT the air hose and hang the hose on the tank hose rack.

26 DISCONNECT the supply hose and hang the hose on the tank hose rack.

27 INSPECT the IGVs and first-stage compressor blades for evidence of contamination.

If the compressor is clean, PROCEED with the post-cleaning engine preparationprocedure below. If contamination is still present; REPEAT the cleaning andrinsing operation.

28 DISCONNECT the flexible drain hose and container from each of the drain lines.






Step Action

29 RECONNECT the air inlet duct, combustor and exhaust collector drain lines at thecheck valve connections.

30 REMOVE the blanking plate FT30222-2 from the gas fuel manifold.

31 CONNECT the gas line flex hose split flange clamps and bolts at the fuel manifolds.

32 INSTALL the torch drain plug into the torch body.

33 CONNECT the torch drain line.

34 CONNECT the compressor discharge pressure line to the fuel control.

35 LOOSEN the seventh stage bleed line bolts at diffuser fittings and remove the boltsfrom the compressor case bosses.

36 LOOSEN the eleventh stage bleed line bolts at the diffuser case boss and remove thebolts from the compressor case bosses. Slide the bleed lines away from thecompressor case

CATASTROPHIC ENGINE FAILURE WILL RESULT IF BLANKING PLATESFROM THE ELEVENTH STAGE BLEED BOSSES ARE NOT REMOVED

PRIOR TO ENGINE RESTART.

37 REMOVE the blanking plates FT30222-1 between the bleed line flanges andcompressor case bosses.

38 MOVE the bleed lines toward the compressor case.

39 INSTALL bolts on the compressor bleed line bosses.

40 TIGHTEN all the bleed line boss bolts at the diffuser case boss.

41 INSTALL the bracket that ties the eleventh stage bleed lines together under the engine.

42 INSPECT the torch igniter plug for signs of contamination from the cleaning solution.Clean as required and reinstall.






Step Action

On-crank Post-cleaning

43 INSTALL the air inlet assembly side panels.

44 CHECK the engine and ENSURE that it is ready to start.

BEFORE STARTING THE ENGINE, ENSURE POSITIVEDRAINING OR VENTING OF THE FOLLOWING AREAS:

• WHERE THE EXHAUST SYSTEM HAS A LONG

HORIZONTAL RUN• WHERE AN EXHAUST HEAT RECOVERY SYSTEM IS

INSTALLED

• WHERE THERE IS ANY SITUATION IN WHICH KEROSENELIQUIDS OR VAPOURS CAN BE TRAPPED

45 START the engine.

46 Allow the engine temperature to STABILISE for 1 hour at full load (or maximumallowable running condition).

47 EVALUATE engine performance and CHECK that the contamination factor hasdecreased below a value of five (refer to Solar Mars 100 Maintenance Guide).

48 If performance has not improved between successive cleaning operations, INSPECTthe engine compressor section using a boroscope.

Note: If excessive contamination is confirmed by the boroscope procedures, manualcleaning of the compressor rotor and stator blades may be required.






SYSTEM/EQUIPMENT: FIELD GAS TURBINE ENGINE

PROCEDURE NO 2/002: TURBINE COMPRESSOR CLEANING ONLINE


FOLLOWING ACTIONS.

THE SOLAR O&M MANUAL VOLUME II SECTION 8 TAKESPRECEDENCE OVER THIS PROCEDURE AND SHOULD BE

FOLLOWED WHEN PERFORMING THIS TASK.

WARNING

INTRODUCTION

The engine compressor can be cleaned while the engine is cranking (on-crank mode) orwhile the engine is operating in the simple cycle mode (online mode). Compressor fouling isa combination of water-soluble and non-water-soluble foulants. The unknowns are thedegree of each and the rate at which these foulants accumulate in the engine compressor.The engine is firing during online cleaning and, therefore, the cleaning liquid ingested mustmeet the more stringent requirements to minimise introduction of contaminants.

The package is equipped with a skid-edge connection routed through two solenoid valveswithin the package – one for online cleaning and one for on-crank cleaning, refer to the GasTurbine Compressor Cleaning Facilities Schematic in Part 2 Section 2. Each connection ispiped to the respective cleaning manifold with the following components:

• Inlet strainer

• Shut-off solenoid

• Triple-cartridge filter

• Three-way hand valve (on-crank only)

Online engine compressor cleaning is performed when the engine is running on load and canbe done as often as needed, usually between on-crank cleaning operations. However,engine cleaning is not recommended if the inlet temperature is below -4°F (-20°C).






Online Cleaning Methods and Specifications

CleaningMethod

Cleaning Solution

(Volume in litres)(Note 2)

DistilledWater toSolution

Ratio

Flow(ltr/m)

AirPressure

(barg)(Note 1)

Air Flow(scfm)

Solution 15 4:1 8.3 to 10.6 6.2 to 6.9 4.6

Mix 75 N/A 8.3 to 10.6 6.2 to 6.9 4.6

Notes:

(1) The optimum pressure at the injectors is between 90 and 100psig (620kPa to690kPa), measured at the skid-edge connection. Optimum pressure may require

pressuring the tank higher than specified, but limited to the relief valve setting forthe tank.

(2) This is the recommended dosage. The compressor should be rinsed until a cleanwaste stream is noted in the engine drains.

Cleaning Solution and Rinse Water Flow Requirements

CleaningMethod

Cleaning ProductVolume

Rinse WaterVolume

Flow Rate forOnline

Cleaning/Rinsing

Online 56.8 to 75.7 litres 75.7 to 151.4 litres 8.3 to 10.6 litres/min

Requirements for Water Used in Ingestive Cleaning of Solar Gas Turbines

Test Method Max LimitOnline Cleaning

Sodium and Potassium ASTM D1428 1.9ppmw

Fluorine – 1.9ppmw

Chlorine ASTM D512 40ppmw

Lead ASTM D3559 0.7ppmw

Vanadium ASTM D3373 0.35ppmw

Iron, Tin, Silicon, Aluminium,Copper, Manganese, Phosphorus

ASTM D857, D858,D1068, D1688

3.8ppmw

Calcium and Magnesium ASTM D3605, D511 3.8ppmw

Total Dissolved Solids ASTM D1888 5ppmw

pH ASTM D1293 6 to 9






Online turbine cleaning differs from on-crank cleaning in that the turbine is in service duringthe cleaning process. Gas turbine online cleaning requires the use of extremely pure DIwater. If the water is not deionised, dissolved materials and salts will precipitate out as thewater flashes to steam at some point in the turbine gas path. The solids will quickly build up

on the rotating and stationary components, which can cause foreign-object damage andprovide an environment for accelerated hot corrosion. Water deionisation is the removal ofionised minerals and salts from solution by a two-phase ion exchange procedure. Only DIwater should be used for online cleaning.

To obtain the required DI water quality, potable water is sent to the locally installed DI watertreatment system (bottle rack). The system includes an array of water treatment bottles thatare life limited and need to be replaced after a certain amount of use. The consumption ratedepends on the quality of the water going into the system. The size of the DI water systemalso dictates the nominal rating on the quantity of water that can be treated beforereplacement of the bottles is required. The online rinse tank used for the turbine washsystem is filled daily with the treated water at the same time as the turbine operator manually

initiates the rinse procedure.Operators of online rinse systems should periodically check the purity of the produced DIwater with a suitable conductivity meter – DI water has very low electrical conductivity sincethere is very little dissolved ions resent to conduct an electrical current. It is recommendedthat water quality be checked once a week. The Myron L Company ( www.myronl.com )manufactures several hand-held instruments that are used to spot-check the water quality.The water quality is measured in units of either conductivity (micro-ohms ( µΩ ), same asmicro-Siemens ( µS)) or TDS (Total Dissolved Solids, Parts Per Million (ppm)). On a properlyfunctioning DI water system, the treated water can be so pure that it does not register onsome model Myron L conductivity meters typically being used. The standard Myron L EPmeter only starts to read at 0.5 µΩ . The water from a DI system with new bottle should be

below the 0.5 µΩ reading.Do not use the water if the conductivity meter reading is above 1.0 µΩ . When the readingstarts to register on the Myron L meter at 0.5 µΩ , some trending should begin to estimate theremaining life of the DI treatment system and schedule a replacement.

Below are some conversions for the different types of water quality measurement units.

Conductivitymicro-ohms ( )

Resistivityohms-cm

TDSppm

2 5,000,000 1.0

1 1,000,000 0.500

0.5 2,000,000 0.250

0.25 4,000,000 0.125








PROCEDURE – TESTING MOBILE/STATIONARY TANK CLEANING SYSTEM

Step Action

Before the mobile tank cleaning system can be used it must be flushed to ensure all debrisis removed.

Flush and pressure test the pressure injection tank as follows:

1 CHECK the quality of the water produced by the deionised water unit to ensure that itmeets the Solar specification prior to performing compressor cleaning (< 1.0 µΩ ).

2 For the mobile tank cleaning system, CONNECT a supply hose between thedeionised water source and the tank water inlet.


4 FILL the injection tank with water until it begins to flow out of the tank vent valve.

5 CLOSE the tank water inlet valve and disconnect the supply hose.


7 CONNECT an air hose between the air source and the air inlet.

8 OPEN the air inlet valve to pressurise the tank to a normal working air pressure of6.9barg then CLOSE the air inlet valve.

9 Leave the tank under PRESSURE for 10 minutes. There should be no pressure dropor leakage at any fittings.

10 Slowly OPEN the drain valve and allow the water to run safely to a drain until tankpressure is zero.

11 CLOSE the drain valve. Remove, clean and replace the filter inserts from the air,water and chemical inlet Y strainers.

12 CHECK the quantity and quality of the water which has passed through thedeionised water unit to ensure that there is sufficient life remaining in the treatmentmaterials (the unit can process 13.25m 3 of deionised water before replacement isrequired). Trending of deionised water quality to commence at a conductivity readingof 0.5 µΩ . Do not use the deionised water with a conductivity reading of greater thanor equal to 1.0 µΩ . Replace the DI unit before the DI water conductivity deterioratesto 1.0 µΩ .

13 CONNECT the supply hose between the deionised water source and the tankwater inlet.

14 OPEN the tank water inlet and vent valves.

15 FILL the tank approximately half full with DI water.

16 MONITOR conductivity of the water at the meter on the outlet of the deionisationpackage (< 1.0 µΩ ).

17 CLOSE the water inlet tank vent valve.


19 CONNECT an air hose between the air supply and the air inlet.

20 OPEN the air inlet valve to pressurise the tank to 2.07barg.






Step Action

21 CONNECT the supply hose between the tank outlet and the online washmanifold inlet.

22 Slowly OPEN the tank wash fluid outlet valve. Any major connector leaks will beimmediately visible. If leaks are detected, CLOSE the tank outlet valve and TIGHTENthe union fittings.

23 REPEAT this exercise by slowly increasing the pressure until the full workingpressure of 6.9barg is attained with no detected leaks.

24 PRESSURE TEST the atomising nozzles by observing the spray pattern toCONFIRM correct spraying.

Note: If any nozzles appear to be blocked or partially blocked, the turbine should beshut down, to allow the operator to DISCONNECT the nozzle from themanifold, and the nozzle tip BACKFLUSHED through the orifice with acommercial electrical instrument cleaner, followed by high-pressure airor water.






PROCEDURE – PREPARATION FOR ONLINE CLEANING

Step Action

1 ENSURE that the cleaning equipment has been prepared as detailed in theProcedure – Testing Mobile/Stationary Tank Cleaning System.

2 CLOSE all valves on the pressure injection tank.

3 CONNECT a supply hose to the deionised water source and tank water inlet valveconnection.


5 FILL the tank with the required amount of deionised water (45.44 to 60.56 litres).

Note: The cleaning liquid required for online cleaning is between 56.8 and 75.7 litresand is made up of 4 parts deionised water to 1 part cleaning concentrate.

6 MONITOR conductivity of the water at the meter on the outlet of the deionisationpackage.

7 CLOSE the tank water inlet valve.


9 RECONNECT the supply hose between the chemical source and the tankchemical inlet.

10 OPEN the tank chemical inlet valve and fill the tank with the required amount ofcleaning concentrate (11.36 to 15.14 litres depending on water quantity).

Note: Chemical feed to the injection tank should be pumped through the chemicaltransfer hose. Positive pressure from source is required to overcomerestrictions in inlet fittings.

11 CLOSE the tank chemical inlet valve.


13 VERIFY that the engine in the compressor train is operating normally with steady loadand speed.

14 CONNECT the air hose between the compressed air source and the tank air inlet.

15 ENSURE that the regulator at the air inlet is set within the specified range.

16 CONNECT a supply hose between the tank wash fluid outlet connection and theonline water wash manifold inlet, located on the skid.


18 OPEN the tank air inlet valve and pressurise the tank to the normal working pressure.Leave the tank air inlet valve open for the duration of the online cleaning to maintain asteady injection pressure and flow.

19 VERIFY that the preparation procedures are completed before undertaking onlinecleaning.






PROCEDURE – ONLINE CLEANING

Step Action

1 Check the inlet plenum temperature on the UCP or DCS HMI.

PRIOR TO ENGINE CLEANING, THE INLET PLENUM TEMPERATUREMUST BE ABOVE 4 ° C (39 ° F). INTERNAL DAMAGE MAY RESULT IF

THIS PRECAUTION IS NOT OBSERVED.

2 OPEN the tank fluid outlet valve and INITIATE engine cleaning from the control panel.3 When the tank is empty, CLOSE the tank air inlet valve, keep the tank fluid outlet

valve open and allow the tank pressure to drop to between 0.69 and 1.38barg.



Note: Based on the recommended volume of cleaning solution and rinse water,it should take approximately 10 to 20 minutes to complete each onlinecleaning cycle (chemical solution injection or rinse water injection) at a steadyinjection pressure. If it takes longer, check the tank outlet filter or injectionnozzles for possible blockage. If it takes less time, check all connections for

possible leaks.6 RECONNECT the supply hose between the deionised water source and the tank

water inlet valve.

7 OPEN the tank water inlet valve and tank vent valve. Fill the tank with the requiredamount of deionised water (75.7 to 151.4 litres) for the rinse.

8 MONITOR conductivity of the water at the meter on the outlet of the deionisationpackage.

9 CLOSE the tank water inlet valve and tank vent valve. Disconnect the supply hose.

10 OPEN the tank air inlet valve and pressurise the tank to the normal working pressure.

Leave the tank air inlet valve open for the duration of the online rinsing to maintain asteady injection pressure and flow.

11 OPEN the tank fluid outlet valve and INITIATE engine cleaning from the control panel.

12 When the tank is empty, CLOSE the tank air inlet valve, keep the tank fluid outletvalve open and allow the tank pressure to drop to between 0.69 and 1.38barg.










Step Action

15 DISCONNECT the air hose and hang the coiled hose on the tank hose rack.

16 DISCONNECT the supply hose and hang the coiled hose on the tank hose rack.

17 EVALUATE engine performance and CHECK that the contamination factor hasdecreased below a value of five (refer to MARS 100 Maintenance Guide).

The online wash is now complete. If performance has not improved between successivecleaning operations, an on-crank wash will have to be carried out.




Part 2 Section 3 Supplementary Operating Procedures



Section 3Supplementary Operating Procedures

ProcedureNumber

WATERFLOOD INJECTION PUMP SUPPLEMENTARY OPERATING PROCEDURES

PROCEDURE NO 3/001: CHANGEOUT OF A LUBE OIL FILTER ELEMENT

PROCEDURE NO 3/002: CHANGEOUT OF WATERFLOOD CHARGE PUMP ANDWATER INJECTION PUMP SUCTION STRAINERS

PROCEDURE NO 3/003: TURBINE ENCLOSURE ENTRY

PROCEDURE NO 3/004: CALCIUM NITRATE (CaNO 3) LOADING OPERATION

PROCEDURE NO 3/005: CALCIUM NITRATE TRANSFER FACILITIES

PROCEDURE NO 3/006: CALCIUM NITRATE INJECTION START-UP AND OPERATION







PROCEDURE NO 3/001: CHANGEOUT OF A LUBE OIL FILTER ELEMENT


FOLLOWING ACTIONS.

INTRODUCTION

When the differential pressure across the in service Lube Oil Filter, FS-901-1 or 2, in awaterflood injection pump lube oil system reaches 1.1bar, the filter should be switched to thesecond chamber to allow changeout of the contaminated filter element. In this operationthere is a risk of exposure to hot lube oil in addition to contaminants present in the circulatinglube oil.

The following generic procedure describes the actions which should be performed to changeout the contaminated filter element.

THE SOLAR O&M MANUAL VOLUME II SECTION 8 TAKES PRECEDENCEOVER THIS PROCEDURE AND SHOULD BE FOLLOWED WHEN

PERFORMING THIS TASK.

PRECONDITIONS

Supporting Documentation

This procedure utilises the following documents:• Solar P&ID 70331-E149293• P&ID P0001-M015-SOLR-019-001-01 Rev 5• Nelson Fleetguard Filters Service Instructions• OCOP 2/001 Preparation of Equipment for Work Activity (OPRM-2004-0018)

Interface Systems

Before the operation can be started, the following system is required to be operational:• Drain System. Refer to POPM Volume 16 (OPRM-2003-0316)

WARNING






Pre-requisites• No Permits to Work are in force that may prohibit access to the lube oil filter• A Permit to Work has been issued for the work to be performed and to allow entry to the

turbine enclosure (refer to Procedure No 3/003)• A suitably rated drain hose and fittings to connect to the filter drain• A suitable container to receive the contaminated filter• Communications are established between all personnel involved in this procedure

PLANT STATUS• The Lube Oil System that is operating with the respective waterflood injection pump is

online• The online lube oil filter is showing a high differential pressure and requires changing






PROCEDURE

Step Action

THE WATERFLOOD INJECTION PUMP TURBINES AND ASSOCIATEDLINES ARE VERY HOT AND NOISE/VIBRATION LEVELS IN THE VICINITY

OF THE UNITS ARE HIGH. TO AVOID PERSONAL INJURY WHENOPERATING THE EQUIPMENT, PPE, INCLUDING GLOVES AND EAR

DEFENDERS, MUST BE WORN.

Changeover to the Standby Filter

1 PRESSURISE the clean chamber of the duplex filter by carefully moving thechangeover lever, VT-901, to the mid position.

2 OPEN the vent valve on top of the clean chamber to vent any air from the chamber.CLOSE the vent valve when oil appears at the vent.

THE CIRCULATING LUBE OIL AT THE VENT WILL BE HOT ANDCONTAMINATED. TO AVOID INJURY, THE CORRECT PPE MUST BE

WORN WHEN VENTING THE FILTER CHAMBER.

3 MOVE the changeover lever fully to the position to select the clean filter and isolatethe dirty filter.

4 CHECK for leaks as the chamber is put in service.

The standby filter is now on line and the contaminated filter is isolated.

Draining the Filter Chamber

5 OPEN the drain valve on the dirty filter chamber to drain the contents of thechamber to the lube oil tank. OPEN the vent valve for the chamber to aid drainage.

THE LUBE OIL DRAINED FROM THE FILTER CHAMBER WILL BE HOT ANDCONTAMINATED. TO AVOID INJURY, THE CORRECT PPE MUST BE

WORN WHEN DRAINING THE FILTER CHAMBER.






Step Action

6 MONITOR the flow of oil from the drain in the flow sight glass, FG-902, on thecommon filter drain line.Note: If flow does not stop, the isolation valves are passing. The waterflood

injection pump should be shut down to make a repair to the duplex filter.

Changing the Contaminated Filter Element

Note: ALLOW the dirty filter chamber to cool before proceeding.

7 POSITION a suitable container to receive the contaminated filter element close tothe filter assembly to avoid spillage of lube oil.

THE FILTER ELEMENT WILL BE SATURATED WITH CONTAMINATEDLUBE OIL. TO AVOID INJURY, THE CORRECT PPE, INCLUDING

RUBBERISED GLOVES, MUST BE WORN TO AVOID CONTACT WITHTHE SKIN WHEN REMOVING THE CONTAMINATED ELEMENT FROM

THE FILTER CHAMBER.

8 REMOVE the lid from the filter chamber by loosening the cap screws and lift offthe lid. Lay down the lid face-side up, taking care not to damage the sealing surface.

9 REMOVE the hold-down spring and filter element plug from the top end of the filter.10 LIFT the element from the chamber and immediately place the element in the

container.

TAKE CARE NOT TO DROP DEBRIS FROM THE FILTER ELEMENT INTOTHE CLEAN CHAMBER THROUGH THE ELEMENT SUPPORT TUBE.

11 ENSURE that the old seal is still attached to the element. If it is not, retrieve the sealfrom the sealing face in the chamber.

12 WIPE CLEAN the internal surface of the filter chamber/housing.

13 INSTALL and SECURE the new filter element with a new seal.

14 INSTALL the filter element plug and hold-down spring in the top end of the filter.






Step Action

15 CLEAN and INSPECT the cover O-ring seal for damage such as nicks, cracks andpermanent deformation. If the O-ring is in good condition it may be reused. If there isany doubt, replace the O-ring.

16 ENSURE that the cover O-ring seal is properly seated in the flange groove.

17 WIPE CLEAN the sealing surface of the cover.

18 ENSURE the spring is in place on top of the element then REPLACE the filterchamber lid using the cap screws washers and nuts. Tighten to the correct torquesetting.

19 CLOSE the drain valve on the dirty filter chamber.

20 ENSURE that the vent valve for the chamber is OPEN to vent air from the chamber.

21 FILL the chamber of the duplex filter by carefully moving the changeover lever to themid position, taking care not to cause a pressure loss in the oil supply.

22 RETURN the changeover lever fully to the online filter position.

23 SIGN-OFF the Permit to Work and tidy up the worksite.







PROCEDURE NO 3/002: CHANGEOUT OF WATERFLOOD CHARGE PUMP ANDWATER INJECTION PUMP SUCTION STRAINERS


FOLLOWING ACTIONS.

INTRODUCTION

This procedure describes the activities required to change the strainer in the suction of awater injection charge pump and a water injection pump.

A water injection charge pump and a water injection pump are each rated at 50% of the totalwaterflood flow requirements, it therefore follows that to shut down one pump in the pairideally requires shutting down the other pump along with it.

In this procedure it is assumed that the strainer to be changed is in the suction of WaterInjection Charge Pump A-4045A and in Water Injection Pump P-4046A. Water InjectionCharge Pump A-4045B and Water Injection Pump P-4046B remain in operation.

PRECONDITIONS

Supporting Drawings

The Shutdown Procedure makes use of the following P&IDs:• BON-AME-3-SP-B-21640-023- C05C06 Injection Water Tank and Charge Pumps• BON-AME-3-SP-B-21640-024- C05C06 Waterflood Injection Pump• BON-AME-3-SP-B-21640-025- C05C06 Waterflood Injection Pump• BON-AME-3-SP-B-21640-026- C05C06 Waterflood Injection Launcher/Receivers• OCOP 2/001 Preparation of Equipment for Work Activity (OPRM-2004-0018)

Interface Systems• Drainage Systems. Refer to POPM Volume 16 (OPRM-2003-0316)• Instrument and Utility Air System. Refer to POPM Volume 25 (OPRM-2003-0325)• Power Generation and Distribution. Refer to POPM Volume 30 (OPRM-2003-0330)

Pre-requisites• No work permits are in force which will prohibit the shutdown of Water Injection Charge

Pump A-4045A and in Water Injection Pump P-4046A• Toolbox talks have been held with all directly and indirectly concerned parties outlining







PROCEDURE

Step Action

1 Carry out a ‘Normal Stop’ of Water Injection Pump P-4046A, as described in Part 2Section 1 Procedure No 1/004 Planned Shutdown Steps 1 to 3.

2 SHUT DOWN whichever water injection wells are required, in accordance with thereduced water injection flowrate. Refer to POPM Volume 2B Subsea WaterfloodSystem (OPRM-2003-0302B) for details.

3 As appropriate, CLOSE 40-SDV-643 and 40-MOV-641 on Water Injection FlowlineRiser 01 and/or, as appropriate, CLOSE 40-SDV-653 and 40-MOV-651 on WaterInjection Flowline Riser 03.

4 ENSURE that water is being dumped overboard downstream of the Injection ChargePumps P-4045A/B via 40-FCV-598.

5 SHUT DOWN Injection Charge Pump P-4045A from the CCR.

6 If both waterflood source pumps are operating, SHUT DOWN Waterflood SourcePump P-4040A or B from the CCR, as required, in order to reduce the amount ofoverboard discharge from 40-FCV-598.

7 REDUCE the production of sodium hypochlorite proportionately by cutting back thesea-cell current in Hypochlorite Generator A-4051.

8 ENSURE that Oxygenator Skids A-4041A and B are operating satisfactorily.

9 ENSURE that Seawater Strainers S-4040A/B, Waterflood Multimedia FiltersS-4041A to F and Waterflood Cartridge Filters S-4042A to C are operating

satisfactorily.Isolation of Injection Charge Pump P-4045A

10 PERFORM an electrical isolation of P-4045A drive motor and complete an ElectricalIsolation Certificate.

11 REMOVE the carriage seal and CLOSE, LOCK and TAG P-4045A suction isolationvalve 40-BUV-230 (40-BUV-232). RECORD that the valve has been locked andtagged closed in the Change Register.

12 CLOSE, LOCK and TAG P-4045A discharge isolation valve 40-BUV-231(40-BUV-233). RECORD that the valve has been locked and tagged closed in theChange Register.

13 DEPRESSURISE and DRAIN the suction and discharge pipework, and the pumpcasing of P-4045A by CAREFULLY removing the plug. SLOWLY OPEN CasingDrain Valve 40-BLV-273 (40-BLV-274) and allow the water to drain to the localsurface drains.

14 PROVE the integrity of the isolations by observing the cessation of the draineddown water.

15 DRAIN the suction strainer by CAREFULLY removing the blind flange. SLOWLYOPEN the suction strainer Drain Valve 40-BLV-219 (40-BLV-220) and allow thewater to drain to the local surface drains. RECORD that the blind has been removedin the Change Register.






Step Action

16 When isolation and site preparation are complete, ENSURE that the PTW iscomplete and a Mechanical Isolation Certificate has been raised.

Isolation of Water Injection Pump P-4046A

17 PERFORM electrical isolation of P-4046A turbine package auxiliaries and completean Electrical Isolation Certificate.

18 ENSURE that P-4046A discharge valve 40-SDV-613 (40-SDV-633) is CLOSED.

19 REMOVE and TAG the actuation line for discharge valve 40-SDV-613(40-SDV-633). RECORD that the line is disconnected and tagged in the ChangeRegister.

20 CLOSE, LOCK and TAG P-4046A manual discharge isolation valve 40-BUV-227

(40-BUV-232). RECORD that the valve has been locked and tagged closed in theChange Register.

21 Carefully REMOVE the blind flange from Drain Valve 40-BLV-228 (40-BLV-233)between 40-SDV-613 (40-SDV-633) and 40-BLV-227 (40-BLV-232), and check forpressure to prove the integrity of the isolation. RECORD that the blind has beenremoved in the Change Register.

22 CLOSE, LOCK and TAG P-4046A suction isolation valve 40-BUV-234(40-BUV-235). RECORD that the valve has been locked and tagged closed in theChange Register.

23 DEPRESSURISE and DRAIN the suction and discharge pipework, and the pumpcasing of P-4046A by SLOWLY OPEN Casing Drain Valve ( HOLD ) and allow thewater to drain to the local tundish. The tundish directs the water to Collection SumpS-4701C.

24 PROVE the integrity of the isolations by observing the cessation of the drained downwater at the tundish.

25 DRAIN the suction strainer by CAREFULLY removing the blind flange. SLOWLYOPEN the suction strainer Drain Valve 40-BLV-224 (40-BLV-229) and allow thewater to drain to the local surface drains. RECORD that the blind has been removedin the Change Register.

26 When isolation and site preparation is complete, ENSURE that a MechanicalIsolation Certificate has been raised and the PTW is complete.

Changeout the Injection Charge Pump P-4045A Suction Strainer

Refer ence to Maintenance Procedure ( HOLD ).

27 ACCESS the suction strainer body as described in the associated MaintenanceProcedure.

28 REMOVE the old strainer and FIT the new suction strainer as described in theassociated Maintenance Procedure.

29 CHECK the condition of the suction strainer seal and sealing faces. DRESSthe sealing faces. REPLACE the seal(s) if necessary.

30 CLOSE the suction strainer body.






Step Action

Changeout the Waterflood Injection Pump P-4046A Suction Strainer

Refer ence to Maintenance Procedure ( HOLD ).

31 CAREFULLY REMOVE the suction strainer top, as described in the associatedMaintenance Procedure.

32 REMOVE the old strainer and FIT the new suction strainer as described in theassociated Maintenance Procedure.

33 CHECK the condition of the suction strainer seal and sealing faces. DRESSthe sealing faces. REPLACE the seal(s) if necessary.

34 REFIT the suction strainer top.

Reinstatement of Injection Charge Pump P-4045A

35 CLOSE Suction Strainer Drain Valve 40-BLV-219 (40-BLV-220). REFIT the blindflange with a new gasket. RECORD that the blind has been refitted in the ChangeRegister.

36 CLOSE Casing Drain Valve 40-BLV-273 (40-BLV-274) and REFIT the plug.

37 REMOVE the lock and OPEN P-4045A suction isolation valve 40-BUV-230(40-BUV-232). RECORD that the valve is carriage sealed open in the ChangeRegister.

38 REMOVE the lock and OPEN P-4045A discharge isolation valve 40-BUV-231(40-BUV-233). RECORD that the valve is carriage sealed open in the ChangeRegister.

39 At the end of the operation, ENSURE that the Mechanical and Electrical IsolationCertificates are signed off, and also that the PTW is signed off. ENSURE the workarea is tidy.

Reinstatement of Waterflood Injection Pump P-4046A

40 CLOSE suction strainer Drain Valve 40-BLV-224 (40-BLV-229). REFIT the blindflange with a new gasket. RECORD that the blind has been refitted in the ChangeRegister.

41 CLOSE the Pump Casing Drain Valve ( HOLD ).

42 CLOSE the Drain Valve 40-BLV-228 (40-BLV-233) between 40-SDV-613

(40-SDV-633) and 40-BLV-227 (40-BLV-232), and REFIT the blind flange with anew gasket. RECORD that the blind has been refitted in the Change Register.

43 REMOVE the lock and OPEN P-4046A suction isolation valve 40-BUV-234(40-BUV-235).

44 REMOVE the lock and OPEN P-4046A manual discharge isolation valve40-BUV-227 (40-BUV-232).

45 REMOVE the tag and REFIT the actuation line for discharge valve 40-SDV-613(40-SDV-633). RECORD that the actuation line is reconnected in the ChangeRegister.






Step Action

46 ENSURE that P-4046A discharge valve 40-SDV-613 (40-SDV-633) is ready foroperation (AUTO).

47 At the end of the operation, ENSURE that the Mechanical and Electrical IsolationCertificates are signed off, and also that the PTW is signed off. ENSURE the workarea is tidy.

The reinstatement of Injection Charge Pump P-4045A and Waterflood Injection PumpP-4046A is complete. The pumps can be started up as normal, as described in theCold Start-up (refer to Part 2 Section 1 Procedure No 1/001).







PROCEDURE NO 3/003: TURBINE ENCLOSURE ENTRY


FOLLOWING ACTIONS.

INTRODUCTION

This procedure describes the checks and activities to be performed in order to open thedoors on a waterflood injection pump turbine enclosure.

Entry to the enclosure may be required as follows:• By the operator prior to start-up and while the machine is running• By maintenance personnel under the PTW System to perform maintenance while the

machine is shut down• By Fire Team Leader/operator following fire in the enclosure

PRECONDITIONS

Supporting Documentation• Solar fire logic

Interface Systems• None

Pre-requisites• No Permits to Work are in force that may prohibit opening of the doors on the waterflood

injection pump turbine enclosure• Communications are established between all personnel involved in this procedure

PLANT STATUS• There is a requirement for personnel to enter the turbine enclosure for the waterflood

injection pump as identified in the introduction






PROCEDURE

Step Action

THE WATERFLOOD INJECTION PUMP TURBINES AND ASSOCIATEDLINES ARE VERY HOT AND NOISE/VIBRATION LEVELS IN THE VICINITY

OF THE UNITS ARE HIGH. TO AVOID PERSONAL INJURY WHENOPERATING THE EQUIPMENT, PPE, INCLUDING GLOVES AND EAR

DEFENDERS, MUST BE WORN.

Routine Entry by the Operator

1 INFORM the CCR that a door on the waterflood injection pump turbine enclosure isabout to be opened to allow entry and COLLECT a key for the enclosure doors.

2 CHECK with the CCR to ensure that there are no alarms relating to fire or gasdetection in the enclosure.

3 INHIBIT the watermist system by rotating on the auto/inhibit switch on the side of theenclosure to ‘Inhibit’.

4 STOP the enclosure fans to reduce the differential pressure across the enclosuredoor.

5 SWITCH on the lights at the switch on the side of the enclosure.

6 CHECK the differential pressure between the enclosure and ambient.7 If the differential pressure is zero, UNLOCK and OPEN the enclosure door.

DO NOT OPEN THE ENCLOSURE DOORS IF THERE IS A DIFFERENTIALPRESSURE BETWEEN ENCLOSURE AND AMBIENT. PERSONAL INJURY

MAY RESULT AS THE DOOR BLOWS OPEN WHEN THE CATCHIS RELEASED.

8 RESTART the enclosure fans to ventilate the enclosure.

9 Entry to the enclosure is now permitted.

Entry to Perform Maintenance

10 The maintenance technician is required to OBTAIN a PTW permitting entry into theenclosure to perform maintenance, and confirms checks have been performed toensure it is safe to enter and the task can be performed.

The operator will prepare the worksite as described in Steps 1 to 9 above. However,the enclosure fans may remain off.






Step Action

Entry Following an Enclosure Fire

Note: Initial entry to the waterflood injection pump turbine enclosure following a firein said enclosure, will be by the Fire Team Leader accompanied by theoperator.

1 INFORM the CCR that a door on the waterflood injection pump turbine enclosure isabout to be opened to allow entry, and COLLECT the keys for the enclosure doors.

2 CHECK with the CCR to confirm that the fire is extinguished.

3 ISOLATE all electrical supplies to equipment in the enclosure.

4 ISOLATE the fuel gas supply to the gas turbine by closing the manual isolation valveon the fuel gas supply line to the enclosure (44-BLV-366 for P-4046A, 44-BLV-370

for P-4046B respectively).5 INHIBIT the watermist system by rotating on the auto/inhibit switch on the side of the

enclosure to inhibit.

Note: The watermist system will most likely be depleted.

On receipt of a fire stop signal the application carries out the following timed actions:• Solar rolldown timer set at 3 minutes. The timer times out in 3 minutes and the

lube oil flow is stopped where possible, ie with the exception of the mechanicaldrives (eg waterflood pumps and field gas compressors) whose lube oil pumpsare mechanically driven

• 0 to 19.5 minutes:− If the fire panel only is acknowledged, the post-lube starts in 20 minutes− If the fire and the local solar panels are acknowledged, post-lube starts

immediately• 19.5 to 20 minutes – The time allocated by solar to build up lube oil pressure in

the system• Greater than 20 minutes – If the fire and/or the solar panel are not

acknowledged, the unit is automatically locked out by solar for 12 hours. Unitlockout means the turbine cannot be restarted for 12 hours

• Greater than 20 minutes – During unit automatic lockout, regardless of whataction is taken, the post-lube starts (SNEPCO requires lube oil flow as per solarstandard post-lube requirements)






Step Action

THE OPERATOR SHOULD BE AWARE THAT THERE IS A POTENTIAL FORHOT LUBE OIL SPLASH AND RE-IGNITION WITH RESPECT TO THE

ABOVE DETAILED TIMED LOGIC ACTIONS.

THE OPERATOR SHOULD CONSIDER TRIPPING THE POST-LUBE PUMPBREAKER IF HE CONSIDERS IT UNSAFE TO CONTINUE POST-LUBE

WHILE THE FIRE IS PRESENT.

DO NOT OPEN THE ENCLOSURE DOORS IF THE FIRE IS NOT OUT ORTHE DOORS ARE HOT.

6 POSITION suitable firefighting equipment by the door in case opening the doorresults in re-ignition.

7 Feel the panels of the enclosure to CHECK for hot spots as a possible sign of fire.

8 CHECK the differential pressure between the enclosure and ambient.

9 If the differential pressure is zero, UNLOCK then OPEN the enclosure doors.

10 WAIT for 15 minutes before entering the enclosure to allow the enclosure to ventilate.

11 RESET fire dampers and vent openings.

12 REPLENISH the nitrogen and water for the water mist system (refer to POPMVolume 27 Fire Protection Systems and Equipment (OPRM-2003-0327) Part 2Section 2 Procedure No 2/004).

Leaving the Enclosure

13 ENSURE that all materials used in maintenance have been removed from theenclosure and any spillage cleaned up.

14 CHECK the security of any item that has been included in the maintenance activity.

15 STOP the enclosure vent fan (if running).

16 TURN OFF the enclosure lights.

17 CLOSE and LOCK the enclosure door(s).

18 ENSURE that the fire dampers and vent openings are OPEN.

19 RESTART the enclosure vent fan.

20 REACTIVATE the watermist system by rotating on the auto/inhibit switch on the sideof the enclosure to ‘Auto’.

3121 RETURN the key(s) to the CCR and sign off the work permit (if access was underwork permit).







PROCEDURE NO 3/004: CALCIUM NITRATE (CaNO 3) LOADING OPERATION


FOLLOWING ACTIONS.

INTRODUCTION

The procedure details the actions required to load Calcium Nitrate (CaNO 3) to bulk StorageTank T-4202.

PRECONDITIONS

Supporting Drawings

The CaNO 3 loading procedure utilises the following P&IDs:• BON-SHI-008-P-000002-016 Storage Compartment 8• BON-SHI-008-P-000002-017 Storage Compartment 8 Tank Utilities• BON-SHI-008-P-000002-080 Fixed Tank Cleaning Machines for Methanol and Deluge

Tanks, Foam Deluge Nozzles for Methanol and Chemical Tanks inside Cofferdam

Pre-requisites

Interface Systems

Before CaNO 3 loading can be started, the following systems are required to be available:• Drainage System. Refer to Volume 16 (OPRM-2003-0316)• Nitrogen System. Refer to Volume 20 (OPRM-2003-0320)• Instrument Air and Utility System. Refer to Volume 25 (OPRM-2003-0325)• Deck Hydraulic System. Refer to Volume 26 (OPRM-2003-0326)• Fire Protection Systems and Equipment. Refer to Volume 27 (OPRM-2003-0327)• Power Generation and Distribution. Refer to Volume 30 (OPRM-2003-0330)• HVAC Systems. Refer to Volume 32 (OPRM-2003-0332)• Deck Machinery and Mechanical Handling. Refer to Volume 33 (OPRM-2003-0333)






Pre-requisites• No Permits to Work are in force that may prohibit (CaNO 3) loading to take place• After completion of all maintenance activities, all work scope documentation must be

completed and signed off by the relevant authorities before the start-up can commence• All spades and spectacle blinds are in their correct positions as per the System P&IDs

listed in the supporting drawings• All disturbed flanges and fittings in the system have been service tested as appropriate,

and any leak test certificate signed off• All system pipework, drain, vent, purge and sample point valves are closed• All system equipment drain and vent valves are closed (excepting tank vents)• All instrument isolation valves are open

• All level bridle vent and drain valves are closed• The DCS, SSDS and ESS control and shutdown facilities are operational and healthy• Communications are established between all personnel involved in this procedure• The relevant Chemical Handling Risk Assessment and MSDS documentation has been

read and understood

PLANT STATUS• The System Isolation Valves are positioned as indicated in Valve Checklist No 1 Calcium

Nitrate Loading Operation

• The plant is operating under normal conditions• Calcium Nitrate Tank T-4202 requires to be filled to maintain the necessary inventory to

accommodate normal injection rates






VALVE CHECKLIST No 1: CALCIUM NITRATE LOADING OPERATION


Refer to P&ID BON-SHI-008-P-000002-016

42-BLV-019 Connection Valve from Tote Tank CLOSED

42-BLV-043 Strainer X-5304-S-01 Inlet Valve CLOSED

42-BLV-044 Strainer X-5304-S-01 Outlet Valve CLOSED

42-BLV-042 Strainer X -5304-S-01 Bypass Valve LOCKEDCLOSED

42_SDV-011 Shutdown valve on loading line to T-4202 CLOSED

42-BLV-010 CaNO 3 Tank T-4202 Inlet Valve OPEN

42-BLV-032 CaNO 3 Transfer Pump P-4201C ManualDischarge Valve

OPEN

42-ZCV-005 CaNO 3 Transfer Pump P-4201C DischargeValve

CLOSED

42-BLV-033 CaNO 3 Transfer Pump P-4201D ManualDischarge Valve

OPEN

42-ZCV-006 CaNO 3 Transfer Pump P-4201D DischargeValve

CLOSED

42-BLV-009 CaNO 3 Transfer Pump P-4201C StrippingValve

CLOSED

42-BLV-012 CaNO 3 Transfer Pump P-4201D StrippingValve

CLOSED

42-BLV-008 Portable Pump Discharge Isolation Valve toP-4201C

CLOSED ANDBLANKED

42-BLV-011 Portable Pump Discharge Isolation Valve toP-4201D

CLOSED ANDBLANKED

42-BLV-054 CaNO 3 return valve OPEN

42-BLV-037 Isolation Valve Pump Discharge to Dirty SlopTank

CLOSED ANDBLANKED


40-SV-075 Isolation Valve on CaNO 3 Tank Cleaning

Machine

CLOSED AND

BLANKEDRefer to P&ID BON-SHI-008-P-000002-017

– Manual Tank Gauging Valve for T-4202 CLOSED ANDBLANKED

42-GBV-061 Cargo Purge Main Flushing Valve at T-4202 CLOSED ANDBLANKED

42-BUV-025 T-4202 to Cargo Purge Main Isolation Valve CLOSED ANDBLANKED

42-BUV-021 Inert Gas Supply to T-4201 from CleanIG Header

CLOSED ANDBLANKED







Step Action

1 ENSURE that isolation valves are positioned as indicated in Valve Checklist 1 –Calcium Nitrate Loading Operation.

2 ENSURE that the Nakakita Hydraulic System is operating normally and highpressure hydraulic oil is available at 85barg for the operation of the isolation valves.

Note: The Nakakita Local Control Panel must be SET to ‘Remote’ control to allowthe isolation valves to be opened and closed from the DCS Console inthe CCR.

3 CONFIRM that the spectacle blind in the nitrogen blanketing header to CaNO 3 TankT-4202 is in the open position, and the nitrogen blanket gas supply is in operation.

4 CONFIRM that the oxygen concentration in the nitrogen system is less than5% (volume).

CANO 3 LOADING MUST NOT PROCEED UNTIL ALL CHEMICAL ANDMETHANOL OIL TANKS ARE FILLED WITH NITROGEN GAS. THIS IS TO

PREVENT ANY INGRESS OF OXYGEN WHICH COULD RESULT IN APOTENTIALLY HAZARDOUS ATMOSPHERE WITHIN THE TANKS.

5 Prior to commencement of CaNO 3 loading, a complete simulation of the loadingsequence must be completed on the loading computer.

6 ENSURE that the loading plan has been issued by the Marine Supervisor andapproved by the OIM.

7 ENSURE any special equipment required to handle spillage, identified in the Risk Assessment and MSDS is available onsite.

8 ENSURE that the supply vessel Wet Bulk Transfer Checklist is completed. Refer tothe Bonga Field Marine Operations Manual (OPRM-2003-0101) Section 5.

THE OPERATOR MUST READ THE MSDS FOR THE CHEMICAL TO BELOADED TO ENSURE HE UNDERSTANDS THE HAZARDS ASSOCIATED

WITH THE CHEMICAL, PPE TO BE WORN AND REQUIRMENTS FORHANDLING ANY SPILLAGE.

9 ENSURE Main Deck Crane No 1 is available for operation. Refer to: POPM Volume

33 Deck Machinery and Mechanical Handling (OPRM-2003-0333) Part 2 Section 2Procedure No 2/002.






Step Action

10 ENSURE the Hull Chemical and Methanol Cofferdam HVAC Facilities are inoperation. Refer to Volume 32 HVAC Systems (OPRM-2003-0332) Part 2 Section 1Procedure No 1/010.






CALCIUM NITRATE LOADING PROCEDURE

Step Action

1 CONFIRM hydraulic power is available at the CaNO 3 Tank Hi-Tec Hose Reel A-5304.

2 LOWER the CaNO 3 hose to the supply vessel using the crane.

3 As the end of the hose is lowered PAY OUT the CaNO 3 hose in a controlledmanner, ensuring communications with the supply vessel at all times.

4 OPEN CaNO 3 Filter X-5304-S-01 Upstream Isolation Valve 42-BLV-043.

5 OPEN CaNO 3 Filter X-5304-S-01 Downstream Isolation Valve 42-BLV-044.

6 ENSURE that CaNO 3 Filter X-5304-S-01 Bypass Valve 42-BLV-042 is LOCKEDCLOSED. The filter bypass shall only be used in case of emergency and when thereis a guarantee that transport fluids are free of contaminants.

7 REQUEST permission from the CRO to start the loading operation.

8 OPEN CaNO 3 Filter Loading Shutdown Valve 42-SDV-011.

9 Request the vessel to START pumping, initially at a slow loading rate. Liase with thesupply vessel throughout the operation.

10 MONITOR the system for leaks as the CaNO 3 begins to flow.

11 CHECK that the level in the CaNO 3 Tank T-4202 is rising on the DCS Console.

12 MONITOR the operating pressure in the CaNO 3 Tank T-4202 to ensure that55-PCV-004 is controlling the pressure at 800mmwg.

13 Monitor the CaNO 3 Filter X-5304-S-01 for loading by observing the PressureDifferential Transmitter (40-PDIT-015). Shut down loading operations and changeout or service the filter if required.

14 When the level is rising, there are no leaks, pressure is being maintained and withagreement from the CRO, INSTRUCT the supply vessel to increase to theagreed rate.

15 MONITOR the system regularly for leaks.

16 As the level approaches, the required level in the tank, the CRO ADVISES thesupply vessel of the intention to stop loading within the agreed notice period.

17 When the agreed volume has been received INSTRUCT the supply vessel to STOPthe loading pump.

18 REMOVE the blank flange and OPEN Isolation Valve 42-BLV-019 on the tote tankloading line for CaNO 3 Tank T-4202 to allow the hose to drain properly to the supplyvessel tank. (It may be worth considering installing a tapped valve on the blankflange, with facilities to connect a nitrogen hose to aid displacement of the liquidback to the supply boat.)

19 DRAIN down the loading hose to the supply vessel.

20 When the CaNO 3 hose is drained down, CLOSE 42-BLV-019 and REPLACE theblank.

21 CLOSE 42-BLV-043, the upstream isolation valve on CaNO 3 Filter X-5304-S-01.






Step Action

22 CLOSE all CaNO 3 loading system valves.

23 RECOVER the loading hose.

24 STOW all loading equipment in the correct location.







PROCEDURE NO 3/005: CALCIUM NITRATE TRANSFER FACILITIES


FOLLOWING ACTIONS.

INTRODUCTION

The procedure details the actions required to be carried out on the Calcium Nitrate (CaNO 3)System prior to and during transfer to consumers.

The Transfer Pump to be used in the operation is P-4201C. The operation of the D pump isidentical except for the tag numbers.

PRECONDITIONS

Supporting Drawings

The CaNO 3 transfer procedure utilises the following P&IDs:• BON-SHI-008-P-000002-016 Storage Compartment 8• BON-AME-3SP-21542-0 11 2-C06 Scavenger Storage Tank and Pumps

Pre-requisites

Interface Systems

Before CaNO 3 transfer can be started, the following systems are required to be available:• Drainage System. Refer to Volume 16 (OPRM-2003-0316)• Nitrogen System. Refer to Volume 20 (OPRM-2003-0320)• Instrument Air and Utility System. Refer to Volume 25 (OPRM-2003-0325)• Deck Hydraulic System. Refer to Volume 26 (OPRM-2003-0326)• Power Generation and Distribution. Refer to Volume 30 (OPRM-2003-0330)• HVAC Systems. Refer to Volume 32 (OPRM-2003-0332)• Deck Machinery and Mechanical Handling. Refer to Volume 33 (OPRM-2003-0333)

Pre-requisites• No Permits to Work are in force that may prohibit CaNO 3 transfer to take place• After completion of all maintenance activities, all work scope documentation must be

completed and signed off by the relevant authorities before the start-up can commence•

All spades and spectacle blinds are in their correct positions as per the System P&IDslisted in the Supporting Drawings






• All disturbed flanges and fittings in the system have been service tested as appropriate,and any leak test certificate signed off

• All system pipework, drain, vent, purge and sample point valves are closed

• All system equipment drain and vent valves are closed (excepting tank vents)• All instrument isolation valves are open• All level bridle vent and drain valves are closed• The DCS, SSDS and ESS control and shutdown facilities are operational and healthy• Communications are established between all personnel involved in this procedure• The relevant Chemical Handling Risk Assessment and MSDS documentation has been

read and understood

PLANT STATUS

The system isolation valves are positioned as indicated in Valve Checklist No 2 CalciumNitrate System Transfer Operation:• The plant is operating under normal conditions• The level in the topside CaNO 3 tank requires replenishment






VALVE CHECKLIST No 2: CALCIUM NITRATE SYSTEM TRANSFER OPERATION



42-BLV-037 CaNO 3 Pump Discharge Valve to Slop Tank CLOSED

42-BLV-032 CaNO 3 Transfer Pump P-4201C ManualDischarge Valve

OPEN

42-ZCV-005 CaNO 3 Transfer Pump P-4201C ActuatedDischarge Valve

CLOSED

42-BLV-009 CaNO 3 Transfer Pump P-4201C Stripping LineIsolation Valve

CLOSED

42-BLV-008 Portable Pump Discharge Isolation Valve CLOSED ANDBLANKED

42-BLV-033 CaNO 3 Transfer Pump P-4201D ManualDischarge Valve OPEN

42-ZCV-006 CaNO 3 Transfer Pump P-4201D ActuatedDischarge Valve

CLOSED

42-BLV-012 CaNO 3 Transfer Pump P-4201D Stripping LineIsolation Valve

CLOSED

42-BLV-011 Portable Pump Discharge Isolation Valve CLOSED ANDBLANKED

42-BLV-054 CaNO 3 Recycle Valve OPEN

Refer to P&ID BON-AME-3SS-B-21542-012-C0 66

42-BLV-1288 Topside CaNO 3 Tank 42-T-4254 Inlet Valve CLOSED

42-BLV-1387 Top Bridle Isolation Valve for 42-LG-731/LZT-731

OPEN

42-BLV-1388 Bottom Bridle Isolation Valve for 42-LG-731/LT-731

OPEN

42-BLV-1397 Isolation Valve for 42-LZT-732 OPEN

42-BLV-1289 Topside CaNO 3 Tank 42-T-4254 Outlet Valve OPEN







Step Action

1 ENSURE that isolation valves are positioned as indicated in Valve Checklist 2Pre-start Positions: CaNO 3 Transfer Operation.

2 ENSURE that the FRAMO hydraulic system is operating normally.

3 ENSURE that the FRAMO Control Panel is set to remote control to allow the CaNO 3 transfer pump to be operated from the DCS.

4 ENSURE that the Nakakita Hydraulic System is operating normally and highpressure hydraulic oil is available at 85barg for the operation of the isolation valves.

Note: The Nakakita Local Control Panel must be SET to ‘Remote’ control to allowthe isolation valves to be opened and closed from the DCS Console in

the CCR.5 CONFIRM that the spectacle blind on the nitrogen header to the hull CaNO 3 Tank

T-4202 is in the open position and the nitrogen blanket gas supply is in operation.

6 CONFIRM that the oxygen concentration in the nitrogen system is less than 5%(volume).

7

CaNO 3 TRANSFER MUST NOT PROCEED UNTIL ALL CHEMICAL AND

METHANOL HULL TANKS ARE BLANKETED WITH NITROGEN GAS. THISIS TO PREVENT ANY INGRESS OF OXYGEN, WHICH COULD RESULT IN A POTENTIALLY HAZARDOUS ATMOSPHERE WITHIN THE TANKS.

87 Prior to commencement of CaNO 3 transfer, a complete simulation of the transfersequence must be completed on the loadmaster computer.

98 ENSURE the Hull Chemical and Methanol Cofferdam HVAC Facilities are inoperation. Refer to Volume 32 HVAC Systems (OPRM-2003-0332) Part 2 Section 1Procedure No 1/010.






CaNO 3 TRANSFER PROCEDURE

Step Action

1 ENSURE that Topsides CaNO 3 Storage Tank T-4254 is lined up for the CaNO 3 Transfer Operation.

2 START CaNO 3 Transfer Pump P-4201C from the DCS.

3 ENSURE that CaNO 3 Transfer Pump P-4201C is operating normally at minimumspeed (5%).

4 ENSURE the CaNO 3 Transfer Pump P-4201C Discharge Valve 42-ZCV-005 hasbeen OPENED by the DCS.

5 Slowly INCREASE the speed of CaNO 3 Transfer Pump P-4201C at the DCSConsole until the required flow rate is achieved.

6 MONITOR the transfer system for leaks.

7 MONITOR the operating pressure in Hull CaNO 3 Storage Tank T-4202 andENSURE that the pressure does not fall below 400mmwg.

8 MONITOR the level in Hull CaNO 3 Storage Tank T-4202 from the DCS Console.

9 MONITOR the level in topside CaNO 3 Storage Tank T-4254 on 42-LI-731 at theDCS Console.

10 When the Topside CaNO 3 Storage Tank T-4254 is filled to maximum operatingcapacity STOP the transfer pump from the DCS.

11 ENSURE the CaNO 3 Transfer Pump P-4201C Discharge Valve 42-ZCV-005 is

CLOSED by the DCS.Note: If the level in the topside CaNO 3 Storage Tank T-4254 reaches the high level

Switch 42-LZH 732, the pump will be tripped automatically.







PROCEDURE NO 3/006: CALCIUM NITRATE INJECTION START-UP ANDOPERATION


FOLLOWING ACTIONS.

INTRODUCTIONThe Calcium Nitrate Injection System is to be started up and calibrated to the injection ratesrequired for injection into the waterflood header.

For the purposes of this procedure it is assumed that the operator will be setting up andoperating P-4254A. A similar procedure can be used to set-up and operate P-4254B. Bothpumps are independently driven by their own electric motor driver.

PRECONDITIONS

Supporting Drawings

The Calcium Nitrate Injection System utilises the following P&IDs:• BON-AME-3SP-B-21542-012-C0 66 Calcium Nitrate Storage Tank and Pumps• BON-AME-3WF-B-21640-023-C0 66 Injection Water tank and Charge Pumps

Interface Systems

Before the Calcium Nitrate Injection System can be started, the following systems arerequired to be available:• Drainage System. Refer to Volume 16 (OPRM-2003-0316)• Instrument Air and Utility System. Refer to Volume 25 (OPRM-2003-0325)•

Power Generation and Distribution. Refer to Volume 30 (OPRM-2003-0330)Pre-requisites• No Permits to Work are in force that may prohibit the Calcium Nitrate Injection System

start-up to take place• After completion of all maintenance activities, all work scope documentation must be

completed and signed off by the relevant authorities before the start-up can commence• All spades and spectacle blinds are in their correct positions as per the System P&IDs

listed in the Supporting Drawings• All disturbed flanges and fittings in the system have been service tested as appropriate,

and any leak test certificate signed off






• All system pipework, drain, vent, purge and sample point valves are closed• All system equipment drain and vent valves are closed (excepting tank vents)• All instrument isolation valves are open• All level bridle vent and drain valves are closed• The DCS, SSDS and ESS control and shutdown facilities are operational and healthy• Communications are established between all personnel involved in this procedure• The relevant Chemical Handling Risk Assessment and MSDS documentation has been

read and understood

PLANT STATUS• The System Isolation Valves are positioned as indicated in Valve Checklist No 3 Calcium

Nitrate Injection System Start-up and Operation






VALVE CHECKLIST No 3: CALCIUM NITRATE INJECTION SYSTEM START-UP ANDOPERATION


Refer to P&ID BON-AME-3SS-B-21542-012-C0 66

42-BLV-1288 42-T-4254 Inlet Valve OPEN

42-BLV-1387 42-LG-731/LZT-731 Top Bridle Isolation Valve OPEN

42-BLV-1388 42-LG-731/LT-731 Bottom Bridle IsolationValve

OPEN

42-BLV-1397 42-LZT-732 Isolation Valve OPEN

42-BLV-1289 42-T-4254 Outlet Valve OPEN


42-BLV-1291 P-4254A Calibration Pot Isolation Valve CLOSED42-BLV-1295 P-4254A Upstream Discharge Valve OPEN


42-BLV-1297 P-4254B Calibration Pot Isolation Valve CLOSED

42-BLV-1301 P-4254B Upstream Discharge Valve OPEN

Refer to P&ID BON-AME-3SP-B-21640-023-C0 66

40-SV-003 Calcium Nitrate Injection Quill to waterfloodheader

OPEN







Step Action

1 CONFIRM that all valves are aligned as per Valve Checklist No 3 Calcium NitrateInjection Start-up and Operation.

2 CHECK the oil level in the Calcium Nitrate injection pumps.

3 ENSURE that there is an adequate level in Calcium Nitrate Storage Tank T-4202.




CALCIUM NITRATE INJECTION START-UP AND OPERATION PROCEDURE

Step Action

1 ENSURE that the injection quill and Isolation Valve 40-SV-003 on the water floodheader is open.

2 ENSURE that Calcium Nitrate Transfer Pumps P-4201C or D is available toreplenish Calcium Nitrate Topsides Tank T-4254. Refer to Procedure No 3/005.

3 ENSURE that there is an adequate level in Calcium Nitrate Storage Tank T-4254.

4 SET the required injection rate on Calcium Nitrate Pump P-4254A via the pump’slocal manual stroke controller.

5 START Calcium Nitrate Pump Driver PM-4254A.

6 CALIBRATE the Calcium Nitrate pump using Steps 7 to 13.

APPROPRIATE PPE MUST BE WORN DURING THIS OPERATION.

7 Slowly OPEN Calibration Pot Isolation Valve 42-BLV-1291.

8 OBSERVE the level increase in Calibration Pot 42-LG-733.

9 At the desired level CLOSE Calibration Pot Isolation Valve 42-BLV-1291.

10 OPEN Calibration Pot Isolation Valve 42-BLV-1291 and CLOSE Calcium NitratePump 42-P-4254A Suction Valve 42-BLV-1290.

N t O t l i lt l i kl ibl

V12 Waterflood System

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