OIL/SU/03

Oil System Normal Start Up.

Table of Contents
Action

Page 2 to 2
Pages 3 to 12

Symbols
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Rev No.
0

Date
Feb. 2004

Safety Action
Verification
Action

Prepared by
PFI

Verified by
G.Faber

Approved by
P.L. dHaussy

Petrofac International Ltd.

JI-163
Doc. No. OIL/SU/03 Rev 0

Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

TABLE OF CONTENTS
1

INITIAL PLANT STATUS.......................................................................................3

PRELIMINARIES...................................................................................................3

VALVE LINE UP.....................................................................................................4

3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20

Line up at tank farm.................................................................................................4

Line up 14 export line..............................................................................................4
Line up GX-312........................................................................................................4
Line up EC-312........................................................................................................4
Line up EB-311.........................................................................................................4
Line up EC-313........................................................................................................4
Line up GX-311A/B...................................................................................................4
Line up of EC-310 (Stabilizer Reboiler)....................................................................4
Line up of CA-310 (Stabilizer)..................................................................................5
Line up of GX-722 A/B..........................................................................................5
Line up of DS-320B (Desalter)..............................................................................5
Line up of DS-320A (Desalter)..............................................................................5
Lining up of GX-310 A/B (Oil Booster Pumps)......................................................5
Lining up of DS-302 ( 2nd stage Separator)...........................................................5
Line up of DS-300 (Test separator).......................................................................5
Line up DS-301 (1st stage separator)....................................................................5
Line up of 10 test manifold at Plant side..............................................................6
Line up of 18 production header at plant side......................................................6
Line up of 10 test header line up at Cluster side..................................................6
Line up of 18 Production header at Cluster side..................................................6

OIL SYSTEM NORMAL START UP......................................................................7

FINAL PLANT STATUS.......................................................................................12

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Petrofac International Ltd.

JI-163
Doc. No. OIL/SU/03 Rev 0

Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

INITIAL PLANT STATUS

Wellheads are closed.

Oil system is under shutdown.

DS-300 inlet SDVs-3000/3001 are closed; outlet SDV-3005 is closed.

DS-301 inlet SDVs-3010/3011 are closed.
Manifold and the pipelines remain pressurized at the pressure switch trip level.
DS-301 outlet SDV-3013 is closed. Separator is pressurized and the liquid levels are
near normal values.
DS-302 is shutdown and is pressurized and the liquid levels are near normal values;
the outlet SDV-3021 is closed.
DS 320 A/B is full.
Stabilizer level is near the normal value and reboiler steam is stopped .
The seawater lifting and de-aeration system is operational.
Instrument air is available.
Fuel gas system is in operation.
Fresh water system is in operation.
Steam system is in operation.

PRELIMINARIES

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Inform Dor-1 / Dor-2 CCR.(Central control room)

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Ensure all personnel have H2S detectors & Escape masks.

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Ensure that all F&G systems are in automatic.

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Any F&G or process Inhibitions to be entered in the RED BOOK.

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3
3.1

Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

VALVE LINE UP
Line up at tank farm
Refer to P&ID No. IR40-B-11-B05-AA310-AAA-1958.
Refer to OIL/SU/02, section 3.13.

3.2

Line up 14 export line

Refer to P&ID No. IR40-B-11-B05-AA310-AAA-1958.
Refer to OIL/SU/02, section 3.12.

3.3

Line up GX-312
Refer to P&ID No. IR40-B-11-B05-AA310-AAA-1958.
Refer to OIL/SU/02, section 3.11.

3.4

Line up EC-312
Refer to P&ID No. IR40-B-11-B05-AA310-AAA-1958.
Refer to OIL/SU/02, section 3.10.

3.5

Line up EB-311
Refer to P&ID No. IR40-B-11-B05-AA310-AAA-1958.
Refer to OIL/SU/02, section 3.9.

3.6

Line up EC-313
Refer to P&ID No. IR40-B-11-B02-EC313-AAA-1953.
Refer to OIL/SU/02, section 3.8.

3.7

Line up GX-311A/B
Refer to P&ID No. IR40-B-11-B05-GX311-AAA-1957.
Refer to OIL/SU/02, section 3.7.

3.8

Line up of EC-310 (Stabilizer Reboiler)

Refer to P&ID No. IR40-B-11-B03-AA310-AAA-1956.
Refer to OIL/SU/02, section 3.6.

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3.9

Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

Line up of CA-310 (Stabilizer)

Refer to P&ID No. IR40-B-11-B03-AA310-AAA-1956.
Refer to OIL/SU/02, section 3.5.

3.10 Line up of GX-722 A/B

Refer to P&ID No. IR40-B-11-B04-GX722-AAA-1851.
Refer to OIL/SU/02, section 3.4.
3.11 Line up of DS-320B (Desalter)
Refer to P&ID No. IR40-B-11-B04-UA320-AAA-1955.
Refer to OIL/SU/02, section 3.3.
3.12 Line up of DS-320A (Desalter)
Refer to P&ID No. IR40-B-11-B04-UA320-AAA-1955.
Refer to OIL/SU/02, section 3.2.
3.13 Lining up of GX-310 A/B (Oil Booster Pumps)
Refer to P&ID No. IR40-B-11-B04-GX310-AAA-1954.
Refer to OIL/SU/02, section 3.1.
3.14 Lining up of DS-302 ( 2nd stage Separator)
Refer to P&ID No. IR40-B-11-B02-DS302-AAA-1953.
Refer to OIL/SU/02, section 3.1.
3.15 Line up of DS-300 (Test separator)
Refer to P&ID No. IR40-B-11-B02-DS300-AAA-1950.
Refer to OIL/SU/02, section 5.1.

3.16 Line up DS-301 (1st stage separator)

Refer to P&ID No. IR40-B-11-B02-DS301-AAA-1951.
Refer to OIL/SU/02, section 5.2.

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Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

3.17 Line up of 10 test manifold at Plant side

Refer to P&ID No. IR40-B-11-B02-AA300-AAA-1940.
Refer to OIL/SU/02, section 5.3.
3.18 Line up of 18 production header at plant side
Refer to P&ID No. IR40-B-11-B02-AA300-AAA-1940.
Refer to OIL/SU/02, section 5.5.
3.19 Line up of 10 test header line up at Cluster side
Refer to P&ID No. IR40-D-11-A06-AA100-AAA-1711.
Refer to OIL/SU/02, section 5.4.
3.20 Line up of 18 Production header at Cluster side
Refer to P&ID No. IR40-D-11-A06-AA100-AAA-1711.
Refer to OIL/SU/02, section 5.6.

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JI-163
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Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

OIL SYSTEM NORMAL START UP

Refer to Initial start up OIL/SU/02
()

Ensure that all emergency conditions, which caused the shut down of
the oil system are corrected and the oil system is ready for start up.

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Check that all liquid levels are healthy.

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Check that the water outlet lines to the OWT package are open.

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Check that the OWT package is ready to receive oily water. Refer to
OIL/OP/05.

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Set the water level control valves to the auto position.

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Reset the SDVs on the oil and water outlet lines by resetting them
manually.

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Start pump GX-311 A/B and start circulation through the minimum
recirculation line.

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When the GX-311 operation is steady, start circulation through the

downstream coolers.

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Start the Off-spec Pump, and begin circulation through the minimum
recirculation line

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Start the oil booster pump GX-310 with the minimum flow recirculation
line fully open and the stabilizer inlet valve closed.

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Ensure that the 1st stage separator pressure is at least 4 barg so that
the oil circulation can be effected to the LP separator.
If the pressure is less, then pressurization of the system is required
from the manifold lines or using nitrogen.

()

Ensure that the Desalter trains are full with oil, and switch on the
Desalter Transformers.

()

Ensure that pumps GX-320 A/B have been primed and the pumps are
ready to start.

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Line up the wash water line to 2nd stage Desalter inlet through the wash
water Preheater.

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Start the wash water pumps GX 722 A/B as per the start up procedure
described in the vendor operating manual.

[]

Start the wash water feed into the Desalter.

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Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

[]

Open SDV-3015.

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Start recycling to the 1st stage separator by manually opening LV/C

3101.

[]

Slightly open FV-3215 manually.

()

Ensure and monitor that the interface level in the second stage
Desalter starts rising.

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When the level reaches the normal value, start the Desalter pump and
start recycling of wash water into 1 st stage Desalter set the interface
level control to auto.

()

Ensure that the water outlet flow from DS-302A to the OWT package is
being controlled automatically on interface control of DS-302A.

[]

Now put 2nd stage separator level control on auto. FV 3215 will control
the level in the 2nd stage separator by starting the flow to stabilizer.

[]

Demulsifier and scale inhibitor injection is started to the inlet of the

Desalter and antifoam injection is started into the stabilizer.

()

Ensure that Oil is flowing down the trays, filling the reboiler, and flowing
into the column bottom.

()

Ensure Cooling Water is flowing through EC-312.

[]

When the reboiler low low level switch (LSLL 3108) becomes healthy,
turn on the steam to the reboiler.

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Adjust the steam valve opening (FV 3105) manually to a low value so
that the reboiler overhead temperature is controlled at 120 oC.
If the reboiler level is healthy even before opening the stabilizer feed
valve, the steam supply can be started just before opening of stabilizer
inlet valve.

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Slowly increase the pressure controller set point to the normal value of
1.5 barg.

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Simultaneously increase the reboiler outlet temperature to 140 oC and

put the reboiler steam flow controller in auto.

()

Ensure that TIC-3100 set point is at 140 oC.

()

Ensure that temperature controls TIC-3111, TIC-3115 and TIC-3124 are

working correctly.

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[]

Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

Adjust the stabilizer column level control set point to 50% of the normal
level. This will allow some part of oil hold up in stabilizer to be recycled
to 1st stage separator.

[]

Sample and check the oil quality to ensure it meets the specification for
export.

The oil system is started and running in closed recycle loop through the
separators, Desalters and stabilizer.
[]

Sample and check the oil quality to ensure it meets the specification for
export.

When the oil meets the export quality the oil export can be started as per the
following procedure.
()

Ensure that the tank farm are ready to receive oil from the export line.

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Open SDV-3114.

()

Ensure that ESDV-3115 is open.

()

Ensure that ESDV-3116 is open.

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Request the tank farm to open an MOV to oil storage.

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Select LV/A-3101 or LV/B-3101 in the stabilizer level control loop by the

selector switch HS 3110 in the PCS.

()

Ensure that the isolation valves of only one of the control valves are
open.

()

Ensure that the other control valve in parallel isolation valves are
closed.

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Open the control valve LV/A-3101 slowly to about 10% opening

position. This will allow oil to flow into the export pipeline.

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Monitor the stabilizer levels adjust the valve opening if required to

maintain a correct level in the stabilizer.

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When the operation is steady, put the level controller on auto.

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Reduce the level set points in the separator gradually to lower than the
normal levels to start the export.

Now the Oil wells can be lined up to production separator.

Refer to Procedure OIL/SU/01

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Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

For this first the first stage separator needs to be lined up to the manifold and
pipelines. Only one cluster pipeline will be lined up first.
The sequence of opening the valves shall be starting from the separator to the
wellhead to prevent increase in manifold fold pressure during start up
HAZOP action item 1.6.
()

Ensure that the pressure in the manifold is not more than 5 bar higher
than the separator pressure.

[]

Reduce the differential pressure by opening the SDV 3010 on the 2

bypass line to the inlet SDV.

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When the pressure is less than 5 bar, open SDV 3011 and connect the
manifold to the separator.

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Also before opening the main SDV, ensure that the pressure in the
manifold is less than the PSHH set point of the separator. This will
prevent high-pressure trip of the separator due to sudden gushing in of
gases accumulated in the manifold.

HAZOP action item 3.13.

Before opening the main ESDV, ensure that the manifold pressure is
less than the PSHH pressure of the separator. This will prevent the
separator trip due to initial surge of vapor from the manifold/pipelines.
Initial surge of vapor is due to the pipeline topology, which allows during
pipeline shutdowns, vapor to migrate towards the portion of the line
closer to the new plant.
HAZOP action no. 2B.6
()

Ensure that the when the manifold flow reduces the pressure has
equalized with DS 301,

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Start the well flow by opening the wellhead valves as per the Wellhead
operating instructions.
Refer to Procedure No.OIL/SU/01

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Start the chemical injection in to the separator at the specified dosage.

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Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

[]

Stop GX-312

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Select LV/A/B-3101 switch HS-3101 and stabilization level control to

auto.

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Set all level controls to original setting.

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Reset and open gas outlet SDVs of DS-300 and DS-301: SDV-3007
and SDV-3014.
Refer to Procedure No. OIL/SU/02
Scale inhibitor, Demulsifier and Antifoam are injected into the inlet of
the 1st stage separator and the 2nd stage separator.
Reverse demulsifier and scale-inhibitor are injected into the separator
water outlet line going to the OWT package.
Corrosion inhibitor is injected into the vapor outlet line from the
separator.

When the separator is operating as a 3-phase separator, the

interconnection valve is to be kept closed.
HAZOP Action item 3.10 & 4.11.

If the water content (WC) of the crude is very low, the separator can be
operated as a 2-phase separator.
()

Ensure that the water outlet line SDV-3012 is closed.

()

Ensure that the isolation valves of LDV-3012 are closed.

[]

Open the valve on the interconnection between water and oil outlet
line.

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Elf Petroleum Iran

Dorood Project Onshore Facilities & New Plant
Oil System Normal Start Up

FINAL PLANT STATUS

The Oil system is started and the operating conditions are within specification.
All shut down bypasses are removed and the RED BOOK updated.
Oil export is on at 80,000 bopd.
Separated gas is routed to DS-305 or to the flare.
Process water is sent to the OW package.
Fire water system is in operation and the network pressurized.
The Fire and Gas detection system is in operation.
Instruments air is available and all instruments are operational.
The Diesel and Fuel gas system is in operation for the Turbine and Boilers.
The Amine system is running.
The Flare system is in operation.
The Turbo power generators are running and power is available.
The Sea water system is running and Fresh water and boiler feed water units are in
operation
The Steam boiler is in operation.
All chemical injection packages are running at the optimum injection rate.
The Wellhead clusters are in production.
Wellhead control panels and safety shutdown systems are in operation.
All spectacle blinds are in the normal operating condition.
All valves are lined up LO & LC confirmed as per P&ID.

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