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KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specification Number

Process Control and Metering

1 23 M A Y 94 ISSUED A S KOC ENG. GROUP SPEC.

0 07 MAR 94 ISSUED FOR INVITATION T O BID

Rev Date Revision BY Chkd Section PE Client


Specification Number Rev Date Sheet
Ewneerlng Omup
01 5-AH-1 0 0 5 1 23-7-94 2 of 11
Specificatbn

CONTENTS

1.0 SCOPE ...........................................3


2.0 STANDARD SPECIFICATIONS ........................... 3
3.0 SERVICE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
4.0 BASIC ENGINEERING INFORMATION ....................... 4
5.0 PROCESS SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.1 Manifolds/Wells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.2 Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.3 Desalters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.4 Oil Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.5 Oil Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.6 Gas Compression and Export . . . . . . . . . . . . . . . . . . . . . . . 7

6.0 UTILITY SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8


6.1 FuelGas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6.2 Wastewater Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.3 Plant Air and Instrument Air . . . . . . . . . . . . . . . . . . . . . . . 9

7.0 METERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.1 Products Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.2 Internal Flow Metering . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0

.
N 1 2-0032
Specification Number Rev Date Sheet
EngineeringGroup
SpeMcathn 01 5-AH-1005 1 23-7-94 30f 11

SCOPE

This specification covers the design of Process and Utility Control Systems
and Metering Systems for installation at the Facility in Kuwait.

This specification shall be used only in the detailed design of the Process
and Utility Control Systems and Metering Systems and is limited t o key
control loops.

Only criteria required for the following activities are described in this
specification.

a. P & ID development.

b. Basis for control engineering.

c. Control logic diagrams development.

The Process Control and Metering specification shall fully comply with all
the relevant contractual requirements specified in the Scope of Work and
Technical Specification of the Contract.

STANDARD SPECIFICATIONS

The process control and metering systems shall conform in design,


materials and performance, except where otherwise specified, with the
current issue of the following standards prevailing on the effective date of
the Contract, and as amended by this specification:

2.1 .I International Standards

API RP520 Sizing, Selection and Installation of Pressure-


Relieving Devices in Refineries

Part I Sizing and Section


Part 2 Installation

API RP521 Guide for Pressure-Relieving and Depressuring


Systems

AGA Report Orifice Metering of Natural Gas


No. 3

2.1.2 Engineering Group Specifications

All the designs covered by this specification shall comply with


all relevant Engineering Group Specifications and standard
Drawings of which the following are specifically referenced in
this specification:
Specification Number Rev Date Sheet
Engfnedng Gmup
4 0 f 11
Spe&ic%tkm 01 5-AH-1 005 1 23-7-94

0 1 5-AH-1001 Basic Design Criteria

0 1 5-AH-10 0 2 International Codes and Standards

0 1 5-KH-1005 Screw Compressors and Dryers for Plant and


lnstrument Air Service

015-KH-1008 Reciprocating Compressors and Dryers for


Plant and lnstrument Air Service

Compliance with this specification shall not relieve the Contractor of its
responsibility t o supply equipment suited t o meet the specified service
conditions and applicable regulations.

Where conflicts exist between this specification and other Drawings,


standards, codes and specifications, the most stringent shall be applied.

SERVICE CONDITIONS

The equipment shall be suitable for continuous operation at a desert


location under high ambient temperatures and humidity. The atmosphere
at the Facility is generally dusty and corrosive and may contain traces of
hydrogen sulphide.

The Process Control and Metering Systems shall in all respects be suitable
for continuous operation in the service conditions stated in the Engineering
Group Specification entitled "Basic Design Criteria" (Number 015-AH-
10011.

BASIC ENGINEERING INFORMATION

The safe management of the Facility is based on three levels of control:

a. The normal Process and Utility Control Systems, which modulate


flows and switch streams on or off.

b. The Process and Emergency Shutdown System, which shuts down


part or all of the process if control variables are outside acceptable
limits.

c. The Flare and Blowdown System, which relieves overpressure


wherever it may occur and disposes of the affected inventory safely.

This specification covers only the Process and Utility Control and Metering
Systems, and the Contractor's main priority shall be t o design the simplest
practicable systems requiring the least attention and yet provide for a safe,
operable Facility.

The basic requirements for control systems for the various parts of the
Specification Number Rev Date Sheet

QKOC Engfneering Group


Speaificatbn
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0 1 6-AH-1 0 0 5 1 23-7-94 5 0 f 11

Facility are given in the relevant sections below.

5.0 PROCESS SYSTEM CONTROL

5.1 Manifolds/Wells

5.1.I Production Wells

Control of wellheads is outside the scope of this specification. In


case of emergency, however, there is a manually operated remote
isolation valve located in each flowline outside the gathering centre
battery limit close t o the fence line.

5.1.2 Production and Test Manifolds

a. Direction of produced fluids t o one production separation train or


another (e.g., wet, dry or buffer) shall be by means of manual
valves at the production manifold.

b. Direction between production and test trains shall also be by


means of manual valves at the Test Manifold.

5.1.3 Control of Flow

The control of flow of produced fluids t o each production train shall


be achieved by manually turning wells onloff or throttling at the
wellhead.

5.2 Seearation

5.2.1 Dry Separator Train

a. Liquid is separated from gas and discharged under level control


from each separator. The oil is discharged from the final stage
under level control t o the dry crude storage tanks.

b. Gas flows under pressure control from medium pressure (MP) and
low pressure (LP) separators (where applicable) into the
appropriate pressure level gas gathering. header. High pressure
(HP) separator off - gas is pressure controlled at the common HP
gas knockout (KO) drum.

5.2.2 Wet Separation Train

a. Oil is separated from gas in HP or MP separators and discharged


under total level control t o LP separators.

b. The oil is discharged from the LP separators t o the wet crude


storage tanks.
Specification Number Rev Date Sheet
Engineering Gmup
01 5-AH-1005 1 23-7-94 6 o f 11
Specificabion

c. Gas flows under pressure control as indicated in paragraph 5.2.1.

d. HP wet separators operate as 2-phase separators, but LP wet


separators are designed for 3-phase separation, and the water
phase is discharged under interface level control t o a degassing
storage tank.

e. The wet crude storage tanks are used t o separate either bulk
water or a further fraction of the water from the crude oil prior t o
pumping t o the desalter trains. The produced water is pumped t o
the degassing tank under interface level control.

5.2.3 Dual Pressure Separators

Some separators are designed for HP and MP operation. On test


separators, the pressure control valve has downstream connections
t o the HP and MP gas collection headers. On dual pressure
production separators, however, there is only a pressure control
valve in the gas line t o the MP header, and in HP operation the
separator "floats" on the HP gas KO drum.

5.2.4 Test Train

Pressure control of the test train shall be as described in paragraph


5.2.3 above, and it shall operate under 2-phase separation as
described in paragraph 5.2.1 above. Bulk water separation shall take
place in the test tank.

5.3 Desalters

Wet crude oil is pumped from the wet crude tanks t o the desalter
units by dedicated pumps operating under flow control which is
reset by the wet crude tank(s) level.

The wet crude is preheated prior t o treatment in the desalting


vessels. The first stage of preheat is by means of counter-current
heat exchange with the desalted crude oil leaving the second
stage desalter vessel. The wet crude is then further heated t o the
desired desalting operating temperature by the desalter feed
heater, which is a water-bath-type heater.

The temperature of the wet crude oil stream leaving the water-
bath coil is used t o control the firing rate of the heater burners.
A temperature controller located in the water bath itself provides
a modulating signal t o the output from the wet crude oil steam
controller.

Washwater is pumped t o the second stage desalter vessel under


flow control which is proportioned to the desalter wet crude feed
Specification Number Rev Date Sheet
Englndng Group
015-AH-1005 1 23-7-94 7 of 1 1
SpeMeathn

flow.

A back pressure control valve in the treated crude outlet line


maintains a high pressure in the desalter vessels to prevent any
buildup of vapour.

Dry crude leaving each desalter unit shall be monitored by BS &


W and salt-in-crude analysers. High salt andlor BS & W content
shall result in the crude being diverted back to the wet crude
storage tanks. Specification quality dry crude passes to the dry
crude storage tanks.

The desalter vessels run full of liquid and the dewatered crude
flows away through the top positioned outlet nozzle. An interface
level controller in each desalter vessel controls the removal rate of
oilylsalty water.

The intimate mixing of wetlsalty crude and wash water upstream


of each desalter vessel is achieved by a differential pressure
control valve followed by an in-line helix-type static mixer.

The injection rates of the various chemicals added to the crude oil
and washwater streams are controlled by manual adjustment.

5.4 Oil Storaae

5.4.1 Facilities in the form of manifolds and motorised switching valves


shall be provided at the inlet and outlets of wet crude oil tanks to
allow crude oil to be selectively flowed tolfrom any individual
tank.

5.5 Oil EX DO^^

5.5.1 The export of dry crude oil shall be under flow control and set
point shall be reset by tank level. Where variable speed motors
are provided, the flow shall be controlled by pump speed. For
fixed speed pumpsets, however, flow control valves shall be used.

5.5.2 The pumps shall be protected for minimum flow-by-flow


measurement and minimum flow recycle back to crude oil storage
tank. The pumps shall also be stopped on tank low low level, on
low low product flow and on low low pressure in the export
pipeline.

5.6 Gas Com~ressionand E x ~ o r t

5.6.1 General

The control philosophy for the main gas compression system is


-
specification Number Rev Date Sheet
Eng/nedng Gmup
01 5-AH-1005 1 23-7-94 8 of 11
SpecrTfication

designed t o satisfy the following key requirements:

a. Meet pipeline delivery conditions.

b. Permit proper control of each stage of compression.

c. Permit parallel operation and load-sharing of t w o machines (where


applicable).

d. Deliver maximum gas t o pipeline.

e. Maintain each compressor stage operation outside the surge


region.

5.6.2 Control

a. To meet the above criteria, the overall control of the compressor


shall be by modulating the speed t o maintain constant suction
pressure on the first stage. The compressor final stage will be
under back pressure control.

b. lnterstage flow and differential pressure parameters shall be used


t o set the anti-surge recycle t o the respective stage suction t o
maintain each stage out of the surge region.

c. The interstage and final stage cooler gas exit temperatures shall
be controlled.

d. Liquid levels in interstage KO drums shall be controlled.

6.0 UTILITY SYSTEMS

6.1 Fuel Gas

6.1.1 Fuel gas is derived from HP separator off gas and for startup can
be imported from the export gas pipeline.

6.1.2 The first letdown is t o the pressure of the highest user, e.g., gas
turbines need about 2 0 barg (300 psig) and further letdowns
occur t o general distribution at about 3.5 barg for purging and
pressurising.

6.1.3 KO drums are generally required at each significant letdown stage,


and if gas turbines require a guaranteed amount of superheat,
then a temperature-controlled fuel gas heater shall be installed.

6.2 Wastewater Conditionirlg

6.2.1 Oily water from the degassing tank is pumped under flow control,
i
Specification Number Rev Date Sheet
Engineering Gmup
0 15-AH-1 005 1 23-7-94 9 of 1 1
Specification

reset by tank interface level, to a number of conditioning trains


consisting of an oily water separator and a gas flotation unit.

6.2.2 Water flows under a steady hydraulic gradient through the oily
water separator, and flotation unit to a water accumulation sump.
Effluent pumps under on-off level control dispose of the treated
water outside the gathering centre.

6.2.3 Recovered oil and waste floats material are both recycled by low
shear pumps under on-off level control.

6.2.4 The oil-in-water analyser in the effluent water stream is to warn


of inadequate operation of the upstream units and is not to
automatically divert the effluent back to the wet crude surge
tanks.

6.3 Plant Air and lnstrument Air

Two instrument air compressors, one in service, one on standby,


with coolers, air dryers and filtration for standalone operation,
shall be supplied per the Engineering Group Specification entitled
"Reciprocating Compressors and Dryers for Plant and lnstrument
Air Service" (Number 015-KH-1008) or "Screw Compressors and
Dryers for Plant and lnstrument Air Service" (Number 015-KH-
1005).

The capacity of each air compressor shall be 1.5 times the normal
consumption rate. Air dryers of compatible capacity shall b e ,
provided.

On the highest pressure setting, pressure control positioned at the


instrument air receiver shall stop, cut-out or off-load the in-service
machine. On progressively lower pressure settings, the pressure
control shall:

1. Start, cut-in or load-up the in-service machine.

2. Start the standby machine.

3. Import air from the plant air receiver.

4. Shut down operation of the Facility.

6.3.4 Two 100% plant air compressors, one in service, one on standby,
complete with coolers and a wet air receiver, shall be supplied.

6.3.5 Air receivers shall provide at least 30 minutes reserve of air. The
package(s) shall be remote controlled and shall operate
unattended. Further requirements are included in the relevant
Specification Number Rev Date Sheet
Engtlneering Gmup
0 1 5-AH-1 0 0 5 1 23-7-94 1 0 0 f 11
Specificatrion

process duty requirements, mechanical specification and P&IDs.

7.0 METERING

7.1

7.1.I The standard of metering required should be sufficient t o provide


indication of the oil, gas, and water produced. (Fiscal metering is
not required.)

a. Crude oil is metered as it leaves the main crude product pumps.

b. Condensate is metered before entering the export line.

c. Gas product is metered before entering the gas export line.

7.2 Internal Flow Metering

7.2.1 Crude oil flows shall be metered at the following positions:

a. Out of every wet, dry and test separator.

b. lnto and out of the test tank.

c. lnto and out of each desalter train, including the off-specification


crude recycle flow.

7.2.2 Gas flows shall be metered at the following positions:

a. Out of every separator. Test separators should be provided with


t w o DP transmitters (smart type) for wide rangeability and t o
minimise physical changing of orifice plates.

b. Out of the test tank.

c. lnto the tank vapour compressor suction scrubber.

d. lnto each stage of gas compression.

e. HP, MP, and LP gas flows t o HP flare header.

f. TV gas t o LP flare header.

7.2.3 Water flows shall be metered at the following positions:

a. Out of each 3-phase separator.

b. Out of test tank water transfer pumps.


Specification Number Rev Date Sheet

0 KOC Engindng Group


Specific~thn 015-AH-1005 1 23-7-94 11 of 11

c. Washwater into and oily water out of each desalter train.

d. Recycle water stream from second stage desalter t o first stage


desalter.

e. Water out of each wet crude tank.

f. Water t o each wastewater conditioning train.

g. Water t o water disposal pit.

7.2.4 Fuel gas flows shall be metered at the following positions:

a. In each supply line t o the fuel gas system.

b. A t each let down station or KO drum.

c. Into each compressor gas turbinelgas engine.

d. To each desalter feed heater.

e. To tank vapour header.

7.2.5 Other metered flows are as follows:

Recovered oil from CPI t o wet crude tanks.