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IN AMENAS PROJECT

ALGERIA

START-UP PROCEDURE
SLUG CATCHER AND TRAIN 1

C02 30/11/04 Issue for IFC L.Pereira E.Faulkner B.Anderson

R01 28/10/04 Issue for ICR L.Pereira E.Faulkner B.Anderson

Reason for JK Project IAP OPS


Rev. Date Prepared By Checked By
Issue Approval Approval

Distribution JK
Document System Sequential French
Matrix Project Discipline Zone Rev.
Type No. No. Trans.
Codes No.

6877 AP VA 99 00 28211 C02


Start-Up Procedure System No: 00

TABLE OF CONTENTS

1.0 SCOPE

2.0 REFERENCE DOCUMENTS.

3.0 HEALTH SAFETY AND ENVIRONMENTAL CONDITIONS

4.0 START-UP SYNOPSIS.

5.0 PROCEDURE

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Start-Up Procedure System No: 00

CAUTION: The procedures contained in this document are provided for guidance to help ensure
a safe and orderly start-up. They are not intended as a substitute for thought, experience or hard
work. Detailed review of all procedures must be carried out prior to use to ensure their
applicability given the circumstances and conditions pertaining at the time.

1.0 SCOPE

This procedure provides a logical and safe sequence for the commissioning of the
instruments, pressure safety valves and blind list. The scope of the procedure is limited to
the activities for commissioning of the components of Train 1 system and associated piping
connected to the same.

The following plant status is assumed:

• Pre-commissioning tasks have been completed


• All utilities are available and fully operational (power, instrument air).

2.0 REFERENCE DOCUMENTS

P&ID No. Rev. Title

DC-PS-00-05-21100 C08 Tiguentourine CPF Inlet Manifold (Trunk lines M2-M3)

DC-PS-00-05-21101 C08 Tiguentourine CPF Inlet Manifold (Trunk lines M1-M4)

DC-PS-00-05-21102 C07 Slug Catcher Side A

DC-PS-00-05-21103 C07 Inlet Gas and Liquid Piping

DC-PS-00-05-21104 C07 Inlet Water Piping

DC-PS-00-05-21105 C02 Slug Catcher Side B

DC-PS-01-10-21107 C07 Train 1 Inlet Gas Cooling

DC-PS-01-10-21108 C08 Train 1 Inlet Gas / Condensate Separation

DC-PS-01-11-21131 C06 Train 1 H2S and Mercury Gas Absorbers

DC-PS-01-11-21112 C05 Train 1 Gas H2S Absorber After Filters

DC-PS-01-10-21109 C07 Train 1 Inlet Gas Exchangers

DC-PS-01-10-21110 C07 Train 1 Dehydration Feed Separation

DC-PS-01-10-21111 C08 Train 1 Dehydration Feed Filtration

DC-PS-01-12-21132 C07 Train 1 Molecular Sieve Dehydration

DC-PS-01-12-21133 C07 Train 1 Dehydration Dust Filters

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Start-Up Procedure System No: 00

P&ID No. Rev. Title

DC-PS-01-12-21134 C07 Train 1 Regeneration Gas Compression and Heating

DC-PS-01-12-21135 C07 Train 1 Regeneration Gas Cooling and Scrubbing

PMJ04-0701 003 Train 1 Sundyne Regeneration Gas Compressor 01-C-121A

PMJ04-0702 003 Train 1 Sundyne Regeneration Gas Compressor 01-C-121B

DC-PS-01-14-21138 C07 Train 1 Dry Gas Exchangers

DC-PS-01-14-21139 C07 Train 1 Expander Inlet Separator

DC-PS-01-14-21140 C08 Train 1 Expander / Compressor

DC-PS-01-14-21141 C07 Train 1 Expander / Compressor Auxiliaries

DC-PS-01-15-21144 C08 Train 1 Deethaniser

PMJ05-0711 004 Expander / Compressor 3 units

PMJ05-0712 004 Instrumentation and Control System P&ID

DC-PS-01-21-21165 C07 Train 1 Inlet Condensate Pre-Flash Separator

DC-PS-01-21-21166 C08 Train 1 Inlet Liquid Filtration

DC-PS-01-21-21167 C07 Train 1 Inlet Liquid Coalescing

DC-PS-01-22-21170 C08 Train 1 Condensate Stabiliser Feed Pre-Heating

DC-PS-01-22-21171 C08 Train 1 Condensate Stabiliser

DC-PS-01-22-21172 C08 Train 1 Condensate Stabiliser Reboiler

DC-PS-01-23-21174 C07 Train 1 Product Splitter Feed Pre-Heating System

DC-PS-01-23-21175 C07 Train 1 Product Splitter

DC-PS-01-23-21176 C07 Train 1 Product Splitter Reflux System

DC-PS-01-23-21177 C07 Train 1 Product Splitter Cooling System


st
DC-PS-01-26-21180 C07 Train 1 1 Stage VRU Compressor
st
DC-PS-01-26-21181 C07 Train 1 VRU Compressor 1 Stage After Cooler
nd
DC-PS-01-26-21182 C07 Train 1 2 Stage VRU Compressor
st
DC-PS-01-26-21183 C07 Train 1 VRU Compressor 1 Stage After Cooler

DC-PS-01-26-21184 C03 Train 1 VRU Compressor Auxiliaries

PMJ03-0949 005 P&I Diagram - Key

PMJ04-0691 005 P&I Diagram - Process

PMJ04-0692 005 P&I Diagram – Oil Service

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Start-Up Procedure System No: 00

P&ID No. Rev. Title

PMJ04-0693 005 P&I Diagram – Cyl Pkg Cooling Water

PMJ04-0694 005 P&I Diagram – Tempered Water

PMJ04-0695 005 P&I Diagram – Purge, Vents, Drains and Air

PMJ04-0696 005 P&I Diagram – Condition Monitoring

DC-PS-01-28-21186 C07 Train 1 Produced Water Flash Drum

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Start-Up Procedure System No: 00

3.0 HEALTH, SAFETY AND ENVIRONMENTAL CONSIDERATIONS

The objective of this procedure is a SAFE start-up.

No task is too urgent to be done safely. If at any moment during the execution of this procedure
an unsafe situation develops then the procedure must be halted and the plant made safe, and the
start-up not resumed until the problem has been resolved.

DON’T FORGET THAT SAFETY IS OUR PRIORITY!

3.1 Personal Protective Equipment required for this procedure follows:

- Protective Headgear.
- Eye Protection Face Shield.
- Protective Gloves.
- Safety Footwear.
- Ear Protection.
- Protective clothing (suitable for chemicals).

4.0 START-UP SYNOPSIS

This section lists the major steps to be completed to start-up Train 1.

- Pre-Start-Checks.
- Reset the Shut Down System.
- Align the CO2 treatment unit main inlet and outlet block valves.
- Preparation to introduce gas from export pipeline.
- Introduce Export Gas to Train 1.
- Start Regeneration of Dehydrators.
- Set flow control to CO2 Absorber in AUTO mode.
- Start-up of Residue Gas Compressor.
- Forward flow from the discharge of the Residue Gas Compressor to metering station
and to plant recycle.
- Pressurize the slug catcher from the trunk lines.
- Reduce Plant Recycle flow to Train 1.
- Place the Inlet Gas Cooler 01-E-101 in service.
- Place the Inlet Gas Coolers 01-E-102/01-E-103A/B temperature controllers in AUTO
mode.
- Start-up of Expander / Compressor.
- Place the Expander / Compressor After cooler 01-E-142 in service.
- Monitor and adjust Deethaniser pressure.
- Open trunk line Emergency Shut Down Valves and start flow to Train 1 at 50% feed
rates.
- Divert Residue Gas to Export Pipeline.
- Start-up and Stabilise Deethaniser.

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Start-Up Procedure System No: 00

- Forward liquid flow from Slug Catcher.


- Forward liquid flows from Inlet Gas Condensate Separator.
- Forward liquid flows from Dehydration Feed Separator.
- Forward liquid flow from Dehydration Feed Filter Separator.
- Forward liquid flow from Inlet Condensate Pre-Flash Separator.
- Establish produced water flow from Inlet Liquid Coalecer 01-V-213A to 01-V-281.
- Start-up and Stabilise Condensate Stabiliser.
- Start-up of Vapour Recovery Unit Compressor.
- Start-up, stabilise Product Splitter and divert LPG and Condensate product to
Storage.
- Place the Produced Water Flash Drum 01-V-281 in service.
- Increase feed rate to train at 100% rates.
- Place the Mercury Absorber in service.

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Start-Up Procedure System No: 00

5.0 PROCEDURE

Step Notes Initials

A. Pre-Start Checks

1. Ensure that all instruments and Pressure Safety Valves Procedure No:
are placed in service before the introduction of 99-00-28210
hydrocarbons into the system.

2. Ensure that the blind list has been completed and checked Procedure No:
99-00-28210

3. Ensure that all the control valves are closed as mentioned Procedure No:
in the check list 99-00-28210

4. Before introduction of hydrocarbon ensure that Train 1 is Procedure No:


free from oxygen and is below 5 mole%. 99-00-28210
Note: Hydrocarbons must not be introduced into the
system if the system contains greater than 5.0 mole %
oxygen. Purge the system with nitrogen to reduce the
oxygen content to less than 5.0 mole %.

5. Place the block valves in Train 1 as mentioned in Procedure No:


checklist. 99-00-28210
Warning: Before introducing hydrocarbon fluids into
the system, all drain valves, to the closed drain
system must be shut.

6. Ensure that the Utility air, instrument air and nitrogen to Procedure No:
Train 1 are commissioned. 01-50-28202

7. Ensure that the Closed and Open Drain Headers to Train Procedure No:
1 are commissioned. 01-56-28203

8. Ensure that the HP Flare header, Cold HP header and the Procedure No:
MP Vent header are in service for Train 1. 01-34-28204

9. Verify that the Hot Oil Inlet and outlet headers to Train 1 Procedure No:
are commissioned. 01-32-282050

B Start-Up Procedure

1. Reset the Shut Down System as follows:


• Board Operator rests the CCR common logic reset
99-HS-0004 in the CMS.
• Outside operator resets (Fire Area 110) 01-HS-0013
located near inlet gas from slug catcher emergency

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Start-Up Procedure System No: 00

Step Notes Initials


shut down valve 01-ESDV-1000.
• Verify that the Gas inlet to Train 1 Emergency Shut
Down valve 01-ESDV-1000 and its bypass 01-ESDV-
1068 are closed.
• Reset and close Blow Down Valve 01-BDV-1062 on
gas outlet from 01-V-103 to HP Flare header.
Outside operator resets blow down valve 01-BDV-
1062 using local hand switch 01-HS-1062A.
Board Operator closes 01-BDV-1062 using 01-
HS-1062 from the CMS.
Outside operator ensures that 01-BDV-1062 is
closed.
Board Operator to confirm by indication of closed
limit switch 01-ZLC-1062 in CMS.
• Open Emergency Shut Down Valve 01-ESDV-1003
on gas outlet from 01-V-103 to 01-V-121A/B/C.
Board Operator closes 01-ESDV-1003 using 01-
HS-1003 from the CMS.
Board Operator to confirm by indication of opened
limit switch 01-ZLO-1003 in CMS.
• Reset and close Blow Down Valve 01-BDV-1412 on
gas outlet from 01-V-141 to HP Flare header.
Outside operator resets blow down valve 01-BDV-
1412 using local hand switch 01-HS-1412A.
Board Operator closes 01-BDV-1412 using 01-
HS-1412 from the CMS.
Outside operator ensures that 01-BDV-1412 is
closed.
Board Operator to confirm by indication of closed
limit switch 01-ZLC-1412 in CMS.
• Reset and close Blow Down Valve 01-BDV-1493 on
discharge of 01-C-141 to HP Flare header.
Outside operator resets blow down valve 01-
BDV-1493 using local hand switch 01-HS-1493A.
Board Operator closes 01-BDV-1493 using 01-
HS-1493 from the CMS.
Outside operator ensures that 01-BDV-1493 is
closed.

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Start-Up Procedure System No: 00

Step Notes Initials


Board Operator to confirm by indication of closed
limit switch 01-ZLC-1493 in CMS.
• Reset and close Blow Down Valve 01-BDV-1532 on
gas outlet from 01-V-151 to Cold HP Flare header.
Outside operator resets blow down valve 01-
BDV-1532 using local hand switch 01-HS-1532A.
Board Operator closes 01-BDV-1532 using 01-
HS-1532 from the CMS.
Outside operator ensures that 01-BDV-1532 is
closed.
Board Operator to confirm by indication of closed
limit switch 01-ZLC-1532 in CMS.
• Reset and close Blow Down Valve 01-BDV-2273 on
overhead of 01-V-221 to HP Flare header.
Outside operator resets blow down valve 01-
BDV-2273 using local hand switch 01-HS-2273A.
Board Operator closes 01-BDV-2273 using 01-
HS-2273 from the CMS.
Outside operator ensures that 01-BDV-2273 is
closed.
Board Operator to confirm by indication of closed
limit switch 01-ZLC-2273 in CMS.
• Reset and close Blow Down Valve 01-BDV-2375 on
overhead of 01-V-232 to Cold HP Flare header.
Outside operator resets blow down valve 01-
BDV-2375 using local hand switch 01-HS-2375A.
Board Operator closes 01-BDV-2375 using 01-
HS-2375 from the CMS.
Outside operator ensures that 01-BDV-2375 is
closed.
Board Operator to confirm by indication of closed
limit switch 01-ZLC-2375 in CMS.
• Reset and close Blow Down Valve 01-BDV-2620 on
overhead of 01-V-211 to HP Flare header.
Outside operator resets blow down valve 01-
BDV-2620 using local hand switch 01-HS-2620A.
Board Operator closes 01-BDV-2620 using 01-
HS-2620 from the CMS.

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Start-Up Procedure System No: 00

Step Notes Initials


Outside operator ensures that 01-BDV-2620 is
closed.
Board Operator to confirm by indication of closed
limit switch 01-ZLC-2620 in CMS.

2. Align the CO2 treatment unit main inlet and outlet block
valves as follows:
Outside operator :
• Verify that the block valves on the inlet 108-V-53 and
108-V-51 of the CO2 Removal unit are closed.
• Verify that the bypass valves 108-V-75 and 108-V-76
across 108-V-53 are closed.
• Open the outlet block valves 108-V-54 and 108-V-55
from the CO2 Absorber unit.

3. Preparation to introduce gas from export pipeline:


• Outside operator verifies that the bypass valves 158-
V-69 and 158-V-60 across 00-ESDV-1649 are
closed.
• Place the Residue Gas Metering in service as per the
start-up procedure.
• Reset and close Blow Down Valve 00-BDV-1673.
Outside operator resets blow down valve 00-
BDV-1673 using local hand switch 00-HS-1673A.
Board Operator closes 01-BDV-1673 using 01-
HS-1673 from the CMS.
Outside operator ensures that 01-BDV-1673 is
closed.
Board Operator to confirm by indication of closed
limit switch 01-ZLC-1673 in CMS.
• Open Emergency Shut Down Valve 01-ESDV-1226.
Board Operator closes 01-ESDV-1226 using 01-
HS-1226 from the CMS.
Board Operator to confirm by indication of opened
limit switch 01-ZLO-1226 in CMS.
• Outside operator verifies
Block valves 159-V-54 upstream of 01-ESDV-
1226 at battery limit are opened.

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Start-Up Procedure System No: 00

Step Notes Initials


Block valves 159-V-52 and 159-V-50 upstream of
01-PV-1225 are opened.
Block valve 159-V-38 downstream of 01-PV-1225
is opened.
Close inlet butterfly valve 131-V-14 to the Mercury
Absorber.
• Board Operator
Open 00-PV-1648 in MAN mode using 00-PIC-
1648 in MAN mode with an OP of 100%.
Close 01-PV-1225 in MAN mode using 01-PIC-
1225 with an OP of 0%.
Close 01-FV-1420 in MAN mode using 01-FIC-
1420 with an OP of 0%.
Close 01-FV-1010 in MAN mode using 01-FIC-
1010 in MAN mode with an OP of 0%.
Place the “Pressure / Flow Option “hand switch
01-HS-1447 on the Expander / Compressor to
“Pressure “option.
Using hand switch “Pressure Option SP” 01-HIC-
1448 on the Expander / Compressor set the
pressure on the Deethaniser at 27.0 barg.
Place the pressure controller 01-PIC-1422 on
discharge of the Expander to Compressor to HP
Flare at 26.0 barg.

4. Introduce Export Gas to Train 1 as follows:


• Inform STC control room about the consumption of
residue gas from export pipeline.
• Outside operator opens bypass block valves 158-V-
60 and 158-V-69 slowly to pressure the pipeline until
the export supply pressure and the pressure on the
plant recycle up to 01-FV-1420 are equal.
• Board Operator to monitor pressure on 01-PIC-1648.
• Board Operator to slowly open flow controller 01-FIC-
1420 in MAN mode with OP increments of 2% to
introduce gas into Train 1 up to 01-FV-1010.
• Board Operator to monitor pressure rise in H2S
Absorber and Mercury Absorber and adjust the
i i 01 FIC 1420

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Start-Up Procedure System No: 00

Step Notes Initials


pressure rise using 01-FIC-1420.
Note: Pressurize the H2S Absorber and Mercury
Absorber at rates not greater than 1 bar per minute
below 10 barg and 10 bar per minute above 10 barg.
• Monitor pressure on 01-PI-1079 until no rise in
pressure is observed. When pressure rise is not
observed then close 01-FIC-1420 in MAN mode with
an OP of 0%.
Board Operator:
• Opens hand valve 01-HV-1015 using 01-HIC-1015
from CMS.
• Place temperature controller 01-TIC-1032 in AUTO
mode with a SP of 39.4ºC.
• Place temperature controller 01-TIC-1034 in AUTO
mode with a SP of 52.0ºC.
• Place the “SEQ-AUTO/MAN” switch in MAN mode,
on the graphics of the Dehydrators in the CMS.
• Open the Adsorption inlet and outlet switching valves
01-KV-1208 and 01-KV-1219 for 01-V-121A from
CMS and confirm opening as indicated by limit switch
indication.
• Open the Adsorption inlet and outlet switching valves
01-KV-1205 and 01-KV-1221 for 01-V-121B from
CMS and confirm opening as indicated by limit switch
indication.
• Open the Adsorption inlet and outlet switching valves
01-KV-1202 and 01-KV-1223 for 01-V-121C from
CMS and confirm opening as indicated by limit switch
indication.
• Open the Regeneration inlet and outlet switching
valves 01-KV-1208 and 01-KV-1218 for 01-V-121A
from CMS and confirm opening as indicated by limit
switch indication.
• Opens the Shut Down Valve 01-SDV-1211 using
hand switch 01-HS-1211 from the CMS.
Outside operator:
• Open bypass valves 108-V-76 and 108-V-75 to
pressurize the CO2 Absorber unit and downstream
equipments up to discharge of Expander /

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Start-Up Procedure System No: 00

Step Notes Initials


Compressor.
• Board Operator
Will need to open the plant recycle flow controller
01-FIC-1420 to compromise for the drop in
pressure.
When no rise in pressure is observed in the train,
close flow controller 01-FIC-1420.
Observe opening of 01-PIC-1422 and allow
flaring for sometime until all nitrogen from the
system is displaced.

5. Start Regeneration of the Dehydrators:


Board Operator:
• Close the Adsorption inlet and outlet switching valves
01-KV-1208 and 01-KV-1219 for 01-V-121A from
CMS and confirm opening as indicated by limit switch
indication.
• Select “3 MODE” operation on the graphics of the
Dehydrators in the CMS.
• Select “V-121A REGN” on the graphics of
Dehydrators.
• Verify that the Regeneration inlet and outlet switching
valve switching valves 01-KV-1218 and 01-KV-1209
for 01-V-121A, are open.
• Verify that the Shut Down Valve 01-SDV-1207
located on the gas from residue gas export pipeline is
closed. Confirm close position as indicated in limit
switch indication provided in the CMS.
• Verify switching valve 01-KV-1231 located on the
tube side bypass of 01-E-121 is in open position.
Confirm open position as indicated in limit switch
indication provided in the CMS.
• Verify switching valve 01-KV-1232 located on the
tube side inlet of 01-E-121 is in closed position.
Confirm close position as indicated in limit switch
indication provided in the CMS.
Note: At the start of the Heating cycle, 01-ZLO-1232
must be confirmed as present before the sequence
generates the command to close 01-KV-1231.

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Start-Up Procedure System No: 00

Step Notes Initials


Note: At the start of the Cool down cycle, 01-ZLO-1231
must be confirmed as present before the sequence
generates the command to close 01-KV-1232.
• Verify that Shut Down Valve 01-SDV-1207 located on
the gas from residue gas export pipeline is closed.
Confirm close position as indicated in limit switch
indication 01-ZLC-1207 provided in the CMS.
Note: Loss of Running Status of the Compressor
when 01-ZLC-1207 is present puts the regeneration
heating cycle timer on hold.
• Place the flow controller 01-FIC-1255, on the
discharge of the Regeneration Gas Compressor is in
MAN mode with an OP of 60%.
Note: Prior to start-up of the Compressor the output
of 01-FIC-1255 is forced to 40% open. When the motor
is started the controller is reverted to AUTO mode
after 10 seconds.
• Verify that “READY TO START REGENERATION
COMP A” indication on the CMS is available on the
graphic of the Dehydrators.
Outside Operator:
• Start Regeneration Gas Compressor as per the Procedure No:
procedure with co-ordination with Board Operator.
01-12-28212
Note: During the start-up of the Regeneration Gas
Compressor it would be necessary to open the plant
recycle flow controller 01-FIC-1420 to compensate for
the pressure drop across the train.
Board Operator:
• Verify that the flow controller 01-FIC-1255 in AUTO
3
mode with a SP of 1225 Sm /d.
• Place the Regeneration Gas Cooler 01-E-122 in
service:
Board Operator to close the damper 01-HIC-1210
located on the Regeneration Gas Cooler 01-E-
121, from the CMS with an OP of 10%.
Outside operator to start the Fin Fan Motor using
the start/stop push button located near 01-E-122.
Check for any abnormalities like excessive
vibrations, etc.

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Start-Up Procedure System No: 00

Step Notes Initials


Note: Initial start-up of the fin fan motor is to be done
from the field. Later on the operator can start/stop the
fin fan motor of 01-E-122 from the CMS using
start/stop hand switches 01-HS-1239A and 01-HS-
1239B located in the CMS.
Board Operator
To confirm “Run” status as indicated by 01-YI-
1239A/B in CMS.
Opens the damper using 01-HIC-1210 with
increments of 5% until the damper is 100% open.
Place the temperature controller 01-TIC-1237
located on the outlet of 01-E-122 in AUTO mode
with a SP of 56.0ºC.
• Place the Regeneration Gas Heater 01-E-121 in
service:
Outside operator:
Ensure that the tubes side of 01-E-121 contains
no free water by opening 134-V-35 and 134-V-36
and then close 134-V-35 and 134-V-36.
Caution: Failure of removal of water from the system
will lead to steam formation in the Heater coil leading
to fluid hammer, displacement of hot oil into the flare
header and possible mechanical damage to piping
and pumps.
Verifies that the Hot Oil supply header and return
headers for train 1 are commissioned.
st nd
Opens the 1 inlet block 134-V-43 and the 2
inlet block valve 134-V-42 slowly to fill and
pressurize the heater with hot oil.
st
Opens the 1 outlet block valve 134-V-32 and the
nd
2 outlet block valve 134-V-33 from 01-E-121.
Board Operator
Places the temperature controller 01-TIC-1258
on MAN mode and opens it with OP increments
of 2%.
Monitor the level on the Hot Oil Expansion Vessel
and the hot oil system, while conducting the
above step.
Place Regeneration Gas Heater, temperature

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Start-Up Procedure System No: 00

Step Notes Initials


controller 01-TIC-1258 is in AUTO mode with a
SP of 260ºC on the graphic of the Dehydrator.
Select “START SEQ” on the graphics of the
Dehydrators in the CMS. Now the regeneration of
the Dehydrators and the switching of the
Dehydrators are automatically controlled.
Note: The heating cycle for the a Dehydrator is
approximately 5 hours followed by cooling of 2 hours
and a stand-by period of 1 hour.
Monitor level on the Regeneration Gas Scrubber
01-V-121 and when the level is above the low low
level shut down of 01-LI-1225 of 7%, open Shut
Down Valve 01-SDV-1210, on the liquid outlet to
01-V-281, using 01-HS-1210 from the CMS.
Place the level controller on the Regeneration
Gas Scrubber, 01-LIC-1224 in AUTO mode with
a SP of 30%.
Note: When Regeneration of 01-V-121A is completed,
the PLC should automatically switch over to
regenerate 01-V-121B and then 01-V-121C.

6. Set Flow control to CO2 Absorber in AUTO mode:


Board Operator: Places the CO2 Absorber inlet flow
controller 01-FIC-1010 in AUTO mode with a SP of 6282
3 3
10 Sm /d.

7. Start-up of Residue Gas Compressor: Procedure No:


• Start Residue Gas Compressor 00-161-A as per
start-up procedure, using Export Gas.
Board Operator:
• After start-up of Residue Gas Compressor increase
the SP of pressure controller 01-PIC-1422 to 25.0
barg.

8. Forward flow from the discharge of the Residue Gas


Compressor to metering station and to Plant recycle:
Board Operator:
• Verify that the Blow Down Valve 00-BDV-1673 on the
inlet of the Residue Gas Fiscal metering station is
closed.

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Start-Up Procedure System No: 00

Step Notes Initials


• Verify that the Emergency Shut Down Valve 00-
ESDV-1649 located on the Residue Gas export at
CPF boundary limits is closed as indicated by 00-
ZLC-1649.
• Verify that the pressure controller 01-PIC-1225 on the
gas from export pipeline to the Regeneration Gas
Heater 01-E-121 is in MAN mode with an OP of 0%.
• Inform analyzer technician to place the dew point
analyzers 00-MT-1609 and 00-MT-1610 and the on
line analyzers 00-AT-1608A/B for H2S, CO2 and
Gross Heating value content on the inlet of the
residue gas fiscal metering station in service.
• Open RGC discharge Emergency Shut Down Valve
0A-ESDV-1646 using hand switch 0A-HS-1646 and
confirm opening as indicated by 0A-ZLO-1646.
• Adjust suction pressure of RGC using 0A-HIC-1630
to stabilise the common suction header pressure 00-
PT-1608A of the RGC to 23.0 barg.
Note: Now Train 1 is in operation with recycle gas
from the Residue Gas Compressor and no export gas
from the STC pipeline.

9. Pressurize the slug catcher from the trunk lines:


Board Operator:
• Verifies that trunk line M3 is pressurised and
indicated in the CMS on 00-PI-0501.
Note: This procedure assumes that trunk line M3 is
pressurised but in actual start-up any one of the four
trunk lines could be pressurised.
• Places the pressure controllers 00-PIC-0502A, 00-
PIC-0502B and 00-PIC-0502C in AUTO mode with a
SP of 82.0 barg, 85.0 barg and 88.0 barg
respectively.
• Reset and close Blow Down Valve 00-BDV-0500.
Field Operator resets blow down valve 00-BDV-
0500 using local hand switch 00-HS-0500A.
Board Operator closes 01-BDV-0500 using 01-
HS-0500 from the CMS.
Field Operator ensures that 01-BDV-0500 is

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Start-Up Procedure System No: 00

Step Notes Initials


closed.
Board Operator to confirm by indication of closed
limit switch 01-ZLC-0500 in CMS.
Field Operator
Verify the line-up as per the procedure.
Verify that the inlet butterfly valve 131-V-14 to the
Mercury Absorber I closed.
st
Open 1 bypass block valve 100-V-06 across 00-
ESDV- 0502.
nd
Open the 2 bypass globe valve 100-V-07 across
00-ESDV-0502 to slowly pressurise the slug
catcher.
Inform Board Operator Board Operator about the
pressurization.
Board Operator
Monitor the pressure on the gas outlet indicated
on 00-PIC-0502A/B and C.
Place the inlet train pressure controller 01-PIC-
1096 in AUTO mode with a SP of 71.3 barg.
• When the pressure is approximately 72.0 barg, at the
gas outlet from the Slug Catcher.
Field Operator
Verify that the battery limit block valve 107-V-02
on gas outlet from slug catcher to Train 1 is
opened.
Board Operator
Verify that the inlet Shut Down Valve 01-ESDV-
1000 is closed.
Opens 01-ESDV-1068 on the bypass of 01-
ESDV-1000 using 01-HS-1068 from the CMS.
Confirm open indication by limit switch 01-ZLO-
1068 in CMS.
Open hand valve 01-HV-1069 downstream of 01-
ESDV-1068 using 01-HIC-1069 with an OP of 2%
and slowly increase until the differential pressure
01-PDI-1067 across 01-ESDV-1000, is 1.0 barg.
Monitor pressure rise in H2S Absorber and
Mercury Absorber and adjust the pressure rise

Page 19 of 43
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Step Notes Initials


using 01-HIC-1069.
Note: Pressurize the H2S Absorber and Mercury
Absorber at rates not greater than 1 bar per minute
below 10 barg and 10 bar per minute above 10 barg.
Opens 01-ESDV-1000 on the inlet of Train 1 using
01-HS-1000 from the CMS.
Note: 01-ESDV-1000 can be opened only when the
differential pressure across the valve is ≤ 5.0 barg.
Confirm open indication by limit switch 01-ZLO-
1000 in CMS.
Close 01-HIC-1069 with an OP of 0%.
Close 01-ESDV-1068 using hand switch 01-HS-
1069 from the CMS.

10. Reduce plant recycle flow to Train 1:


Inside Operator:
• As gas feed to Train 1 is introduced, it will be
necessary to reduce plant recycle valve 01-FV-1420
using flow controller 01-FIC-1420 in MAN mode with
OP decrements of 2%.

11. Place the Inlet Gas Cooler 01-E-101 in service:


Field Operator
• Start fin fan motor using local start/stop push button.
Note: The Fin Fan motor can also be started from the
CMS using 01-HS-1005A/B, but first start-up to be
carried out using local start/stop push buttons.
• Checks for any abnormalities viz. excessive
vibrations and informs Board Operator.
Board Operator
• Confirm “Run” status as indicated by 01-YI-1005A/B.
• Place the temperature controller 01-TIC-1011, on the
outlet of 01-E-101 in AUTO mode with a SP of 56ºC.
• If the temperature on the inlet feed gas to Train is
25ºC
Board Operator stops Fin Fan motor of 01-E-101
using hand switch 01-HS-1005A/B.
Field Operator to open bypass block valve 107-V-

Page 20 of 43
Start-Up Procedure System No: 00

Step Notes Initials


18 across 01-E-101 and close inlet block valve
107-V-17 to 01-E-101.

12. Place the Inlet Gas Coolers temperature controllers in


AUTO mode:
Board Operator:
• Verify that temperature controller 01-TIC-1032 on the
tube side outlet of 01-E-102/ 01-E-103A/B is in AUTO
Mode with a SP of 39.4ºC.
• Verify that temperature controller 01-TIC-1034 on the
shell side outlet of 01-E-103A/B is in AUTO mode
with a SP of 52.0ºC.
• Informs analyzer technician to place the H2S analyzer
01-AI-1100 in service.
• Monitors the performance of the H2S Absorber 01-V-
1112 by checking H2S content on the outlet as
indicated by 01-AI-1100.

13. Start Expander / Compressor 01-C-141 and its auxiliaries Procedure No:
as per start-up procedure. 01-14-28213

14. Place the Expander / Compressor After cooler 01-E-142 in


service:
Field Operator
• Start fin fan motor using local start/stop push button.
Note: The Fin Fan motor can also be started from the
CMS using 01-HS-1442A/B, but first start-up to be
carried out using local start/stop push buttons.
• Checks for any abnormalities viz. excessive
vibrations and informs Board Operator.
Board Operator
• Confirm “Run” status as indicated by 01-YI-1442A/B.
• Place the temperature controller 01-TIC-1441, on the
outlet of 01-E-141 in AUTO mode with a SP of 56ºC.

15. Monitor and adjust Deethaniser pressure:


Board Operator:
• Monitors the temperatures across the Cold Gas
Exchanger 01-E-141.

Page 21 of 43
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Step Notes Initials


• Observes that the JT-Valve 01-PV-1420 closes and
the Expander IGV controls the Deethaniser pressure.
• Reduce the pressure SP of the Deethaniser using
“Pressure Option SP” 01-HIC-1448 from 27.0 barg to
17.3 barg.
• Monitor the CO2 content on the outlet of CO2
Absorber unit as indicated by analyzer 01-AI-1000.

16. Open trunk line Emergency Shut Down Valves and start
flow to Train 1 at 50% feed rates:
• Open trunk line ESDV’s and increase feed to 50% of
3
design (approximately 4704.0 10 Sm3/d):
Board Operator:
• Ensures differential pressure 00-PDI-0538, 00-PDI-
0539, 00-PDI-0540 or 00-PDI-0541 is less than 1.0
barg across 00-ESDV-0502, 00-ESDV-0505, 00-
ESDV-0508 or 00-ESDV-0517 (depending on which
trunk line is in service).
Note: 00-ESDV-0502, 00-ESDV-0505, 00-ESDV-0508 or
00-ESDV-0517 can be opened only when the
differential pressure across the valve is ≤ 5.0 barg.
• Reset and open Emergency Shut Down Valve 00-
ESDV-0502 on trunk line M3.
Field Operator resets Emergency Shut Down
valve 00-ESDV-0502 using local hand switch 00-
HS-0502A.
Board Operator opens 00-ESDV-0502 using 00-
HS-0502 from the CMS.
Field Operator ensures that 00-ESDV-0502 is
opened.
Board Operator to confirm by indication of opened
limit switch 00-ZLO-0502 in CMS.
• Reset and open Emergency Shut Down Valve 00-
ESDV-0505 on trunk line M2.
Field Operator resets Emergency Shut Down
valve 00-ESDV-0505 using local hand switch 00-
HS-0505A.
Board Operator opens 00-ESDV-0505 using 00-
HS-0505 from the CMS.

Page 22 of 43
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Step Notes Initials


Field Operator ensures that 00-ESDV-0505 is
opened.
Board Operator to confirm by indication of opened
limit switch 00-ZLO-0505 in CMS.
• Reset and open Emergency Shut Down Valve 00-
ESDV-0508 on trunk line M4.
Field Operator resets Emergency Shut Down
valve 00-ESDV-0508 using local hand switch 00-
HS-0508A.
Board Operator opens 00-ESDV-0508 using 00-
HS-0508 from the CMS.
Field Operator ensures that 00-ESDV-0508 is
opened.
Board Operator to confirm by indication of opened
limit switch 00-ZLO-0508 in CMS.
• Reset and open Emergency Shut Down Valve 00-
ESDV-0517 on trunk line M1
Field Operator resets Emergency Shut Down
valve 00-ESDV-0517 using local hand switch 00-
HS-0517A.
Board Operator opens 00-ESDV-0517 using 00-
HS-0517 from the CMS.
Field Operator ensures that 00-ESDV-0517 is
opened.
Board operator to confirm by indication of opened
limit switch 00-ZLO-0517 in CMS.
• Board operator monitors condensate level and the
interface level on the Slug Catcher.
• Board Operator
Place the “Pressure / Flow Option“ hand switch
01-HS-1447 on the Expander / Compressor to
flow option.
Increase OP of “Flow Option SP” using hand
switch 01-HS-1449 in OP increments of 2%
monitoring temperature drop across 01-E-141.
Note: Maximum Cool Down rate across 01-E-141 is
2ºC per minute (ie. 120ºC per hour). Maximum
temperature difference of 30ºC between cooling
medium and local metal temperature.

Page 23 of 43
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Step Notes Initials


WARNING: Do not exceed maximum operating
pressure for the design or working temperature of the
Cold Gas Exchanger.
Close plant recycle valve using flow controller 01-
FIC-1420 until the flow plant recycle is closed and
the flow to Train 1 as indicated on 01-FIC-1420 is
3
approximately 3461 10 Sm3/d.
Open Deethaniser reflux control valve 01-FFIC-
1410 in MAN mode with OP increments of 2%.
When the reflux flow is approximately around
3
1211 10 Sm3/d, then place ratio controller 01-
FFIC-1410 in AUTO Mode with a ratio SP of 0.35.
After gas flow to the train is increased, place the
“Pressure / Flow Option” hand switch 01-HS-1447
on the Expander / Compressor to “Pressure
Option”.
Adjust the “Pressure Option” hand switch 01-HIC-
1448 on the Expander / Compressor to adjust the
Deethaniser pressure at 17.3 barg.

17. Divert Residue Gas to Export Pipeline:


Board Operator
• Place Residue Gas export pressure controller 00-
PIC-1648 in AUTO mode with a SP of 84.3 barg.
• Inform STC about pipeline export of residue gas from
CPF to STC.
• Verify that the export pipeline block valve stations
Shut Down Valves 10-SDV-1690 and 10-SDV-1691
is opened and indicated by 10-ZLO-1690 and 10-
ZLO-1691 on the CMS.
• Verify the CO2 and H2S content on the residue Gas to
export pipeline on line analyzers.
Note: Residue Gas should contain CO2 ≤ 2.0 mole%,
3
Total Sulphur content should be ≤ 50.0 mg/m and
hydrocarbon dew point should be -6ºC.
• Reset and open Emergency Shut Down Valve 00-
ESDV-1649 on Residue Gas to export pipeline.
Field Operator resets Emergency Shut Down
valve 00-ESDV-1649 using local hand switch 00-

Page 24 of 43
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Step Notes Initials


HS-1649A.
Board Operator opens 00-ESDV-1649 using 00-
HS-1649 from the CMS.
Field Operator ensures that 00-ESDV-1649 is
opened.
Board operator to confirm by indication of opened
limit switch 00-ZLO-1649 in CMS.

18. Start-up and Stabilise Deethaniser:


Board Operator:
• Monitors level rise at the bottom of the Deethaniser,
as indicated on 01-LIC-1502 / 01-LI-1506.
• Verify that the heat input controller 01-UIC-1508 is in
MAN mode with an OP of 0%.
• Verify that the Emergency Shut Down Valve 01-
ESDV-1520, from the LPG Re-run Pumps to the
Deethaniser feed line from 01-E-103A/B, is in the
closed position as indicated by the limit switch
indication in the CMS
• Verify that differential pressure controller 06-PDIC-
3284 is in AUTO mode with a SP of 1.85 bar.
• Verify that differential pressure controller 06-PDIC-
3281 is in AUTO mode with a SP of 4.90 bar.
• Introduce hot oil Deethaniser Reboiler when the level
on 01-LIC-1502 is around 20%:
Field Operator:
Ensure that the tubes side of 01-E-151 contains
no free water by opening 144-V-46 and 144-V-47
and then close 144-V-46 and 144-V-47.
Caution: Failure of removal of water from the system
will lead to steam formation in the Heater coil leading
to fluid hammer, displacement of hot oil into the flare
header and possible mechanical damage to piping
and pumps.
Open the manual bypass valve 175-V-25 across
Product Splitter Reboiler.
Open the manual ball valves 144-V-49 and 144-V-
50 on the outlet of 01-E-151.

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Open the manual ball valves 144-V-41 and 144-V-
42 on the inlet of 01-E-151.
Board Operator:
Open heat input controller 01-UIC-1508 in MAN
mode with OP increments of 2% to slowly
introduce hot oil in to 01-E-151.
Monitor level in the Hot Oil Expansion Vessel and
if necessary make-up level from the Hot Oil
Storage Tank.
• Establish bottom liquid flow from 01-V-141 to 01-V-
151.
As level is observed on 01-V-141 and is above
low level shut down on 01-LI-1417 of 14%, open
shut down valve 01-SDV-1411 on liquid outlet of
01-E-141, using hand switch 01-HS-1411 from the
CMS.
As level further builds up in 01-V-141 and is
above 40%, open level controller 01-LIC-1418 in
MAN mode with 2% increments and establish flow
of liquid to 01-E-141, 01-E-103A/B and to 01-V-
151.
Place level controller 01-LIC-1418 in AUTO mode
with a SP of 45%.
Monitor temperatures on tube side outlet of 01-E-
102 and 01-E-103A/B on 01-TIC-1032.
Monitor the temperature 01-TIC-1034 on the shell
side outlet of Deethaniser.
Note: If the OP on 01-TIC-1034 is 100%, then reduce
the OP on 01-HIC-1015, so that OP on 01-TIC-1034 is
approximately 80%.
• Monitor the temperature on tray 31 as indicated on
01-TIC-1503 and control the temperature at 63ºC.
• Place the energy input controller 01-UIC-1508 in CAS
mode and the temperature controller 01-TIC-1503 in
AUTO mode with a SP of 63ºC.
• As level build sup in the bottom of the Deethaniser
draw off bottom product from the Deethaniser:
Board Operator
Open Deethaniser bottom shut down valve 01-

Page 26 of 43
Start-Up Procedure System No: 00

Step Notes Initials


SDV-1531 using hand switch 01-HS-1531 from
CMS.
Open flow controller 01-FIC-1500 in MAN mode
with OP increments of 2% to establish flow to
Product Splitter Pre-Heater 01-E-233.
When the level on the Deethaniser stabilises then
place 01-FIC-1500 in CAS mode and level
controller 01-LIC-1507 in AUTO mode with a SP
of 45%.

19. Forward liquid flow from Slug Catcher:


• Establish produced water flow from slug catcher to
01-V-281.
Field Operator
Open battery limit block valve 104-V-19 for
produced water to train 1.
Board Operator
Verify that interface level controllers 00-LIC-0543
and 00-LIC-0545 are in MAN mode with an OP of
0%.
• As interface level builds up in Side A and B of the
slug catcher and is above the low low interface level
shut down value of 00-LALL-0544/0548:
Board Operator
Open Emergency Shut Down Valve 00-ESDV-
0590 using hand switch 00-HS-0590 on the CMS.
Select one of the interface level controller 00-LIC-
0543 or 00-LIC-0545 using hand switch 00-HS-
0543.
Open 00-LIC-0543 in MAN mode with OP
increments of 2% until the interface level
stabilises.
Place the interface level controller 00-LIC-0543
and 00-LIC-0545 in AUTO mode with a SP of x%.
Monitor Interface level in Produced Water Flash Refer: Step 25
Drum as indicated on 01-LIC-2807.
• Establish condensate flow from slug catcher to 01-V-
211 and pressurize/fill 01-V-211, 01-X-212 and 01-V-
213A.

Page 27 of 43
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Field Operator:
Open battery limit block valve 165-V-01 for
condendsate to train 1.
Open inlet block valve 166-V-01 and outlet block
valve 166-V-11 to 01-X-212.
Ensure that the bypass block valve 166-V-05
across 01-X-212 is closed.
Switch power on LCP (Local Control Panel) OF
01-X-212, using hand switch 01-HS-2105.
Reset the system using black push button 01-HS-
2102 on the LCP.
Verify that the process inlet (01-KV-2112) and
outlet (01-KV-2113) switching valves are opened
and the back wash inlet (01-KV-2110) and outlet
(01-KV-2111) switching valves are closed for the
“A” filter.
Verify that the process inlet (01-KV-2122) and
outlet (01-KV-2123) switching valves are closed
and the back wash inlet (01-KV-2120) and outlet
(01-KV-2121) switching valves are opened for the
“B” filter.
Verify that the inlet block valves 167-V-03 and
167-V-05 and the outlet block valves 167-V-11
and 167-V-13, on Inlet Liquid Coalescer 01-V-
213A are opened.
Verify that the Back wash line block valve 166-V-
25 from the filter is initially lined up to the Closed
Wet HC drain system.
Board Operator:
Verify that emergency Shut Down Valve 01-
ESDV-2162 on the condensate to train 1 at
battery limit is closed as indicated by 01-ZLC-
2162.
Place the pressure controller 01-PIC-2641 on the
overhead line of 01-V-211 to HP Flare in AUTO
mode with a SP of 30.5 barg.
Place pressure controller 01-PIC-2256 on the
Condensate Stabiliser in AUTO mode with a SP of
19.7 barg.
Place the condendsate flow controller 01-FIC-

Page 28 of 43
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Step Notes Initials


0521 in MAN mode with an OP of 100%.
Verify that 01-V-211 condensate level controller
01-LIC-2122 is in MAN mode with an OP of 0%.
Place the condensate flow controller 01-FIC-2222
from 01-V-211 to 01-E-222A/B/C/D in MAN mode
with an OP of 100%.
Note: Inform instrument technician to force open Shut
Down Valve 01-SDV-2161 temporarily, to pressurise
and fill the Inlet Liquid Filters and Inlet Liquid
Coalecers.
Field Operator:
st
Open 1 bypass ball valve 165-V-03 and slowly
nd
open 165-V-04, the 2 globe valve across 01-
ESDV-2162, to pressurize 01-V-211.
Board Operator:
Monitors pressure on 01-V-211 as indicated on01-
PI-2115.
When pressure on 01-V-211 is approximately
equal to 30 barg, then close flow controller 01-
FIC-0521 in MAN mode with an OP of 0%.
• As condensate level builds up in slug catcher 00-V-
051 in Side A and Side B and is above the low low
condensate level shut down value of 00-LALL-
0550/0552:
Board Operator:
Open the Emergency Shut Down Valve 01-ESDV-
2162 using hand switch 01-HS-2162.
Open 01-FIC-0521 in MAN mode with OP
increments of 2%, until the condensate level is
stabilised in the Slug Catcher.
Place the condensate flow controller 01-FIC-0521
in CAS mode and the condensate level controllers
00-LIC-0551 and 00-LIC-0553 in AUTO mode with
a SP of x%.
Open vent valves 166-V-12 and 166-V-13 on Inlet
Liquid Filter “A” to displace gases from the filter.
After displacement close 166-V-12 and 166-V-13.
Open vent valves 166-V-16 and 166-V-17 on Inlet
Liquid Filter “B” to displace vapours from the filter.

Page 29 of 43
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Step Notes Initials


After displacement close 166-V-16 and 166-V-17.
Open vent valves 167-V-06 and 167-V-07 on Inlet
Liquid Coalescer 01-V-213A to displace gases
from the Coalescer. After displacement close 167-
V-06 and 167-V-07.
Close condensate flow controller 01-FIC-2222
from 01-V-211 to 01-E-222A/B/C/D in MAN mode
with an OP of 0%.
Note: Inform instrument technician to return Shut
Down Valve 01-SDV-2161 back to its normal position.
Field Operator
st nd
Close 1 bypass ball valve and the 2 globe valve
across 01-ESDV-2162 and install a lock on it in
the closed position.

20. Forward liquid flows from Inlet Gas Condensate


Separator:
• Establish produced water flow from 01-V-101 to 01-
V-281.
Board Operator:
Verify that 01-V-101 interface level controller 01-
LIC-1089 is in MAN mode with OP of 0%.
As interface level builds up in 01-V-101 and is above the
low low interface level shut down value of 01-LALL-1086
(18.5%):
Board Operator:
Open Shut Down Valve 01-SDV-1010 using hand
switch 01-HS-1010 on the CMS.
Open 01-LIC-1089 in MAN mode with OP
increments of 2% until the interface level
stabilises.
Place the interface level controller 01-LIC-1089 in
AUTO mode with a SP of 45%.
Refer: Step 25
Monitor Interface level in Produced Water Flash
Drum as indicated on 01-LIC-2807.
• Establish Condensate flow from 01-V-101 to 01-V-
281.
Board Operator:

Page 30 of 43
Start-Up Procedure System No: 00

Step Notes Initials


Verify that 01-V-101 condensate level controller
01-LIC-1093 is in MAN mode with an OP of 0%.
As condensate level builds up in 01-V-101 and is above
the low low condensate level shut down value of 01-LALL-
1091 (21%)
Open Shut Down Valve 01-SDV-1002 using hand
switch 01-HS-1002 on the CMS.
Open 01-LIC-1093 in MAN mode with OP
increments of 2% until the condensate level
stabilises.
Place the condensate level controller 01-LIC-1093
in AUTO mode with a SP of 40%.

21. Forward liquid flows from Dehydration Feed Separator:


• Establish produced water flow from 01-V-102 to 01-
V-281.
Board Operator:
Verify that 01-V-102 interface level controller 01-
LIC-1023 is in MAN mode with OP of 0%.
As interface level builds up in 01-V-102 and is above the
low low interface level shut down value of 01-LALL-1020
(18.5%):
Board Operator:
Open Shut Down Valve 01-SDV-1011 using hand
switch 01-HS-1011 on the CMS.
Open 01-LIC-1023 in MAN mode with OP
increments of 2% until the interface level
stabilises.
Place the interface level controller 01-LIC-1023 in
AUTO mode with a SP of 45%.
Monitor Interface level in Produced Water Flash
Refer step 25
Drum as indicated on 01-LIC-2807.
• Establish Condensate flow from 01-V-101 to 01-V-
281.
Board Operator:
Verify that the condensate level controller 01-LIC-
1093 is in MAN mode with an OP of 0%.
As condensate level builds up in 01-V-102 and is above

Page 31 of 43
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Step Notes Initials


the low low condensate level shut down value of 01-LALL-
1026 (23%)
Open Shut Down Valve 01-SDV-1002 using hand
switch 01-HS-1002 on the CMS.
Open 01-LIC-1093 in MAN mode with OP
increments of 2% until the condensate level
stabilises.
Place the condensate level controller 01-LIC-1093
in AUTO mode with a SP of 40%.

22. Forward liquid flow from Dehydration Feed Filter


Separator:
Board Operator:
• Place level controller 01-LIC-1010 in AUTO mode.
• Place level controller 01-LIC-1012 in AUTO mode.

23. Forward liquid flows from Inlet Condensate Pre-Flash


Separator:
• Establish produced water flow from 01-V-211 to 01-
V-281.
Board Operator:
Verify that 01-V-211 interface level controller 01-
LIC-2124 is in MAN mode with OP of 0%.
As interface level builds up in 01-V-211 and is above the
low low interface level shut down value of 01-LALL-2117
(12%)
Open Shut Down Valve 01-SDV-2163 using hand
switch 01-HS-2163 on the CMS.
Place the interface level controller 01-LIC-2124 in
AUTO mode.
Monitor Interface level in Produced Water Flash Refer step 25
Drum as indicated on 01-LIC-2807.
• Establish Condensate flow from 01-V-211 to 01-X-
212.
Board Operator:
As condensate level builds up in 01-V-211 and is above
the low low condensate level shut down value of 01-LALL-
2184 (16%)
Open Shut Down Valve 01-SDV-2161 using hand

Page 32 of 43
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Step Notes Initials


switch 01-HS-2161 on the CMS.
Open condensate flow controller 01-FIC-2222 to
01-E-222A/B/C/D in MAN mode with OP
increments of 2%.
When the level in 01-V-211 stabilises then place
01-FIC-2222 in CAS mode and 01-LIC-2122 in
AUTO mode with a SP of 45%.
Close back wash line block valve 166-V-25 from
the Inlet Liquid Filters to the Closed Wet HC drain
system.

24. Establish produced water flow from Inlet Liquid Coalecer


01-V-213A to 01-V-281:
Board Operator:
• Verify that 01-V-213A interface level controller 01-
LIC-2194 is in MAN mode with OP of 0%.
As interface level builds up in 01-V-213A and is above
the low low interface level shut down value of 01-LALL-
2191 (16%):
• Open Shut Down Valve 01-SDV-2167 using hand
switch 01-HS-2167 on the CMS.
• Place the interface level controller 01-LIC-2194 in
AUTO mode.
• Monitor Interface level in Produced Water Flash
Drum as indicated on 01-LIC-2807. Refer step 25
• Monitor differential pressure 01-PDI-2105 across 01-
V-213A/B.

25. Start-up and Stabilise Condensate Stabiliser:


Board Operator:
• Verify that the Emergency Shut Down Valve 01-
ESDV-2240, from the Condensate Re-run Pumps to
the Stabiliser Feed Pre-Heater is in the closed
position as indicated by the limit switch indication in
the CMS.
• Monitor interface level on stand-pipe located on line
Tray 1 and as interface level builds up and is above
low low level shut down value of 01-LALL-2247
(85%):

Page 33 of 43
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Step Notes Initials


Open Shut Down Valve 01-SDV-2250 using hand
switch 01-HS-2250 on the CMS.
Place the interface level controller 01-LIC-2211 in
AUTO mode.
Monitor Interface level in Produced Water Flash
Refer Step 25
Drum as indicated on 01-LIC-2807.
• Verify that the hot oil flow controller 01-FIC-2252 is in
MAN mode with an OP of 0%.
• Verify that the hot oil differential pressure controllers
06-PDIC-3284 and 01-PDIC-3281 are in AUTO mode
with SP’s of 1.85 bar and 4.90 bar respectively.
• Introduce hot oil to Stabiliser Reboiler, when the level
on 01-LIC-2245 is 20%:
Field Operator:
Ensure that the tubes side of 01-E-221A/B
contains no free water by opening 172-V-06 and
172-V-07 and then close 172-V-06 and 172-V-07.
Caution: Failure of removal of water from the system
will lead to steam formation in the Heater coil leading
to fluid hammer, displacement of hot oil into the flare
header and possible mechanical damage to piping
and pumps.
Open the manual ball valves 172-V-03 and 172-V-
02 on the inlet of 01-E-221A/B.
Open the manual ball valves 172-V-09 and 172-V-
10 on the outlet of 01-E-221A/B.
Board Operator:
Open hot oil flow controller 01-FIC-2252 in MAN
mode with OP increments of 2% to slowly
introduce hot oil to 01-E-221A/B.
Monitor level in Hot Oil Expansion Vessel and if
necessary make-up level from the Hot Oil Storage
Tank.
Increase hot oil flow steadily to achieve a
temperature of 140ºC as indicated by 01-TIC-
th
2241 on the 19 tray.
As level builds up in 01-V-221 and is above the low low
level shut down value of 01-LALL-2286 (5%):
Board Operator:

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Start-Up Procedure System No: 00

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Place the pressure controller 01-PIC-2332 on the
Product Splitter Overhead Accumulator in AUTO
Mode with a SP of 16.0 barg.
Open flow controller 01-FIC-2265 in MAN mode
with OP increments of 2% to divert flow from
bottom of 01-V-221 to 01-V-231.
As the level stabilises at 45% on the bottom of 01-
V-221 as indicated on 01-LIC-2245, place flow
controller 01-FIC-2265 in CAS mode and level
controller 01-LIC-2245 in AUTO mode with a SP
of 45%.
Monitor and adjust column profile so as to obtain
approximately an overhead temperature as
indicated on 01-TI-2243 at 71.6ºC.

26. Start VRU Compressor 01-C-261 and its auxiliaries as per Procedure No:
start-up procedure. 01-26-28214

27. Start-up, stabilise Product Splitter and divert LPG and


Condensate product to Storage.
• Place the Product Splitter Overhead Condenser 01-
E-232 in service.
Field Operator
Start fin fan motor using local start/stop push
button.
Note: The Fin Fan motor can also be started from the
CMS using 01-HS-2349A/B/C/D/E/F/G/H, but first start-
up to be carried out using local start/stop push
buttons.
Note: It would not be necessary to start all the fin
fans at the same time, but can be started one at a
time by monitoring the temperature on the outlet of
01-E-232
Checks for any abnormalities viz. excessive
vibrations and inform Board Operator.
Board Operator
Confirm “Run” status as indicated by 01-YI-
2349A/B/C/D/E/F/G/H.
Place the temperature controller 01-TIC-2349, on
the outlet of 01-E-232 in AUTO mode with a SP
f 61 5ºC

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Step Notes Initials


of 61.5ºC.
• Place the Condensate Product Cooler 01-E-234 in
service.
Field Operator
Start fin fan motor using local start/stop push
button.
Note: The Fin Fan motor can also be started from the
CMS using 01-HS-2365A/B, but first start-up to be
carried out using local start/stop push buttons.
Board Operator
Confirm “Run” status as indicated by 01-YI-
2365A/B.
Place the temperature controller 01-TIC-2367, on
the outlet of 01-E-234 in AUTO mode with a SP of
56.0ºC.
CAUTION: Ensure that the condensate product exiting
tube side of 01-E-222A/B/C/D is within design
operating temperature of 56.0ºC and there-by
preventing a potential high temperature on On-Spec
Condensate Product Storage Tanks.
Note: On high-high temperature at 160ºC as indicated
by 01-TT-2251, on the tube side outlet of 01-E-
222A/B/C/D closes 01-ESDV-2290 on the On-Spec
Condensate and opens 01-ESDV-2285 on the Off-Spec
Condensate.
• Line-up bottom condensate product from 01-V-231 to
Off-Spec Condensate Tank 05-T-432.
Board Operator
Open Shut Down Valve 05-SDV-4322 on the inlet
of Condensate Degassing Vessel 05-V-431, using
hand switch 05-HS-4322 on the CMS.
Open Shut Down Valve 05-SDV-4336 on the inlet
of Condensate Off-Spec Tank 05-T-432, using
hand switch 05-HS-4322 on the CMS.
Verify that Off-Spec Condensate Emergency Shut
Down Valve 01-ESDV-2285, on the condensate
from 01-E-222A/B/C/D is opened and indicated by
01-ZLO-2285 on the CMS.
Verify that On-Spec Condensate Emergency Shut

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Down Valve 01-ESDV-2290, on the condensate
from 01-E-222A/B/C/D is closed and indicated by
01-ZLC-2285 on the CMS.
Note: Tubes side of Stabiliser Feed Pre-Heater to be
bypassed when shell side inlet operating temperature
exceeds 60ºC.
• Line-up overhead LPG product from 01-V-231 to Off-
Spec LPG Storage Bullets via LPG H2S Absorbers.
Field Operator
Ensure that LPG H2S Absorber 05-V-241B inlet
block valves 436-V-59 and 436-V-57 and outlet
block valves 436-V-46 and 436-V-44, to process
off-spec LPG are opened.
Ensure that LPG H2S Absorber 05-V-241A inlet
block valves 436-V-07 and 436-V-09 and outlet
block valves 436-V-38 and 436-V-40, to process
on-spec LPG are opened.
Board Operator
Open Shut Down Valve 05-SDV-4150 on the inlet
of LPG Off-Spec Storage Bullets 05-V-412A/B,
using hand switch 05-HS-4150 on the CMS.
Verifies that the Shut Down Valve 05-SDV-4100
and 05-SDV-4120 on the inlet of LPG On-Spec
Storage Bullets 05-V-411A/B and 05-V-411C/D
respectively are closed.
Verify that Off-Spec LPG Emergency Shut Down
Valve 01-ESDV-2384, on LPG from 01-P-231A/B
is opened and indicated by 01-ZLO-2384 on the
CMS.
Verify that On-Spec LPG Emergency Shut Down
Valve 01-ESDV-2388, on LPG from 01-P-231A/B
is closed and indicated by 01-ZLC-2384 on the
CMS.
• Introduce hot oil to Product Splitter Reboiler, when
the level on 01-LIC-2330 is 20%:
Field Operator:
Ensure that the tubes side of 01-E-231 contains
no free water by opening 175-V-27 and 175-V-29
and then close 175-V-27 and 175-V-29.
Caution: Failure of removal of water from the system

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will lead to steam formation in the Heater coil leading
to fluid hammer, displacement of hot oil into the flare
header and possible mechanical damage to piping
and pumps.
Open the manual ball valves 175-V-23 and 175-V-
22 on the inlet of 01-E-231.
Open the manual ball valves 175-V-30 and 175-V-
31 on the outlet of 01-E-231.
Board Operator:
Open hot oil flow controller 01-FIC-2338 in MAN
mode with OP increments of 2% to slowly
introduce hot oil to 01-E-231.
Monitor level in Hot Oil Expansion Vessel and if
necessary make-up level from the Hot Oil Storage
Tank.
Increase hot oil flow steadily to achieve a
temperature of 190ºC as indicated by 01-TIC-
th
2326 on the 36 tray.
Field Operator:
Close the manual bypass valve 175-V-25 across
Product Splitter Reboiler.
• As level builds up in 01-V-231 and is above the low
low level shut down value of 01-LALL-2331 (24%):
Board Operator:
Start bottom flow from 01-V-231 by placing level
controller 01-LIC-2331 in MAN mode with OP
increments of 2%.
Note: This step is done slowly in order to slowly
pressurise and fill the Off-Spec Condensate line.
As the level stabilises at 45% on the bottom of 01-V-231
as indicated on 01-LIC-2331, place level controller 01-LIC-
2331 in AUTO mode with a SP of 45%.
• As level builds up in the Product Splitter Overhead
Accumulator:
Board Operator
Verify that the pressure controller 01-PIC-2332 on
the Product Splitter Overhead Accumulator is in
AUTO Mode with a SP of 16.0 barg.
Place the Product Splitter pressure controller 01-

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PIC-2374 is in MAN mode with an OP of 0%.
Opens Reflux flow controller 01-FIC-2340 in MAN
mode with an OP of 60%.
Inform Field operator to Start Product Splitter
Reflux Pump 05-P-231A or B.
Field Operator
Start Product Splitter Reflux Pump as per
procedure.
Board Operator
Monitors level on 01-V-232 and adjusts reflux flow
to approximately 2193 t/day using flow controller
01-FIC-2340 in MAN mode.
Place reflux controller 01-FIC-2340 in AUTO
mode with a SP of 2193 t/day.
Note: It is important to maintain the reflux flow of 2193
t/day on the Product Splitter at all times in order to
control and maintain the purity of product LPG.
Place level controller 01-LIC-2356 on 01-V-232 in
AUTO mode with a SP of 50%.
Note: The Product Splitter Overhead Accumulator
operates liquid full and the level controller 01-LIC-
2356 is reverse acting controller.
Monitor pressure on 01-V-231 as indicated on 01-
PIC-2374 and as pressure increases open
pressure controller 01-PIC-2374 in MAN mode
with OP increments of 2% to introduce LPG to 05-
V-241B.
Note: This step is done slowly in order to slowly
pressurise and fill the Off-Spec LPG line and the Off-
Spec LPG H2S Absorbers 05-V-241B.
Place pressure controller 01-PIC-2374 on 01-V-
231 in AUTO mode with a SP of 16.3 barg.
Monitor and adjust column profile so as to obtain
approximately an overhead temperature as
indicated on 01-TI-2305 at 71.4ºC and a bottom
temperature as indicated on 01-TI-2303 at
215.9ºC.
Field Operator
• Send a check sample of condensate product and

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Start-Up Procedure System No: 00

Step Notes Initials


LPG product from train 1 to laboratory.
• As LPG product is within specification, divert LPG
product to On-Spec LPG H2S Absorbers:
Note: LPG Product specification is as follows:
Maximum vapour pressure=1434kPag at 37.8ºC.
Volatile Residue=2.2ºC.
Maximum Ethane and lighter=3.0 mole%.
Maximum Pentane and Heavier=2.0 liquid vol% /
0.4mole%.
Total Sulphur concentration=140 ppmw.
Free Water=None.
Board Operator:
Open Shut Down Valve 05-SDV-4100 and 05-
SDV-4120 on the inlet of LPG On-Spec Storage
Bullets 05-V-411A/B and 05-V-411C/D using 05-
HS-4100 and 05-HS-4120 respectively.
Field Operator
st
Open 1 jumper block valve 436-V-04 across LPG
H2S Absorbers.
nd
Open 2 jumper block valve 436-V-06 across
LPG H2S Absorbers slowly to pressurise 05-V-
241A.
When pressure equalises then close 436-V-04
and 436-V-06.
Board Operator
Open Emergency Shut Down Valve 01-ESDV-
2388 on the discharge of Product Splitter Reflux
Pumps to On-Spec LPG storage using hand
switch 01-HS-2388.
Close Emergency Shut Down Valve 01-ESDV-
2384 on the discharge of Product Splitter Reflux
Pumps to Off-Spec LPG storage using hand
switch 01-HS-2384.
• As Condensate product is within specification, divert
Condensate product to On-Spec Condensate Product
Tank 05-T-431A.
Note: Condensate Product specification is as follows:
Reid Vapour Pressure=0.69 bara max.

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Total Sulphur=0.005 wt%.
Total Salt by weight=Less than 0.66 kg/tonne.
BS&W by volume=Less than 0.5% by volume
Field Operator
Close block valve 170-V-53 on downstream of 01-
ESDV-2290 at battery limit.
Board Operator
Open Shut Down Valve 05-SDV-4300 on the inlet
of Condensate Product Storage Tank 05-T-431A
by using hand switch 05-HS-4100 from the CMS.
Open Emergency Shut Down Valve 01-ESDV-
2290 on the bottom product of Product Splitter to
On-Spec Condensate Product Storage using 01-
HS-2290 from the CMS.
Field Operator slowly opens block valve 170-V-53
on downstream of 01-ESDV-2290 at battery limit,
to pressurise the downstream piping.
When the pressure is equalised then close
Emergency Shut Down Valve 01-ESDV-2285 on
the bottom product of Product Splitter to the Off-
Spec Condensate Storage Tank using 01-HS-
2285 from the CMS.

28. Place the Produced Water Flash Drum 01-V-281 in


service:
• As interface level builds up in the Produced Water
Flash Drum 01-V-281:
Field Operator:
• Ensures that vent block valve 186-V-15 on 01-V-281
to MP vent header is “Locked Open”.
CAUTION: Increased flow to 01-V-281 will result in
additional flash gas and increase in operating
pressure of the drum and finally liquid carry over to
the MP vent header. Hence it is important to ensure
186-V-15 is “Locked open”.
• Ensures that the upstream block valve 186-V-17 and
downstream block 186-V-19 on 01-LV-2807 are
open.
• Monitor the interface level on the sight glass 01-LG-

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2807.
Board Operator:
• When the level in 01-V-281 is above the low low level
shut down value of 9% as indicated on 01-LI-2802,
open shut down valve 01-SDV-2801 using hand
switch 01-HS-2801 from the CMS.
• Initially if no HC’s are present in 01-V-281, open 01-
LIC-2807 in MAN mode to establish produced water
flow to CPI Separator 06-X-571.
• When HC’s enter 01-V-281 and the interface level as
indicated by 01-LIC-2807 is approximately at 50%
level then place 01-LIC-2807 in AUTO mode with a
SP of 50%.
• On high interface level alarm on 01-LIC-2807 at 60%,
inform Field Operator.
Field Operator:
• Open the internal stand-pipe block valve 186-V-23
and 186-V-14 from 01-V-281 to Closed Wet HC drain
system.
• Close 186-V-23 and 186-V-14, when the interface
level as indicated by 01-LIC-2807 is around 50%.

29. Increase feed rate to train at 100% rates:


Board Operator
• Monitor train 1 conditions and scan through all the
graphics to ensure stable operations of Train 1.
• Increase feed as follows:
Place the “Pressure / Flow Option “hand switch
01-HS-1447 on the Expander / Compressor to
“Flow “option.
Using hand switch “Flow Option SP” 01-HIC-
1449 on the Expander / Compressor slowly
increase the SP the flow to Train 1 as indicated
3
on 01-FIC-1420 is approximately 6922 10 Sm3/d.
Monitor train 1 conditions and scan through all
the graphics to ensure stable operations of Train
1.
After gas flow to train 1 is increased, place the
“Pressure / Flow Option” hand switch 01-HS-
1447 on the Expander / Compressor to “Pressure

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Step Notes Initials


Option”.

30. Place the Mercury Absorber in service:


Note: The following step may be carried out at 50%
feed rate to the train, if the train is operated at this
mode for an extended time frame.
Field Operator:
• Open the butterfly valve 131-V-14 slightly at the inlet
of the Mercury Absorber.
Board Operator:
• Monitors the H2S content on the analyzer as
indicated by 01-AI-1100 and instruct Field Operator
to continue opening until the H2S content as indicated
on 01-AI-1100 is less than 1.5 ppm.
Field Operator:
• Send a check sample of the gas from the outlet of the
Mercury Absorber and Gas H2S Absorber to the
laboratory.
• During normal operations whenever the H2S content
tends to rise the Field Operator in co-ordination with
the Board Operator, partially closes the butterfly
valve 131-V-14 on the inlet of the Mercury Absorber
so that the H2S content as indicated on 01-AI-1100 is
less than 1.5 ppm.

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