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Saih Nihayda Depletion Compression Phase 1

Process Control Narrative

Rev. Date Description Originator Checker Approver

CONTENTS:

1.0 OBJECTIVE.........................................................................................................4
2.0 INTRODUCTION................................................................................................4
2.1 Background.......................................................................................................4
2.2 Objective...........................................................................................................4
2.3 Project Description...........................................................................................4
2.4 Design Capacity................................................................................................6
3.0 CONTROL PHILOSOPHY (GENERAL)...........................................................6
3.1 Process Control Narrative.................................................................................6
4.0 PROCESS DESCRIPTION & CONTROL NARRATIVE..................................7
4.1 Inlet manifold....................................................................................................7
4.2 Inlet Separators (V6801, V-6802)....................................................................8
4.3 Compressor suction header pressure controller..............................................11
4.4 Suction Coolers (E-6811, E-6821 & E-6831).................................................12
4.5 Compressor Suction Scrubbers (V-6811, V-6821 & V-6831).......................13
4.6 Booster Compressors (K-6810, K-6820 & K-6830).......................................15
4.7 Compressor After Coolers (E-6812, E-6822 & E-6832)................................17
4.8 Condensate Separator (V-6803).....................................................................19
5.0 REFERENCE.....................................................................................................23
6.0 Attachments........................................................................................................23
ABBREVATIONS

AADL Average Annual Daily Load

CCR Central Control Room
CESD Controlled Emergency Shutdown
COGS Central Oman Gas System
CPSD Controlled Process Shutdown
DCS Distributed Control System
EPC Engineering Procurement & Construction
ESD Emergency Shutdown
FAR Field Auxiliary Room
FCS Field Bus Control System
FEED Front End Engineering Design
FGS Fire & Gas Detection System
HMI Human Machine Interface
IPS Instrumented Protective System
LCP Local Control Panel
MADL Maximum Annual Daily Load
MMSCFD Million Metric Standard Cubic Feet per Day
MMSCMD Million Metric Standard Cubic Meter per Day
PAS Process Automation System
PDO Petroleum Development Oman
PEFS Process Engineering Flow Scheme
PFS Process Flow Scheme
PLC Programmable Logic Control
PSD Process Shutdown
SGS Safeguarding System
SNDC-1 Saih Nihayda Depletion Compression
SNGP Saih Nihayda Gas Plant
SNOS Saih Nihayda Oil station
SNS Saih Nihayda Shuaiba
SROS Saih Rawl Oil Station
UCP Unit Control Panel
1.0OBJECTIVE

The objective of this document is to provide a Process Control Narrative of the

Depletion Compression Facility (Project Phase I) at Saih Nihayda Gas Plant. It is
expected that this document will be kept up to date during FEED and detailed
engineering stage.

2.0INTRODUCTION
2.1 Background
The Saih Nihayda Deep Field is located within the cluster of non-associated gas fields
in the central Oman. The field is situated 28 km north east of the Saih Rawl Central
Processing Plant and 20 km west of the Qarn Alam Oil station. The field has been
producing via the Saih Nihayda Gas Plant (SNGP) since Q1 2005. Based on the current
forecasts the reservoir pressure will begin to decline below the current inlet pressure of
the SNGP within the next 6 years. At this point, the 1st Stage of Saih Nihayda
Depletion Compression (SNDC-1) Project will be required to deliver the gas from the
wells to the required inlet pressure of the SNGP.

2.2 Objective
The principal objective of the SNDC-1 Project is to receive about 21 MMSCMD gas
and the accompanying condensate, at pressures from 70 to 38 bara, separate the
condensate, compress the gas and deliver compressed gas to the existing Gas Plant Wet
gas Cooler E-6212 at the conditions matching design of the existing gas plant.

The SNDC-1 involves installation of 3 nos of gas compressor units at upstream of the
existing inlet wet gas cooler E-6212. This will enable the SNGP to continue exporting
to the Central Oman Gas System (COGS), a sustainable Maximum Annual Daily Load
(MADL) of 20 MMSCMD gas. The planned on-stream date is January 2013.

Based on the 2008 Gas Business Plan, the SNGP is to produce an Annual Average
Daily Load (AADL) of 12 MMSCMD from the SN Deep reservoirs (Barik, Miqrat &
Amin), with a potential upside of 14 MMSCMD. However, in either case the
compression facility must meet MADL at 20 MMSCMD while being capable of
turndown to 6 MMSCMD at high energy efficiency.

2.3 Project Description

The SNDC-1 facility will be installed downstream of the Plant Inlet Manifold and the
upstream of Wet gas Cooler E-6212, bypassing the two existing SNGP Inlet Separators
V-6211/12. Upstream and downstream facilities remain unaffected by this project
except for tie-ins.

In order to meet the above project requirements, a 3-compression train configuration

has been selected for the SNDC-1, with each train being able to deliver, at the early
stage of operation, 50% of MADL (10 MMSCMD)

The SNDC-1 Project will comprise the following major processing equipment:
 Inlet Separators (V-6801, V-6802)
 Suction Coolers (E-6811, E-6821 & E-6831)
  Suction Scrubbers (V-6811, V-6821 & V-6831)
 Booster Compressor package units (A-6810/20/30) consisting of
compressors (K-6810, K-6820 & K-6830)
 Compressor Aftercoolers (E-6821, E-6822 & E-6832)
 Condensate Separator.(V-6803)
The overall schematic of process equipment lineup of the new SNDC-1 facility is
shown in the Figure 2.1.1 below.

Figure 2.1.1: SNDC-1 Facility Schematic

SNDC-1 facility need to perform the following gas and liquid processing functions:

1. Equally split the field production from the Plant Inlet Manifold between
2 new Inlet Separators, by use of symmetrical piping and automatic
control.
2. Separate bulk liquids from the inlet fluid in two Inlet Separators and
send water and condensate to their respective destinations in the SNGP
plant.
 3. Apportion the separator gas equally among running compression trains,
each train consisting of a Suction Cooler, Suction Scrubber, Booster
Compressor and After cooler.

Each train will be performing the following functions:

a. Cool, by means of an air cooled Suction Cooler, the incoming gas to
minimum achievable but not less than 30oC to avoid hydrate
formation.
b. Separate, in a Suction Scrubber, the condensed liquids with >99%
efficiency and send the liquids to a new common condensate
separator.
c. Compress the gas from Suction Scrubber to a pressure sufficient for
the SNGP to meet the 20 MMSCMD gas off-take from the plant.
d. Cool the compressed gas in an after cooler to 100 oC and deliver it to
the inlet of existing gas plant Inlet Cooler E-6212.
4. Collect all liquids from Suction Scrubbers in a new Condensate
Separator operating at about 4 bar below of the common compressor
suction manifold operating pressure to minimize flashing and separate
the condensate.
5. Dispose of the Condensate Separator streams into the current gas plant
tie-in points as follows: send flashed gas to off gas Pipeline, condensate
to Condensate Cooler E-6213, and produced water to Produced water
degassing vessel V-6214.

2.4 Design Capacity

The table below summarises the existing SNGP design capacities
Existing System Capacity
Saih Nihayda Gas Plant – Gas throughput 20 MM Sm3/d
Saih Nihayda Gas Plant – Condensate production 10000 m3/d
Saih Nihayda Gas Plant - Water production 1000 m3/d
48” Export Gas Pipeline (SNGP-48” Pipeline) 20 MM Sm3/d
12” Interfield Condensate Pipeline (SNGP-CPP) 10000 m3/d
4” Water SNGP-SNOS Pipeline 1000 m3/d
4” Off Gas Pipeline SNGP-SNOS Pipeline 0.016 MM Sm3/d

3.0CONTROL PHILOSOPHY (GENERAL)

3.1 Process Control Narrative

The philosophy shall adhere to the requirements outlined in the following documents:
 Saih Nihayda Depletion Compression Phase-1, Basis for Design (Ref-1)
 OG-00.20489- Guidelines for preparing process control & IPF narratives
Version-2.0
 Process control refers to automatic manipulation of the process in order to meet process
objectives (e.g. production rate, product qualities and safety).

The main purpose of the Process Control Narrative is:

 Ensuring an appropriate and well-considered functional design of the
process control.

 Establishing a design document to be used for:

1. Control & Automation to develop the functional analysis and to define
the operating philosophy.
2. General process control aspects and background
Classes of process control can be distinguished as follows:
I. Regulatory control (keep process variables at steady point of
operation)
II. Integrated Capacity & Antisurge Control ( For Booster Compressors
operation)
III. Optimizing control (adjusts process variables in order to achieve
optimum point of operation)
IV. Constraint Control (Pressure constraint for well heads and compressor
systems , Power constraint for compressor motor)
V. Safeguarding Control (bring the process to safe state when a potential
hazard with SIL level L1 is detected)
VI. Sequence Control for automation of start-up and shutdown.(one
permissive from compressor package and other from main system)
The functional design of process control relates to normal operating modes (for
continuous processes essentially regulatory controls and, if applicable, optimizing
controls) and is performed in parallel with the PFSs, PEFSs and documented in this
Process Control Narrative.

4.0PROCESS DESCRIPTION & CONTROL NARRATIVE

4.1 Inlet manifold
Refer the following PEFS:
1) SNG-249-PX-2365-68001-0001
2) SNG-1-6213-001
4.1.1 Process

During SNDC-1 Station commissioning and transition period, both ends of the
manifold will be active, supplying gas simultaneously to both SNDC-1 and SNGP
facilities. Since SNGP process requires inlet pressures well in excess the upper
operating limit of the SNDC-1 inlet pressure, a pressure let down valve (68PCV-0006)
is provided in the common outlet header of the inlet separators (V-6801/02.) During the
transition, the let down valve will be modulated by a pressure controller installed on
common inlet header of compressor units.
SNDC-1 Compressors will operate at constant speed during the transition period. The
high pressure constraint controller (68PICA-0003) to the well head will remain inactive
during transition period. The existing high pressure constraint controller (62PICA-103)
will protect the flow lines, manifold and inlet piping.

Past the transition period, the entire field production will feed the SNDC-1 Facility and
the pressure letdown valve (68PCV-0006) will be bypassed. The control of SNDC-1
inlet pressure from now on will be from the pressure controller (68PICA-0003) on the
feed line to inlet separators.

4.2 Inlet Separators (V6801, V-6802)

Refer the following PEFS. 1) SNG-249-PX-2365-68002-0001
2) SNG-249-PX-2365-68002-0002
4.2.1 Process

Plant Inlet Separators are the first component of SNDC-1 Facility and will operate as
vertical 3-phase separators. The upstream system consists of gas producing wells,
production gathering flow lines, and Plant Inlet Manifold.

The Plant Inlet Manifold will be extended on its top and a new header will be installed
to direct well production to SNDC-1 area. The symmetrical inlet piping is considered
for both inlet separators. An additional measure for flow balancing, a flow control valve
and a flow transmitter are provided in each of the Inlet Separator gas outlet lines.

Each of the inlet separators is a vertical 3-phase separator with an inlet Schoepentoeter,
mistmat, swirldeck and plate pack. The separator is also designed to receive transient
liquid flow (slugs) from the bulk header.

The control narrative for one inlet separator V-6801 is discussed in this document and
the same is applicable for the other inlet separator V-6802.

4.2.2 Condensate Level Control Logic

68LICA-0107B-Condensate level controller

68FICQ-0102-Condensate flow controller

4.2.2.1 Objective

To control condensate level in the separator.

4.2.2.2 Functional Description

The V-6801 condensate level control is performed by 68LICA-0107B (master

controller). To achieve better control, level control is cascaded to slave flow controller
68FICQ-0102 which regulates the control valve 68FCV-0102 located on condensate
outlet line.

Opening & closing of 68FCV-0102 is linked to the opening/closing of PSD valve

(68UZV-0101) which is located upstream of 68FCV-0102.

4.2.2.3 Operational and Implementation Aspects

 I. Start-up
During start-up the controller shall be in manual mode. However opening of
68UZV-0101 will drive 68FCV-0101 in auto mode.
II. Normal Steady-State
Level transmitter is tracking the actual value.
III. Crippled mode operation
In case of input signal failure the level cotroller will be put in manual mode.
Valve opening and closing will be done manually.

IV. Shut down

During the PSD or ESD of the inlet separator, upstream PSD valve
(68UZV-0101) will close and activates 68XS-0101 which will close 68FCV-
0102.
V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.
4.2.3 Gas flow Control Logic
68LICA-0107A-Condensate level controller
68FICQA-0101-Gas flow controller
68Y-0101-Low selector
4.2.3.1 Objective
To control the flow of gas passing through inlet separator.
4.2.3.2 Functional Description
The V-6801 outlet gas flow control is performed mainly by 68FICQA-0101.
The output of 68FICQA-0101 is sent to the low selector 68Y-0101. The low
selector also receives signal from high condensate level controller 68LICA-
0107A. The output of low selctor signal regulates the control valve 68FCV-
0102 located on gas outlet line.
Normally flow control valve 68FCV-0101 is regulated by gas flow controller
68FICQA-0101. When condensate level reaches high value, then 68LICA-
0107A overrides the flow signal and it will start controlling 68FCV-0101 to
avoid liquid carryover to the outlet gas line. When condensate level reaches
below set point, then the control is handed over to flow controller 68FICQA-
0101.

4.2.3.3 Operational and Implementation Aspects

 I. Start-up
During start-up the controller shall be in manual mode and after stabilisation
of operation, it will be put in the auto mode.
II. Normal Steady-State
Flow transmitter is tracking the actual value.
III. Crippled mode operation
In case of input signal failure, the flow cotroller will be put in manual mode.
Valve opening and closing will be done manually.
IV. Shut down
During station ESD, 68FCV-0101 will be opened.

V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.

4.2.4 Produced Water Level Control Logic

68LICA-0103- Produced water level controller

4.2.4.1 Objective

To control the produced water (interface) level in the inlet separator.

4.2.2.4 Functional Description

Inlet separator (V-6801) produced water level control is performed by 68LICA-0103

which regulates the control valve 68LCV-0103 located on produced water outlet line.

Opening and closing of 68LCV-0103 is linked to the opening/closing of PSD valve

(68UZV-0102) located upstream of 68LCV-0103.

On high interface level, the liquid level switch 68LS-0104 will regulate corrosion
inhibitor injection pumps P-6372A/B to inject corrosion inhibitor to condensate header
to avoid corrosion. If the interface level increases then one of the corrosion inhibitor
injection pumps (P-6372 A/B) is started automatically and stopped when the level
comes down.

4.2.2.5 Operational and Implementation Aspects

I. Start-up
 During start-up the controller shall be in manual mode. However opening of
68UZV-0102 will drive 68LCV-0103 in auto mode.
II. Normal Steady-State
Level transmitter is tracking the actual value.
III. Crippled mode operation
In case of input signal failure the level cotroller will be put in manual mode.
Valve opening and closing will be done manually.
IV. Shut down
During the PSD or ESD of the inlet separator , upstream PSD valve
(68UZV-0102) will close and activates 68XS-0102 which will close 68LCV-
0103.
V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.

4.3 Compressor suction header pressure controller

Refer the following PEFS:
1. SNG-249-PX-2365-68003-0001
4.3.1 Process

The gas leaves Inlet Separators and shall be routed to suction scrubbers V-6811
/6821/6831 through suction coolers

4.3.2 Suction header pressure Control Logic

68PICA-0006-Compressor Suction common header pressure.

4.3.2.1 Objective

During transition period, the inlet manifold pressure is 100 barg and compressor can
not be started with such a high suction pressure. Therefore 68PICA-0006 and 68PCV-
0006 will be used to control compressor common suction header pressure in order to
achieve the required pressure at compressors suction (i.e. approximately 70 barg).

4.3.2.2 Functional Description

During the transition period, the suction pressure header controller 68PICA-0006
regulates the pressure let down valve 68PCV-0006.

68PICA-0006 also actuates creep valve (68USV-0014) located on common suction

header. During PSD of compressors, there is possibility of rise of pressure in this
header. 68PICA-0006 maintains the pressure of suction header below 70 barg with the
help of creep valve.

When the pressure on the common suction header is more than 70 barg, the pressure
controller shall open the creep valve 68USV-0014, located on the common header and
releases excess gas to flare header.

When the common header pressure reaches 65 barg, the pressure controller shall close
the creep valve.

4.3.2.3 Operational and Implementation Aspects

I. Start-up
During start-up the controller shall be at manual mode. The pressure letdown
valve 68PCV-0006 shall be opened manually. Then the controller will be
changed to AUTO mode.

II. Normal Steady-State

During normal operation, the controller shall be in auto mode and regulates the
pressure letdown valve.
III. Crippled mode operation
No special provisions are required
IV. Shut down
No special provisions are required.
V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.

4.4 Suction Coolers (E-6811, E-6821 & E-6831)

Refer the following PEFS:
2. SNG-249-PX-2365-68010-0001
3. SNG-249-PX-2365-68020-0001
4. SNG-249-PX-2365-68030-0001
The control narrative for a suction cooler E-6811 is discussed in this document and the
same is applicable for the other suction coolers (E-6821 & E-6831).

4.4.1 Process
The gas leaves Inlet Separators at about 100°C and requires cooling before it is
compressed. This is accomplished in an air-cooled suction cooler. The cooler consists
of 4 bays, each housing 2 bundles and cooled by 2 fans, both on variable speed drives.
It is the design intent to cool the gas but not less than 30°C to prevent hydrate
formation. Cooler outlet fluid containing varying amounts of condensed water and
hydrocarbons then proceeds to suction scrubber (V-6811).

4.4.2 Suction Cooler Outlet Temperature Control Logic

68TICA-1102-Suction Cooler Outlet Temperature

4.4.2.1 Objective

To control the suction cooler fans in order to achieve the required temperature of the
gas at the outlet of the inlet separator.

4.4.2.2 Functional Description

The only parameter requiring control is the outlet temperature.

When outlet temperature of the gas is at 40°C, both the cooler fans shall be running at
the minimum possible speed. If the cooler outlet temperature reduces further to a
temperature 35°C, 68TICA-1102 will stop one of the running fan and at the
temperature 30°C, it will also stop the other fan.

The outlet temperature starts rising due to stopping of both fans. When outlet
temperature of the gas is at 35°C, 68TICA-1102 will start first stopped fan and at the
temperature 40°C, it will also start the other fan.

4.4.2.3 Operational and Implementation Aspects

I. Start-up
During start-up the low low temperature trip (68TZA-1103) shall be
overridden. The temperature controller 68TICA-1102 implemented in the DCS
is configured with a default setting with 0.0 % output and will "only" transfer
to AUTO mode and local set point on having received a request to start the fin
fans from the start-up sequence
II. Normal Steady-State
Temperature transmitter will control the variable speed drives of the cooler
fans in order to keep the outlet temperature of the gas between 60 to 30 deg C.
III. Crippled mode operation
Temperature transmitter will be put in manual mode. Start / stop of the cooler
fans will be done manually.
IV. Shut down
No special provisions are required.
V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
 No calculations are required.
VII. Special consideration
None.
VIII. History
None.

4.5 Compressor Suction Scrubbers (V-6811, V-6821 & V-6831)

Refer the following PEFS:
1. SNG-249-PX-2365-68010-0001.
2. SNG-249-PX-2365-68020-0001.
3. SNG-249-PX-2365-68030-0001.

4.5.1 Process

The control narrative for compressor suction scrubber V-6811 is discussed in this
document and the same is applicable for the other suction scrubbers (V-6821 & V-
6831).

Compressor Suction Scrubber is a vertical 2-phase separator which receives fluids from
cooler outlet, separates the gas and liquid. The bulk liquid is sent to the common
condensate separator (V-6803). Gas leaves the scrubber top and proceeds to the Booster
Compressor (K-6810).

The scrubber is designed in accordance with DEP to achieve liquids removal better than
99% of the inlet liquid volume, and is equipped with a Schoepentoter, mistmat,
swirldeck, and second mistmat. (SMSM).

4.5.2 Liquid Level Control Logic

68LICA-1101-Liquid level controller

4.5.2.1 Objective

To control liquid level in the suction scrubber.

4.5.2.2 Functional Description

The compressor suction scrubber (V-6811) liquid level control is performed by

68LICA-1101 which regulates the control valve 68LCV-1101 located on liquid outlet
line.

Opening & closing of 68LCV-1101 is linked to the opening/closing of PSD valve

(68UZV-1120) located upstream of 68LCV-1101.

4.5.2.3 Operational and Implementation Aspects

I. Start-up
During start-up, the controller shall be in manual mode. However, opening of
68UZV-1120 will drive 68LCV-1101 to auto mode.
 II. Normal Steady-State
Level transmitter is tracking the actual value.
III. Crippled mode operation
In case of input signal failure the level cotroller will be put in manual mode.
Valve opening and closing will be done manually.
IV. Shut down
During the PSD or ESD of the suction scrubber, upstream PSD valve
(68UZV-1120) will close and activates 68XS-1140 which will close 68LCV-
1101.
V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.

4.6 Booster Compressors (K-6810, K-6820 & K-6830)

Refer the following PEFS:
1. SNG-249-PX-2365-68010-0002 6.SNG-249-PX-2365-68010-0003
2. SNG-249-PX-2365-68020-0002 7.SNG-249-PX-2365-68020-0003
3. SNG-249-PX-2365-68030-0002 8.SNG-249-PX-2365-68030-0003
4. SNG-249-PX-2365-68003-0001
5. SNG-249-PX-2365-68004-0001

4.6.1 Process
Gas from the suction scrubber is routed to compressor. Between start-of-run to end-of-
run conditions for Phase SNDC-1, Booster Compressor will receive from about 10.5 to
7 MMSCMD gas at pressures ranging from 70 to 38 bara and compress it to a pressure
required at SNGP inlet for meeting its export gas target. The most severe discharge
temperature at the end-of-run is estimated to be about 175°C.

The compressor will be a single stage centrifugal type and will be driven by a
synchronous electrical motor

The suction pressure of the compressors will depend on the supply pressure at the Plant
Inlet Manifold, which will be controlled as described in Section 4.1.1. During initial
phase of operation, gas inlet pressure will be high enough for two compressor
operation, with the third on standby, resulting in a marked improvement in availability
and production efficiency.
Compressor control will have an integrated capacity & antisurge control. Each unit will
have an independent antisurge control integrated with overall capacity control for the
entire trains. The integration will ensure the turndown and stability.

Compressor will have a dry gas seal system, with process gas for primary seal and
instrument air as separation gas for secondary seal. Primary seal vents will be routed to
the existing SNGP AP Flare system. Normally, seal gas for the compressor primary seal
will be provided from compressor discharge, with a cold start supply from fuel gas line.
Each compressor will have its own seal gas treatment unit consisting of a heater,
pressure letdown valves and a filter.

The control narrative for a Booster Compressor K-6810 is discussed in this document
and the same is applicable for the other booster compressors (K-6820 and K-6830).

4.6.2 Controls
4.6.2.1 Control of Compressor Systems

Each compressor control consists of the following:

 All 3 stages of Start-up, i.e. Startup of Auxiliaries, Pressurizing, and
Startup of compressor – performed by automatic start sequence, with
each stage initiated from FCS HMI process schematic.
 PSD – isolate compressor train and remain pressurized.
 ESD – isolate compressor train and, depressurize using blow down
valves.
 Control of auxiliaries, viz. suction scrubber, coolers, inlet and outlet
ESD valves, lube oil, and seal gas system.
 Normal Shutdown – Automatic shutdown sequence initiated from FCS
HMI process schematic in the CCR, FARI and LCP.

4.6.2.2 Control of Compressor Machine

The Machine control consists of the following functions:

 Speed (Capacity) control with manual override
 Integrated Capacity & Anti-surge control system
 Compressor performance machine monitoring (pressure, temperature,
vibration and speed)
 Start-up/Stop sequence
 Control of Utilities
 Lube oil control system
 Seal gas control system with temperature controller.
 Remote monitoring of compressor performance from Qarn Alam/Saih
Nihayda Conditioning Monitoring Group.

4.6.2.3 Integrated Capacity and Anti-Surge Control

Two separate measures are provided to protect machine against damage from surging
due to insufficient loading: an anti-surge control, and a capacity control. The capacity
control scheme may be interfaced from the FCS HMI process schematic.
 Each machine has a dedicated integrated capacity & anti-surge controller. Integrated
Capacity and Anti-surge controller shall perform as a minimum the following
functions:
 In normal operation, the speed of all three compressors will be controlled
from the pressure controller (68PICA-0007) located in the common SNDC-1
discharge header, which will receive its set point from the SNGP Master Flow
Controller located in the export gas line.
 In case the throughput demand of the SNGP Master Flow Controller exceeds
gas supply from the wells and the suction pressure falls below its set point, the
low suction pressure constraint controller (68PICA-1108) will control
compressor speed. It will reduce the speed to maintain the suction pressure.
 In case the compressor discharge pressure increases beyond the design limit of
discharge system, then the discharge pressure constraint controller
(68PICA-1203) will control compressor speed. It will reduce the speed to
maintain the discharge pressure.
 Incase the compressor motor power increases on demand, a high power
constrain controller (68XIC-1209) will control the compressor speed. It will
reduce the speed to maintain compressor motor power within the limit.
 In case the compressor discharge temperature increases beyond the design
limit of discharge system, then the discharge temperature constraint controller
(68TICA-1202) will control compressor speed. It will reduce the speed to
maintain the discharge temperature.
 The anti-surge controller (also included in the integrated capacity & anti-surge
control block 68UIC-1001) is intended to prevent the compressor’s operating
point to move towards the surge line.
During normal compressor operation, the capacity controller will adjust the compressor
speed attempting to meet the process flow demand; however if the compressor
operating point moves towards the compressor surge line based on the operating
conditions, the capacity control will demand the opening of the capacity control valve
68UCV-1215 first and then the anti-surge control will demand the opening of the anti-
surge valve 68UCV-1210.

The integrated capacity & anti-surge controller block 68UIC-1001 receives the process
measurements from the three pressure transmitters (68PICA-1108, 68PICA-0007 &
68PICA-1203) and the compressor suction flow transmitter 68FT-1103. These process
measurements are used to calculate the compressor operating point which is used as the
process measurement for the capacity controller.

The integrated capacity & anti-surge controller block 68UIC-1001 also receives the
process measurements from the two pressure transmitters (68PI-1107 &, 68PI-1201),
temperature transmitters (68TT-1105 & 68TT1201) and the compressor suction flow
transmitter 68FT-1103. These process measurements are used to calculate the
compressor operating point which is used as the process measurement for the antisurge
controller.

All the transmitters involved in the anti-surge control shall be fast response (< 100
msec) type transmitters.
The antisurge controller block will give a surge alarm in case the operating point has
reached the surge point and an indication signal when the operating point is closed to
surge and the antisurge valve start to open.

For the detailed description of the Control of Compressor (e.g. anti surge / capacity
control, start- up sequence, shut down sequence,etc) refer Compressor Vendor
Document.

4.7 Compressor After Coolers (E-6812, E-6822 & E-6832)

Refer the following PEFS:
1. SNG-249-PX-2365-68010-0003
2. SNG-249-PX-2365-68020-0003
3. SNG-249-PX-2365-68030-0003
The control narrative for an after cooler E-6812 is discussed in this document and the
same is applicable for the other after coolers (E-6822 and E-6832).

4.7.1 Process

Depending on the suction pressure, the temperature of the compressed gas on Booster
Compressors discharge will be about 90 to 165°C and requires cooling before it enters
the existing inlet cooler of SNGP. This is accomplished in an air cooled compressor
heat exchanger installed on each compressor train downstream of the compressor. The
cooler consists of 2 bays, each housing 2 bundles and cooled by 2 fans, both on variable
speed drives. In order to match original design conditions of the existing SNGP, it is the
design intent to control the gas exit at 100°C.

4.7.2 After Cooler Outlet Temperature Control Logic

68TICA-1203-After Cooler Outlet temperature

4.7.2.1 Objective

To control the discharge cooler fans in order to achieve the required temperature of the
gas at the outlet of the discharge cooler.

4.7.2.2 Functional Description

The only parameter requiring control is the outlet temperature.

When outlet temperature of the gas is at 90°C, both the cooler fans shall be running at
the minimum possible speed. If the cooler outlet temperature reduces further to a
temperature 85°C, 68TICA-1203 will stop one of the running fan and at the
temperature 80°C, it will also stop the other fan.

The outlet temperature starts rising due to stopping of both fans. When outlet
temperature of the gas is at 85°C, 68TICA-1203 will start first stopped fan and at the
temperature 90°C, it will also start the other fan. To maximize the cooling, both fans
will run at controlled speed to maintain temperature at 100°C.
4.7.2.3 Operational and Implementation Aspects

I. Start-up
During start-up the low low temperature trip (68TZA-1204) shall be
overridden. The temperature controller 68TICA-1203 implemented in the DCS
is configured with a default setting with 0.0 % output and will "only" transfer
to AUTO mode and local set point on having received a request to start the fin
fans from the start-up sequence.
II. Normal Steady-State
Temperature transmitter will control the variable speed drives of the cooler
fans in order to keep the outlet temperature of the gas at 100 deg C.
III. Crippled mode operation
Temperature transmitter will be put in manual mode. Start / stop of the cooler
fans will be done manually.
IV. Shut down
No special provisions are required.
V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.

4.8 Condensate Separator (V-6803)

Refer the following PEFS No. 1) SNG-249-PX-2365-68005-0001
4.8.1 Process

The Condensate Separator V-6803 collects hydrocarbon and water separated from
Compressor Suction Scrubbers V-6811/6821/6831 and separates condensate and water.
Some flashing occurs due to a pressure differential between the source and destination
vessels. Therefore, the Condensate Separator will be designed and operated as a
horizontal 3-phase separator.

Separated liquids will proceed on their own pressure head to their respective
destinations existing in the SNGP Facility. Condensate will be sent to E-6213
Condensate Cooler and produced water to V-6214 Produced water degassing vessel.
Flashed off-gas will be disposed of into Off-Gas Pipeline.

The separator is designed in accordance with DEP to achieve liquids removal better
than 99% of the inlet liquid volume, and is equipped with a Schoepentoter, Single weir,
Mismat, vortex breaker and plate pack.

4.8.2 Condensate Level Control Logic

68LICSA-0302-Condensate level controller
68FICQ-0302-Condensate flow controller

4.8.2.1 Objective

To control condensate level in the condensate separator.

4.8.2.2 Functional Description

The V-6803 condensate level control is performed by 68LICSA-0302 (master

controller). To achieve better control, level control is cascaded to slave flow controller
68FICQ-0302 which regulates the control valve 68FCV-0302 located on condensate
outlet line.

Opening & closing of 68FCV-0302 is linked to the opening/closing of PSD valve

68UZV-0303 which is located upstream of 68FCV-0302.

On condensate high level, the controller 68LICSA-0302 also initiates bypass operation.
For high level, it opens condensate separator bypass PSD valve 68UZV-0311 and
closes inlet PSD valve 68UZV-0310. When level reaches below high level set point,
condensate separator will be taken to normal mode by closing bypass PSD valve
(68UZV-0311) and opening inlet PSD valve (68UZV-0310).

4.8.2.3 Operational and Implementation Aspects

I. Start-up
During start-up the controller shall be in manual mode. However, opening of
68UZV-0303 will drive 68FCV-0302 in auto mode.
II. Normal Steady-State
Level transmitter is tracking the actual value.

III. Crippled mode operation

In case of input signal failure the level controller will be put in manual mode.
Valve opening and closing will be done manually.
IV. Shut down
During the PSD or ESD of the condensate separator , upstream PSD valve
(68UZV-0303) will close and activates 68XS-0301 which will close 68FCV-
0302.
V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.
 4.8.3 Produced Water Level Control Logic

68LICA-0301- Produced water level controller

4.8.3.1 Objective

To control the produced water (interface) level in the condensate separator.

4.8.3.2 Functional Description

Condensate separator (V-6803) produced water level control is performed by

68LICA-0301 which regulates the control valve 68LCV-0301 located on produced
water outlet line.

Opening and closing of 68LCV-0301 is linked to the opening/closing of PSD valve

(68UZV-0304) located upstream of 68LCV-0301.

4.8.3.3 Operational and Implementation Aspects

I. Start-up
During start-up the controller shall be in manual mode. However , opening of
68UZV-0303 will drive 68LCV-0301 in auto mode.
II. Normal Steady-State
Level transmitter is tracking the actual value.
III. Crippled mode operation
In case of input signal failure the level cotroller will be put in manual mode.
Valve opening and closing will be done manually.
IV. Shut down
During the PSD or ESD of the condensate separator , upstream PSD valve
(68UZV-0304) will close and activates 68XS-0302 which will close 68LCV-
0301.

V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.
4.8.4 Pressure Control Logic

68PICA-0303A- and 68PICA-0303B- Condensate separator pressure controllers.

4.8.4.1 Objective
 To control the pressure of the condensate separator.

4.8.4.2 Functional Description

The Condensate Separator (V-6803) pressure control is performed by two independent

pressure controllers 68PICA-0303A and 68PICA-0303B. The pressure of the
condensate separator is transmitted to both pressure controllers by 68PT-0303 installed
on condensate separator gas outlet line. The compressor common suction header
pressure shall be given to calculation block 68PYC-0302. The pressure controllers
(68PICA-0303 A/B) receive signal from pressure control calculation block 68PYC-
0302 and from the pressure transmitter 68PT-0303. The pressure controller 68PICA-
0303A maintains the condensate separator pressure 4 bar lower than the common
suction header pressure by regulating control valve 68PCV-0303A which is located on
vessel off-gas outlet line.

Another control valve (68PCV-0303B) is provided on the flare line from vessel. This
control valve is regulated by controller 68PICA-0303B which also receives the set
point from calculation block 68PYC-0302 and from the pressure transmitter 68PT-
0303. The control valve shall have set point approximately 1 bar more than 68PCV-
0303A set point. In case of any upset of 68PCV-0303A, the vessel pressure will
increase and then vessel pressure will be reduced by opening control valve (68PCV-
0303B) and excess gas will be sent to flare system. When vessel pressure reduces, then
68PCV-0303B will close and again control will be handed over to another valve
68PCV-0303A.

4.8.4.3 Operational and Implementation Aspects

I. Start-up
During start-up both the controllers shall be in manual mode until the pressure
will reach to normal value, then it will be put in the auto mode.
II. Normal Steady-State
Pressure transmitter is tracking the actual value.
III. Crippled mode operation
In case of input signal failure the both cotrollers will be put in manual mode.
Valves opening and closing will be done manually.
IV. Shut down
No special provisions are required as controller will become disabled for direct
pressure control and switch to manual mode.
V. Operator interface
DCS graphic displays will show all real time process data. All control modes
and parameters, except the calculation functions of pressure controllers, will
be available in standard graphic displays and accessible to the operator.
VI. Calculation
Calculations block is required.
VII. Special consideration
None.
VIII. History
 None.
4.8.5 Differential Pressure Switch Logic

68PDSA 0305- Condensate separator pressure differential switch.

4.8.5.1 Objective

To prevent high level in compressor suction scrubbers.

4.8.5.2 Functional Description

The Condensate Separator (V-6803) pressure control is performed by two independent

pressure controllers 68PICA-0303A and 68PICA-0303B. Failure of this pressure
controllers leads to increase the level in the compressor suction scrubbers which further
leads to compressors PSD.

To prevent Compressors PSD, due to the above reason, a pressure differential switch
68PDSA-0305 is provided.

The differential pressure switch receives the signals from a pressure transmitter 68PT-
0301 installed on condensate separator and compressor suction common header
pressure controller 68PICA-0006. When the differential pressure is less than 2 bar (at
low differential pressure), the pressure differential switch opens condensate separator
by pass valve 68UZV-0311 and closes condensate separator inlet valve 68UZV-0310 to
allow condensate separator to work in bypass mode.

When the pressure differential is more than 2 bar (low differential pressure set point, it
opens condensate separator inlet PSD valve (68UZV-0310) and closes the bypass PSD
valve (68UZV-0311) to allow condensate separator to work in normal mode.

4.8.5.3 Operational and Implementation Aspects

I. Start-up
During start-up pressure differential switch shall be in manual mode and inlet
valve shall be kept open. When the pressure in the condesate separator reaches
to normal value, then it will be put in the auto mode.
II. Normal Steady-State
Pressure transmitter is tracking the actual value.
III. Crippled mode operation
In case of input signal failure, the pressure differentail switch will be put in
manual mode. Valves opening and closing will be done manually.
IV. Shut down
No special provisions are required.
V. Operator interface
DCS graphic displays will show all real time process data. The switch mode
and other parameters, except the calculation functions of pressure switch, will
be available in standard graphic displays and accessible to the operator.
VI. Calculation
 Calculations block is required.
VII. Special consideration
None.
VIII. History
None.

5.0REFERENCE
 Saih Nihayda Depletion Compression Phase- I, Basis for Design Doc no
VEC4552/RPT/101, Rev-B.
 Saih Nihayda Depletion Compression Phase- I, Process Description and
Control Philosophy, Doc no- VEC4552/RPT/102, Rev-B

6.0 ATTACHMENTS
 Process Control Schematic Diagram
 Process Engineering Flow Schemes
 Appendix-I
Process Control Schematic Diagram
 Appendix-II
Process Engineering Flow Schemes