Вы находитесь на странице: 1из 17

-

1.0 INTRODUCTION-

1.1 SCOPE-

Kashagan Development Project comprises of both offshore and


onshore
facilities as well as two independent onshore export pipeline
systems which
will be installed to transport treated and stabilized crude oil and
conditioned
gas for sales to existing in country infrastructure.

,

,
,

The Export Pipeline project comprise of engineering and design of


Export Oil
and Export Gas Pipelines. This document gives a brief description of
commissioning procedure for Export Oil Pipeline.

.
-

Oil Export Pipeline is used for transporting treated and stabilized


crude from
the Onshore Process Facilities (OPF) to a receiving terminal near
Atyrau. At
the receiving terminal the pipeline branches into two spur lines for
transporting
crude to CPC and KTO terminals.


.

The Export Oil Pipeline mainly consists of- :


Approximately 55km of 24 onshore mainline pipeline from OPF to
Atyaru receiving terminal- 55 24

4 nos of OE stations (Oil Export Sectionalizing Valve)


Pigging Facility at both OPF and Atyrau Receiving Terminal
Remote Monitoring, closing and opening of mainline valves on the
Pipeline- ,

Flow and Pressure control unit and Metering package at both
CPC and KTO terminals-

Installation of Fibre Optic Cable along the pipeline-

Commissioning is commenced after Pre-Commissioning is
completed.
This commissioning manual provides a broad guidelines and
procedures to be
followed for commissioning of facilities described above. However,
the plant
owners standard commissioning guidelines have to be adhered to.
This
commissioning manual has to be augmented by experience as well
as
presence of mind and proper training of commissioning personnel in
real life
situation. Further for package items specific instructions regarding
commissioning procedures given by respective vendors should be
followed to
safeguard the facility.
- -
.
-
.
, -
.
,
.

,
.
2.0 DESCRIPTION OF FACILITIES-

2.1 PIPELINES-

Oil Export pipeline is used to transport treated and stabilized


crude from
Onshore Process Facilities to pipeline receiving terminal adjacent to
CPC
pump station near Atyrau.

,
.
The Oil Export Pipeline is a buried pipeline with 24 inch diameter
and
covers a distance of 51.5km from the Onshore Facility to the
Pipeline
receiving terminal. The pipeline has one major River Crossing (Ural
River)
and one Atyrau-Uralsk Highway crossing.
- 24
51.5
. -
( ) -
Pipeline is installed with a Launching trap at the OPF.
Two spur lines from the receiving terminal to CPC and KTO tie in
points
are provided for Oil transport. The spur lines are designed for full
flow
conditions. Both CPC and KTO terminals are provided with Pressure
and
Flow Control Unit for Oil Flow Control.
.

.

.
.

Sectionalizing valve stations have been provided before and after


the
crossings. The valves are motor operated and are interlocked for
low-low
pressure shut down.

Emergency Shutdown Valves (ESDs) are provided at the pig
launcher and
pig receiver end of the pipeline and also at CPC and KTO terminals.

3.0 DESIGN BASIS-

3.1 PROCESS DESCRIPTION-

The offshore Process facilities separate the oil and associated


gases. Export
Oil is then pumped to an onshore Process facility via an oil trunkline
where it
is stabilized, de-watered and de-sulphurised. After that it is exported
via 24
Oil Export pipeline to an existing Kazakhstan pipeline distribution
system.
The 24 Oil Export Pipeline is routed underground approximately
51.5kms to
Atyrau Receiving terminal. At the Atyrau terminal the pipeline
branches into
two 24 spur lines routed to CPC and KTO terminals. The spur lines
have
individual flow and pressure control unit and Metering package.
During normal
operations, the pressure requirement at CPC and KTO terminal is
around 3.5-
14barg and the flow to CPC and KTO terminals can be either
simultaneous or
one at a time, depending on the requirement at each terminal, the
flow and
pressure control unit is used to achieve these purpose.
.

, ,
. 24
.
24 51.5
.
24 .

.
3.5-14


.

4.0 BASIC OUTLINE OF COMMISSIONING-


-
The pipeline commissioning will be done with a column of Nitrogen
Gas
followed by Export Oil. The nitrogen column will displace air and will
displace nitrogen in the pipeline and associated piping.

.

4.1 STEPS OF COMMISSIONING


-

The commissioning of the pipeline at the Launcher area is divided


into 3 steps
as described below.
:

4.1.1 STEP 1--1

In this step the Launcher and connected pipelines are vented out to
remove
any residual pressure in the system-


Commissioning activity will be taken-up, after pre-commissioning
activities
have been completed. At the point of commissioning activities
commencement it is assumed that all main construction and testing
related
activities i.e. pre-commissioning have been fulfilled and
documented. Any
document, proving execution of any project activities and testing on
any
section may be requested for information purposes.
On this step a 100 per cent inspection of the actually erected
equipment with
respect to as-built documentation shall be conducted (specific
attention to be
paid to the inspection of Valves tag numbers correspondence).
-
- , -

. -
.

.

4.1.2 STEP 2- 2
In this step approximately 5000 m column of nitrogen will be filled
in the
pipeline with the pressure slightly above the atmospheric pressure,
the
nitrogen column will be propelled by the second pig. The flow of
nitrogen will
be controlled by flow meter so that the pigs movement will be not
be more
than 1m/sec (3.6Km/h). After creating the 5000 m nitrogen column
the second
pig to be introduced. Due to Export Oil pressure the nitrogen column
between
the two pigs moves within the pipeline, fills all sections and
displaces the air
from the pipeline making systematic purging of pipelines specified
sections.
This finally results in a complete displacement of air from the
pipeline (oxygen
content shall not exceed 10% V). Filling of nitrogen and pipeline
purging
related detailed step-by-step instructions are given in the respective
chapters
of the procedure below.
5000
,
.

1 .
,


.
(
10% )

4.1.3 STEP 3
This step takes place immediately after creation of the nitrogen
plug and
launching of a second pig. The second pig is propelled by Export Oil.
Export
Oil will be consistently moving within the pipeline pushing the
nitrogen column
(between the 1st and 2nd pig) and will be filling all sections of the oil
pipeline
displacing nitrogen in the pipeline by executing systematic Oil-in of
the
required sections of the pipeline. Export Oil will consistently
displace the
nitrogen from the pipeline venting off nitrogen into atmosphere at
the Pig
Receiving Station until complete filling of the pipeline with Oil.

.
.
,

.

11.0 COMMISSIONING ACTIVITIES- -

11.1 NITROGEN INJECTION/OIL IN AT ESKENE WEST PROCESS


/
General:

The conceptual idea is to create a nitrogen column. The nitrogen


column
should be created in between the two pigs (1ST Pig and 2ND Pig) with
positive
pressure around 0.3 bar. The estimated required quantity of Nitrogen
for main
line Eskene West Process to Tie-in points CPC and KTO (TP011 and
TP012
respectively) is around V =1739 (scm) and accordingly weight of
nitrogen is
2172 Kg. .

0.3 .

(TP011 and TP012
respectively) V- =1739 (scm)
2172 K
435 Kg (348 scm) of nitrogen is kept as reserve (20%). The nitrogen
tankers
and vaporizers should provide the nitrogen flow rate capacity not
less than
1500 m3/h.This flow rate provides velocity of pigs around 1-2 m/s (4
7
km/h). The velocity of pigs should be limited not more than 2 m/s.
Approximately 40m length of hose is required for the nitrogen piping
Arrangement

Preparatory Activities:

1. Shifting and mobilization of Nitrogen tanker and vaporizer


positioning of
the same should be taken care by commissioning
team.

2. Readiness of temporary manifold connections for Nitrogen


injection
should be ensured. The connection point is shown on schematic
diagram of Eskene West Process station.

.

3. Check for leakages in temporary connections shall be carried out.


4. Check for pressure gauges / Flow rate meter installation shall be


carried out. /

ACTIVITIES AT PIPELINE CONTROL UNIT, METERING STATION AND


EXPORT
OIL TIE-IN AT CPC AND KTO:
,

1. Report to Station and following shall be checked-



a. Communication with Eskene West Process station and all
stations.-
.

b. Placement of all tools and tackles as per list.


.
c. Check and confirm the pre-oil-in valve position. It has to be
ensured as
per valve chart of pipe line pig receiver.-
.
2. The both tie-in stations is under nitrogen pressure, since the pig
receiver area
(OE-5) commissioning period itself nitrogen has been filled up to tie-
in point.
During nitrogen filling, the complete purging has done with
nitrogen.-
.

TIE IN AT CPC:
1. Open 24 1600 HV 008 for commissioning of CPC oil terminal.
Prior
Information to the terminal authorities to be given at every stage of
commissioning.
24-1600-.008

2. The CPC pressure and flow control unit have two branches of pipe
lines (one
is in service and another is in standby). Both the control unit lines
commissioning is carried out simultaneously.
(
)
3. For commissioning the control unit C3-1600-PO-021-24-C13-HC
and C3-
1600-PO-023-24-C13-HC below steps to be followed,
a) Open the 24 RB 128 ball valve followed by the PCV029.-
24 RB128 PCV029
b) Then one by one open the following valves FCV 009A, RB 129,
RB130,
RC103 (check valve), ESV002 and ESV004 respectively.
d) By the above operation the export oil commissioning will be
completed
via the C3-1600-PO-021-24-C13-HC branch line up to CPC tie in
point
TP 011.
e) Simultaneously one by one open the following valves FCV 009B,
RB
132, RB133, RC103 (check valve), ESV002 and ESV004 respectively.
f) By the above operation the export oil commissioning will be
completed
via the C3-1600-PO-023-24-C13-HC branch line up to CPC tie in point
TP
011.
C3-1600-PO-023-24-C13-HC
After completing these steps at CPC tie-in points, report to Eskene
west process
station and all stations that commissioning of CPC has been
completed.
,
,

TIE IN AT KTO:
1. Open 24 1600 HV 009 for commissioning of KTO oil terminal.
Prior
Information to the terminal authorities to be given at every stage of
commissioning. 24-1600-.009
.

2. The KTO pressure and flow control unit have two branches of pipe
lines (one
is in service and another is in standby). For both the control unit
lines
commissioning is carried out simultaneously.
(
)
- .

3. For commissioning the control unit C3-1600-PO-018-24-C13-HC


and C3-
1600-PO-024-24-C13-HC below steps to be followed,
C3-1600-PO-018-24-C13-HC
C3-1600-PO-024-24-C13-HC
a) Open the 24 RB 134 ball valve followed by the PCV032.-
24 rb 134

b) Then one by one open the following valves FCV 010A, RB 135,
RB136,
RC105 (check valve), ESV003, ESV005, 24 RB211 and RB204
respectively.-
c) Consequently the export oil flows via the C3-160-JM-002 and
come out
of it, then open RC107 (check valve) and RB205.
C3-160-JM-002
RC107 and RB205
d) By the above operation the export oil commissioning will be
completed
via C3-1600-PO-018-24-C13-HC line up to KTO tie in point TP
012.
C3-1600-PO-018-24-C13-HC

d) Simultaneously one by one open the following valves FCV 010B,
RB
138, RB139, RC105 (check valve), ESV003, ESV005, 24 RB211 and
RB204 respectively.
c) Consequently the export oil flows via the C3-160-JM-002 and
come out
of it, then open RC107 (check valve) and RB205.
c) By the above operation the export oil commissioning will be
completed
via C3-1600-PO-024-24-C13-HC line up to KTO tie in point TP 012.
6. After completing these steps at KTO tie-in points, report to
Eskene west
process station and all stations that commissioning has been
completed.
7. Once the commissioning of CPC and KTO has been completed
successfully,
start the leak test procedure as given below
,

LEAK TEST (BETWEEN LAUNCHER AREA AND TIE-IN POINTS)


PROCEDURE:
(
)

1. Report to Station and following shall be checked-


a. Communication with Eskene West Process station and all


stations. -

b. Placement of all tools and tackles as per list.-



c. Check and confirm the pre-oil-in valve position. It has to be
ensured as
per valve chart of Leak test.-
.

After completion of commissioning, leak test to be carried out


(between Launcher
area and Tie-in points) in all the flanges and fittings at various
pressure 5 barg, 10
barg, 20 barg, 30 barg and at final pressure, at every stage of
pressurization, it
should be closely monitored for any oil leakages in the flanges and
fittings. A
complete patrolling to be done for the entire length of piping
section, the visual
observation of soil condition (Leaking area may wet the soil). This
should be carried
out while increasing the pressure up to MAOP (or design pressure).
Effective monitoring is necessary for all pressure, temperature and
flow instruments
are essential during the leak test.
-,
(
)
5 ,10 ,20 ,30 ,

, .


( ).

( )
,

.

12.0 GENERAL REPORTING REQUIREMENTS-

Following Data records shall be maintained at Stations during


commissioning
(where applicable):
- ( )
i) Date / Time of Pig launching /Receiving for both the Pigs.

ii) Line Pressure at every 10 minute intervals.
10
iii) Pressure and Temperature on the up-stream and down stream
pipe
work at station shall be recorded through the local Gauges. The
respective Team leaders shall do the same at their respective
stations
& intervals between two recordings shall be 10 minutes.


. ,
, 10 .
iv) Patrol / Leak survey team shall be mobilized to perform a Leak
survey
over the route of the pipeline to check for any leakage.
,
.
v) All the documents, data records shall be verified and signed by
Client /
Contractor/ ,
.

12.2 COMMISSIONING CO-ORDINATOR TASKS-


-
i) Check line pressure prior to Gas Fill-

ii) Co-ordination with owner, Contractor, and Operation Coordinator


&
Station teams leaders.-

iii) Check completion of nitrogen purging.-

iv) Contact receiving end for readiness.-

v) Give permission to operation coordinator & station Team leaders
for
subsequent activities.

vi) PIG movement monitoring.-

vii) Safety coordination.-


viii) Announce closing of activity.-

12.3 OPERATION COORDINATOR TASKS-


i) It will be available at Eskene West Process station & the operation


coordinator should communicate to O&M (Operation and
Maintenance)
team and pass on all the information required to the station team
leaders.



ii) Instruct operator to operate valve(s).

iii) He will check valve position. Vent valves.-
.
iv) Maintain log book.-
v) Help station Teams for various checks and measurements.-

vi) Signing of commissioning records.- -

vii) Conduct leak test at various pressures.


12.4 STATION TEAM LEADERS-

i) Communicate with operation coordinator & other Terminals.-



ii) Permits for next activity.-
iii) Help operation supervisor to maintain log book.-

iv) Man power coordination and control.

v) Signing of commissioning records.- -

vi) Monitoring the oxygen percentage.



vii) Monitor the percentage of Hydrocarbon.

viii) Monitor records and reports the line pressure & temperature.

ix) Safety monitoring.-

12.5 OPERATING CREW-


i) Act as per operation Coordinator instr uctions.

ii) Checking of all joints for leakage.-

12.6 SAFETY OFFICER-


i) Safety crew coordination.-

ii) Overall safety assurance.-


The commissioning team shall make a consolidated report of all the
activities
and present it to the Owner.-

Procedure for commissioning the pressure and flow control units
and metering
package shall be as per respective approved vendor documents.


12.7 REPORTING DOCUMENTATION AND RECORDS-



A daily report will be produced to the Construction Manager. The
report
covering the days operation will be handed to The Company
Representative
by 09:00hrs of the day.
All records will be witnessed and signed by the Company
Representative and
other signing authorities.
A daily operations log will be maintained in the Control cabin and
will be used
to record events relevant to the operation taking place.

.

.

.

.

14.0 APPENDIX-
Appendix1. Figure 1 Typical First and Second Pig run driven by
Nitrogen & Export
Oil respectively.-

Appendix2. Figure 2 Schematic of manifold connections for nitrogen
injection-
Appendix3. Four cup batch Pig record.

Appendix4. Nitrogen and Export oil pigging Pressure log.




Appendix5. Pigging acceptance certificate.- -

Appendix6. Export oil Filling Log.-

Appendix7. Air content P/V Log.-


Appendix8. Dead weight pressure record. -
Appendix9. Calculations for the requirement of Nitrogen.-

Appendix10. Commissioning check sheet for Export oil Pig
launcher-
-

Appendix11. Commissioning check sheet for Export oil-Pipeline
-
.
Appendix12. Provisional Acceptance Certificate-

Appendix13. Oil Fill completion certificate--

Оценить