starting the simulator

KENSON SCHOOL OF PRODUCTION TECHNOLOGY

ADVANCED DIPLOMA IN OIL & GAS PROCESS TECHNICIAN

RESEARCH PROJECT REPORTON

PROCEDURE FOR STARTING KSPT SIMULATOR

PREPARED BY

BYENSITA EMMANUELA RESEARCH PROJECT REPORT SUBMITTED FOR THE AWARD OF AN

INTERNATIONAL VOCATIONAL QUALIFICATION ADVANCED DIPLOMA IN OIL & GAS PROCESS TECHNICIAN OF CITY & GUILDS

JUNE 2012

STARTING UP KSPT SIMULATOR

Table of ContentsOBJECTIVE................................................................................................................................................3

INTRODUCTION.......................................................................................................................................3

START-UP METHODS..............................................................................................................................3

PERFORMING SYSTEM CHECKS..........................................................................................................4

CHECKS MADE ON A GENERATOR.................................................................................................4

CHECKS MADE ON THE AIR COMPRESSOR...................................................................................4

CHECKS MADE ON PUMPS AND TANKS........................................................................................5

CHECKS ON A CHRISTMAS TREE....................................................................................................6

CHECKS ON THE THREE PHASE SEPARATOR...............................................................................7

PRESSURE TESTING AND PURGING THE SYSTEM.......................................................................8

CHECKS ON THE CONTROL PANEL.................................................................................................8

PROCEDURE STARTING UP A GENERATOR..................................................................................9

PROCEDURE STARTING UP A COMPRESSOR................................................................................9

PROCEDURE STARTING UP THE CENTRIFUGAL PUMPS..........................................................10

OPENING THE WELL.........................................................................................................................10

START-UP RISKS....................................................................................................................................11

CONCLUSION.........................................................................................................................................12

REFERENCES..........................................................................................................................................12

ANNEX A: PHOTOS & CHECKLISTS OF SIMULATOR COMPONENTS.........................................13


OBJECTIVE

This project aims at giving the operator fundamental techniques and procedures to safely,

efficiently and effectively start up the KSPT Simulator

INTRODUCTION

The KSPT Simulator is a replica of an oil and gas Production Platform (Upstream Industry)

showing the various activities that happen in "real life" for purposes training and analysis.

This report involves the description of all the equipment that make the KSPT simulator an

integrated system, the basic operational checks that are made on each of the equipment prior to

start-up, procedures for starting each component of the entire system.

It also involves identifying risks that are likely to be encountered at the start of the system and

how they can be prevented from occurring.

The report also contains annex, a section of diagrams and drawings illustrating the equipment

and the entire KSPT Simulator described in the first chapters.

START-UP METHODS

There are two methods used to start up the system and these are;

First time start up or commissioning of the system

Reinstating or start up after a shut down when the system has malfunctioned or after a planned shut down.

Commissioning- Start-up done on a new system and involves an inch by inch inspection of every

piece of equipment, testing of lines, vessels, pumps and compressors to ensure functionality prior

to starting for production because of the many operational and safety uncertainties that may

result.

Reinstating- Start up after a shutdown simply requires that the system be brought back to stream

by restarting the equipment that were already functioning, opening valves, lines and vessels that

were in service prior to the shutdown as may be outlined in operating procedures.


Therefore this project will focus at start up after a shut down since the KSPT simulator system

has been in operation before. It is however important to check the various systems of the plant

prior to start up to avoid unforeseen eventualities.

PERFORMING SYSTEM CHECKS

Below are the necessary checks made to the various equipment that are part comprise the KSPT

Simulator as an integrated system.

CHECKS MADE ON A GENERATOR

A generator is an integrated electrical machine which produces electricity by a prime mover which is driven by an internal combustion engine, powered by either diesel fuel or natural gas.

The following are some of the regular checks that can be made on a generator prior to starting it;

Ensure the generator clean from dirt, dust, oil, grease and other foreign material (such as rags or tools left by maintenance techs) at all times.

Check the coolant levels in the radiator.

Check the fuel levels before starting the generator.

Check and clean air cleaners, fuel strainer cup and filter and where necessary replace them.

Check for the quality and quantity (use the engine shut down side of dip stick) of lubricant oil and where necessary, replace it.

Look for loose or damaged lead wires and hoses, loosely mounted components and other signs of damage to the generator equipment and immediately request repair.

Check the distilled water in the battery and top up if needed. Also check the battery's voltage.

Ensure that the fan belt is tight and fan guards are secure.

Check that the generator is properly grounded.


CHECKS MADE ON THE AIR COMPRESSOR

A compressor is a device that raises the pressure of air by compressing it to higher pressures so

that it can be used by the various pneumatic instruments on the plant.

The following are the basic checks that can be made on the KSPT Compressor in the simulator

prior to start.

Ensure that the compressor and its environment are clean.

Check the air filters to ensure that it is dust free. If filter is dirty – replace same.

Check and ensure that the electric motor and the pulley are intact and the pulley belt is tight.

Ensure Fly wheel is free to rotate by quickly turning the starter On and Off, the direction of rotation can be checked. This tip is particularly useful when you are starting compressor after very long period or after the motor had been disconnected electrically.

Check for the integrity of the receiver tank and ensure that it is securely bolted to the ground.

Open the bleed at the receiver tanker and bleed off the moisture in the tank and close it thereafter.

Check that the pressure gauge is clean and within calibration.

Check the pressure switch or safety shut down switch. It should be in normal working condition.

Drain condensate from moisture traps/separators by opening their bleed valves manually on the discharge line to avoid sending moist air in the instrumentation line which may damage the equipment.

Check the integrity of the discharge hose and ensure that hose whips are intact.

Ensure that the discharge valve is closed.

Ensure that there are no “Do not operate” tags on the breaker for the Compressor. Turn

the circuit breaker on in preparation for start up.

http://www.glossary.oilfield.slb.com/Display.cfm?Term=pressure


CHECKS MADE ON PUMPS AND TANKS

A centrifugal pump is typically used in plumbing to propel liquids in the pipes. The pump

utilizes impellers which raises the pipe pressure to move the liquid. Such pumps can be used in

homes and in industries to move the liquids from one place to another.

Starting the pump involves performing the following checks before the pumps are put into

service:-

Check and ensure that the supply tanks are at operating levels and pumps are clean and

surrounding house keeping is good.

Ensure that discharge and suction valves are open.

Check that the pressure gauges are clean and clear and have a zero reading.

Check the diaphragm and the electric motor.

Check and ensure that the pumps are securely bolted and are in good working condition.

Check to make sure the centrifugal pumps are connected to a reliable electrical power

source before attempting to start it. Such pumps typically use an insulated, water-proof

cable to connect to the power source. Make sure the cable is securely plugged in.

CHECKS ON A CHRISTMAS TREE

This is an assembly of valves, spools, pressure gauges and chokes fitted to the wellhead of a

completed well to control production.

It often provides numerous additional functions including chemical injection points, well

intervention means, pressure and temperature gauges, corrosion coupons, sand detector, flowline

choke, Flow line pilots and transmitters and connection points for devices such as down hole

pressure transducers (DHPT)and temperature thermocouples.


The following are the checks made on a Christmas tree;

Ensure that all valves are in good working conditions and if necessary grease can be injected to improve performance.

Ensure that the master valve is open.

Ensure that the SSV and wing valve are closed and the quick exhaust is functional.

Check that the swab valve is closed.

The pressure gauge must be clean and visible with a zero reading and of a range that is larger than the Shut In Tubing Pressure of the well.

The adjustable choke must also be in closed position with 0/64th or 0% reading.

Ensure that the instrument lines connecting to the pilots are intact and pilots are not isolated.

Check all instrument and flow line and fittings for leaks.

CHECKS ON THE THREE PHASE SEPARATOR

A three phase separator is a vessel that separates the well fluids into gas and two types of liquids:

oil and water. This type of separator is commonly called a free-water knockout separator because

its main use is to remove any free water that can cause problems such as corrosion and formation

of hydrates or tight emulsions, which are difficult to break.

The liquids (oil, water) leave the vessel at the bottom through different valves, and the gas leaves

the vessel at the top, passing through a mist extractor to remove the small liquid droplets in the

gas.

The following are some of the checks made on a pressure vessel or three-phase separator;

Ensure that the vessel is clean and free from oil spills.


Ensure that the isolating valve before the rupture disc (PSE) and the relief valve (PSV)

are car sealed opened.

Check and ensure there are no leaks in the instrument line.

Ensure all pressure gauges are clean and visible.

Ensure that both the oil and water level controllers are functional.

Ensure that the pressure controller and the pressure control valve are functional.

Check for the response of the oil and water level control valve to signals from the

controller.

Ensure that the level glass is clean and indicating normal water and oil levels

Ensure that all bleed valves around the vessel are closed.

Check and ensure that the blow down valve is open and that the ball valve upstream of it

is open.

PRESSURE TESTING AND PURGING THE SYSTEM

Where necessary, pressure test and purge the system.

Vessels are pressure tested to 1.5 times the Max allowable working pressure of the vessel while

pipelines are tested to 1.25 times the maximum Operating Pressure of the pipeline.

Purging involves pumping nitrogen into the system to displace all oxygen that could combine

with the hydrocarbon to form an explosive mixture..

CHECKS ON THE CONTROL PANEL

A control panel is a user interface to the integrated system where the operator is able to observe

and take note of the various parameters in different parts of the plant, make any necessary and

possible adjustments and start stop and tune the system.


The following are the possible checks that can be made to the KSPT Simulator Control Panel

prior to the start of the system.

Ensure that the panel casing is clean and free from oil spills and all pressure gauges are

clear and visible

Check the integrity of the alarm system and gas detection system

Ensure that hydraulic oil level is ¾ full.

SYSTEM START UP

Starting up the system involves turning on the various equipment that make up a system in a

chronological order beginning with the electric generator followed by the compressor, control

panel and then Christmas tree. These are explained in details as follows;

PROCEDURE STARTING UP A GENERATOR

After performing the necessary checks and the generator is found in a good state, it can then be

started following the procedures started below;

Turn off all electrical loads by opening the main circuit breaker on the generator control panel as well as individual breakers to major components such as motor driven pumps, air compressors, air condition units etc.

Start the generator prime-mover.

Bring the generator up to its rated speed as stated on the name plate by adjusting the governor-motor speed control.

At no load condition set the voltage adjusting rheostat to 480 volts.

Turn on the electrical loads by firstly closing the main circuit breaker on the operating unit and then gradually increasing the load to the generator by closing the breakers to the individual components.

With the breaker for the compressor and pumps energized these units can now be turned on

PROCEDURE STARTING UP A COMPRESSOR

Starting the compressor involves undertaking the following procedures


Turn on the power switch of the Air Compressor

Ensure the oil level is at mid point in the sight glass.

Open the compressor discharge valve.

Check discharge pressure. Compressor cycle range is 100psi cut in or load – 150psi cut out or unload.

Guards should be in place and all belts should be properly tensioned

Compressor motor should be cool enough to touch and there should be no unusual sound or vibration.

While the compressor is running, check for leaks throughout the instrument line. If any leak is found, rectify immediately.

Open the instrument supply line and ensure controllers on the separator are fully functional.

Open the air supply to pressurize the three phase Separator.

Open the instrument air supply to the Well Control panel.

Push to reset the Well Control Panel; this causes the three way valve on the 1/2 inch air supply line to the separator to switch routing pressurizing air to the separator.

PROCEDURE STARTING UP THE CENTRIFUGAL PUMPS

Turn on the circuit breakers to both pumps.

Open the suction (Produce oil, Produce water and reservoir tanks) and discharge valves

for each pump.

Start the transfer pump and then the feed pump by flicking on their power switches. The

pump motors will begin to spin, and it will build up pressure within the pump in order to

move the liquids in the pipes.

Prime the pumps by keeping the discharge valves closed and make sure that there is no

entrapped air.

Listen to unusual sounds from the pumps and rectify them where necessary.


Check the temperature of the electric motors and vibrations. These should be within the

recommended range.

Check for leaks on fittings and seal them.

Check the pump discharge pressure gauge reading. Pump cuts in at 30psi and cuts out at

50psi.

The following must be observed while operating a pump;

Throttling must not be done with the suction valve.

Never shut off the pump with the suction valve.

Monitor tank levels to prevent pumps running dry.

Never run the pump against a closed pressure valve.

The pump motor unit must run vibration free and must not be too hot to touch.

Temperature of roller bearings must not exceed tolerated limit.

OPENING THE WELL

Establish the ESD pressure to protect the entire platform should anything go wrong. This is done

by pushing the Push to reset button. Without the ESD pressure, the horn is activated until ESD

pressure is established by pushing the push to reset button.

Once the valve on the air supply line to the well control panel is opened the air

Compressor establishes panel supply, and panel operating pressure. ESD pressure is

established by pressing the ‘Push to Reset’ button to energise the system.

Before opening the SCSSV switch the hydraulic supply from the Primary manifold to the Start-up manifold to facilitate the opening of the SCSSV.

Open the wing valve, Swab, SSV, and lower master valve. It would be necessary to “Pin” the SSV in the open position since the pressure pilot on the flowline are isolated to prevent over-pressurizing.

Equalize the pressure across the closed SCSSV by filling the tubing with water or diesel to displace all gas from the tubing through the open bleed on the Crown of the Xmas tree.. When the tubing is filled (as seen by water overflowing through the bleed on the crown) connect a high pressure pump and build the tubing pressure until tubing pressure rises no more.


Apply hydraulic pressure approx. 3000psi using the Start up pump to open the SCSSV.

The SCSSV is now open.

Open the valve on the header to the separator.

Set the choke at 5% and slowly open the wing valve to the full open position

Slowly start opening the choke to the required flow rate.

Thus following the above procedures, the KSPT simulator can be brought into service. However

there could be some shortfalls resulting from human error or failure to abide by the stated

procedures which may result into workplace risks as discussed below.

START-UP RISKS

Critical situations in this process industry are those that have potential to cause damage to plant,

equipment and death or injury to personnel. The risks that are most likely to happen in the

simulator include;

Piping and vessel bursting due to overpressure

Over pressure of downstream vessels due to loss of liquid level in the separator

Liquid over flow due to high level in the Separator

Liquid overflow of the Produced water and Produced oil tank.

Therefore before starting the plant it is vital to familiarize with the response procedure for in the

event of the above happening.

In case of a pipe bursting, it is recommended that you block the two adjust valves to it so as to

isolate the area for maintenance. This same procedure can be used for liquid spillages as well.

Liquid levels and overpressure in the vessel can be controlled using the level and pressure

controllers respectively and synchronizing these with the production rate set at the choke and

pumps ratings.


CONCLUSION

Once all the necessary precautions mentioned are observed and adhered to, the KSPT Simulator,

a representation of an Oil and Gas Processing Plant upstream can be started and run efficiently

and effectively.

REFERENCES

1. Subrata K. Chakrabarti, Handbook of Offshore Engineering Volume I 2005

2. NORSOK Standard D-010, Well Integrity in Drilling & Well Operations, Rev 3, August

2004

3. Havard Devold, Oil and gas Production Handbook, Edition 1.3 Oslo, June 2006

4. Heinz P. Bloch, A Practical Guide to Compressor Technology 2nd Edition, Wiley-

Interscience, 2006

5. D. Berger & Kenneth E. Anderson, Modern Petroleum, Pennwell Publishing


ANNEX A: PHOTOS & CHECKLISTS OF SIMULATOR COMPONENTS

TYPICAL DIESEL GENERATOR

TYPICAL AIR COMPRESSOR


TYPICAL CENTRIFUGAL PUMP

TYPICAL CHRISTMAS TREE


TYPICAL 3-PHASE SEPARATOR

TYPICAL WELL CONTROL PANEL


TYPICAL FLOW DIAGRAM

Generator ChecklistMachine No DateMake & model Time Last service Date Hours on Unit

Generator Position OFF ON AUTO

Description State Comments Daily CheckLUBRICATING SYSTEM

Engine Oil ViscosityOil levelOil FilterOil Leaks

FUEL SYSTEM Fuel LevelFuel FilterSediment from TanksFuel Leaks

EXHAUST SYSTEM FlexExhaust Manifold

COOLING SYSTEM Coolant LevelAIR INTAKE SYSTEM Air Filter ElementELECTRICAL SYSTEM

Condition of BatterySpark plugs

Operator’s Signature Name Date

Instructor’s Signature Name DateState of use Yes/No Comments

Air Compressor ChecklistMachine no Date

Make & model Time

Description State Comments

Daily Check

1 Compressor Integrity

2 Oil level

3 Air Filter

4 Pressure Gauge

5 Moisture Traps

6 Pulley and Pulley Belt

7 hose

8 Hose whips

9 Bleed on receiver tank

10 Discharge valve

11 Power switch & circuit breaker


Instructor’s Signature Name Date

State of use Yes/No Comments

Pump ChecklistMachine no Date

Make & model Time


Daily Check

1 Compressor Integrity

2 Position of Suction Valve

Discharge valve

Power switch

Circuit Breaker

3 Pressure Gauge

4 Pressure Switch

5 Accumulator

6 Electric Connections




Christmas Tree ChecklistMachine no Date

Make & model Time


Daily Check

1 Christmas Tree Integrity

2 Position of Master Valve

Surface Safety Valve

Swab Valve

Wing Valve

3 Adjustable Choke

4 Pressure Gauge Reading

5 Bleed Valve at Pressure Indicator

6 Quick Exhaust

7 Instrument Lines




3 Phase Separator ChecklistMachine no Date

Make & model Time


Daily Check

1 Valve Positions Blow Down Valve Open Closed

Shut Down Valve Open Closed

Bleed off Valve Open Closed

Pressure Control Valve %

Oil level Control Valve %

Water Level Control %

2 Safety Valves Pressure Safety Element I/S O/S

Pressure Relief Valve I/S O/S

3 Gauge Readings

(psi)

Pressure Control Gauge IN OUT

Oil Level Control IN OUT

Water Level Control IN OUT

4 Level Glass Readings Glass Blots




Control Panel ChecklistMachine no Date

Make & model Time

Description State/Value Comments

Daily Check

1 Gauge Readings

(psi)

Panel Supply Pressure

Panel Operating Pressure

ESD Pressure

Control Signal Pressure

Blow Down Valve Pressure

Shutdown Valve Pressure

Startup Hydraulic Header Pressure

SCSSV holding pressure

SSV holding pressure

PSL Upstream of Choke

PSH Downstream of Choke

PSL Downstream of Choke

2 Integrity of Alarm System

Emergency Shutdown System

Pressure Equalizers

3 Positions of Pull and Push to Open SSV

4 Hydraulic Oil Levels




Control Panel Checklist

starting the simulator

Documents

gas process technician

instructors signature state

main circuit breaker

model date time

instrument line

christmas tree

control panel

operators signature