Heater Treater Control and

Shutdown Philosophy

Prepared by:

Client Document No.-1902001-BTN-10-MDO-101

Project Document No.- CPE-19037-EN-7200

0 14-Aug-19 Issued for Construction DBR BBG BBG

C 16-July-19 Issued for Approval DBR BBG BBG
B 27-June-19 Issued for Approval BBG DBR BBG
A 21-June-19 Issued for Approval DBR BBG BBG
REV DATE DESCRIPTION ORIG CHK APPR
APPROVED BY: COMPANY APPROVAL:

DATE: DATE:
Heater Treater Project Control and Shutdown Philosophy

Change Log
REV SECTION PAGE CHANGE DESCRIPTION
B 8.0 10-14 Addition of Desalter Information
Removal of Desalter info (created separate document) and
C 8.0 N/A revisions based on content redlines by client (added
setpoints and inlet and outlet oil conditions)
0 All All IFC, Added Burner information and removed burner hold

Document Holds
REV SECTION PAGE HOLD DESCRIPTION

Notes:

1. Change Log only reflects changes from previous issuance. Hold Log reflects current
"holds" in issued document.

2. If changes and/or holds exceed one page, additional page(s) shall be generated.

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TABLE OF CONTENTS

1.0 INTRODUCTION .............................................................................................................4

2.0 SCOPE ...........................................................................................................................4
3.0 RELATED DOCUMENTS AND REFERENCES ..............................................................4
4.0 ABBREVIATIONS ...........................................................................................................4
5.0 NEW INSTRUMENTATION ............................................................................................5
6.0 ADDITION TO THE EXISTING SAFETY AND PROCESS CONTORL SYSTEM ...........5
7.0 HEATER TREATER ........................................................................................................5

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1.0 INTRODUCTION
The Bretaña Field is located in Peruvian Amazon.
As a part of the project, the following major process equipment will be installed to tie in the
existing production facilities:
• Heater Treater
• Desalter
2.0 SCOPE
The purpose of this document is to describe the control and shutdown philosophy for the
new heater-treater and the required interfaces via hardwired signals and communication
links between the existing Basic Process Control System (BPCS) / Safety System (SSS)
/ Human Machine Interface (HMI) systems:
• Remotely monitor process equipment at the facility HMI
• Control Levels, temperatures, and pressures
• Closing of shutdown valves and associated equipment in case of
emergency events.
3.0 RELATED DOCUMENTS AND REFERENCES
The following documents should be used in conjunction with this Control and Shutdown
Philosophy.

CPE-19037-DW-2000 Heat-Treater P&ID

CPE-19037-EN-7201 Heater-Treater Cause & Effect Matrix
CPE-19037-EN-7204 Treater Install., Ops., and Maintenance Manual

4.0 ABBREVIATIONS
SDV: SHUTDOWN VALVE
SSS: SAFETY SYSTEM
BPCS: PROCESS CONTROL SYSTEM
BMS: BURNER MANAGEMENT SYSTEM
PCV: PRESSURE CONTROL VALVE
LCV: LEVEL CONTROL VALVE
TCV: TEMPERATURE CONTROL VALVE
FWKO: FREE WATER KNOCKOUT
IA: INSTRUMENT AIR
ESD: EMERGENCY SHUTDOWN
PV: PROCESS VARIABLE
CV: CONTROL VARIABLE
Cv: VALUE ASSOCIATED WITH CONTROL FLOW CAPACITY

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DP: DIFFERENTIAL PRESSURE

UCP: UNIT CONTROL PANEL
TBD: TO BE DETERMINED

5.0 NEW INSTRUMENTATION

New instruments will follow SERTECPET’s recommendations for manufacturers, model
numbers, and specifications as the existing equipment installed at the production facility
for consistency in operating, maintenance and safety practices.
Process and safety instruments will not be connected to the same process taps.
Transmitters will be SMART type with 4-20 mA analog outputs and HART
communication capability. SMART transmitters will be configured to output in the
direction of the trip alarm when an internal fault is detected unless otherwise noted on
instrument data sheets. For example, if the trip direction is HIGH HIGH, the transmitter
will be configured to output greater than 20 mA value; if the trip direction is LOW LOW,
the transmitter will be configured to output less than 4.0 mA value; if the trip direction is
both LOW LOW and HIGH HIGH, the transmitter will be configured to output less than
4.0 mA value. SMART temperature transmitters will be configured to output greater than
20.0 mA value upon sensing of sensor burnout. Discrete shutdown signals will be
configured as failsafe (i.e., de-energize to stop / trip). All instruments will be provided
with stainless steel wires and tags.

6.0 ADDITION TO THE EXISTING SAFETY AND PROCESS CONTROL SYSTEM

In general, the Safety system is designated by Safety System (SSS) and control system
has the designation Basic Process Control System (BPCS). All signals will be hardwired
to the existing facility SSS and BPCS.

7.0 HEATER TREATER

The Heater Treater offers enhanced 3-phase separation over standard gravity
separation. In the first section (Heater section), the inlet feed is diverted to the outer
portion of the vessel by means of an inlet shroud which guides the fluid underneath the
firetubes. Free water and suspended solids drop out as the oil rises to pass over and
across the firetubes. The firetubes deliver heat via two (2) 5 MMBTU/hr burners which
maintain an operating temperature of 220-240°F. As the oil is heated, the viscosity
decreases, and the oil is also degassed. A pressure control loop holds a back pressure
of 40-60 psig on the vessel. The oil then flows up and over a weir to the coalescing
section where the oil encounters a coalescing plate pack where water droplet
coalescence takes place allowing for additional water removal. After passing thru the
plate pack, the oil then flows over the oil bucket weir and then out of the vessel. Water is
removed from the vessel via two separate water outlet which maintain independent
levels.

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Two instrument junction boxes will be part of the heater treater package, JBS-1H400-01
and JBP-1H400-01. All safety related signals will be terminated to the existing SSS and
are wired to JBS-1H400-01. All other signals are terminated to JBP-1H400-01 and will
be connected to the BPCS.

In order to accommodate maintenance and troubleshooting scenarios, manual bypass

provisions exist so that flow can completely bypass the vessel. The bypass and
upstream block valves are located downstream of the heater treater mixing arrangement.
The downstream block valves are the ball valve immediately downstream of the oil outlet
control valve (LCV-1H400-01) and the bypass valve around it. For isolation procedures
related to maintenance, descriptions of vessel internals, and commissioning and startup
information please refer to the package Installation, Operation, and Maintenance Manual
(CPE-19037-EN-7204).

7.1 Crude Oil Inlet

7.1.1 Line 6”-PO-A3-CPF1-202A

PDIT-1H400-01 provides monitoring to the BPCS of the DP across the

inlet mixing valve and static mixer MXR-1H400-01. Multiple isolation
valves tubed to PDIT-1H400-01 allow isolation in various arrangements
making it possible to monitor the differential pressure across either (1) the
mixing valve, (2) the static mixer, or (3) the combined mixing
arrangement.

The SDV for the crude oil inlet is SDV-1H400-01. The valve will have
position status feedback to the SSS and HMI. SDY-1H400-01, a
shutdown solenoid, is installed on the IA and controlled by the SSS.
When SDY-1H400 is de-energized, SDV1H400-01 will fully close. Refer
to the Cause & Effect for associated actions.

7.2 Gas Outlet

7.2.1 Heater Treater Pressure Control

Pressure control for the Heater Treater is accomplished by means of a

back-pressure control loop consisting of PCV-1H400-01 on the produced
gas outlet line and PIT-1H400-02 on the Heater Treater vessel.

The position of pressure control valve PCV-1H400-01 is modulated by

applying a 4-20 mA signal to PY-1H400-01. 0%, once calibrated and set,
will correspond to 4 mA and fully open position. 100%, once calibrated
and set, will correspond to 20mA and fully closed position. PCV opening,
travel, and Cv shall be per control valve manufacturer operating manual.
Please refer to section 7.6 for information related to set points.

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PIT-1H400-02 provides monitoring and alarming for pressure in the BPCS

for the Heater Treater 1-H-400. PIT-1H400-02 provides the PV for PIC-
1H400-01 in which the CV modulates PCV-1H400-01 by means of PY-
1H400-01. This pressure transmitter is located on the Heater Treater.
Please refer to section 7.6 for information related to set points.

There is a 2” globe valve in a bypass line around PCV-1H400-01 that is

intended for continuous operation if maintenance of PCV is needed.
SDY-1H400-05 is installed on the IA and controlled by the SSS as a
permissive solenoid. When de-energized it will fully open PCV-1H400-01.
Please refer to section 7.6 for information related to set points.

PIT-1H400-01 provides monitoring and PALL/PAHH safety protection in

the SSS for the Heater Treater 1-H-400. This pressure transmitter is
located downstream of SDV-1H400-01 on the vessel. Refer to Cause &
Effect for associated actions. PALL shall have an initial bypass timer for
an appropriate amount of time to allow the vessel pressure to build upon
energizing of SDY-1H400-01 upon startup. Please refer to section 7.6 for
information related to set points.

.
7.3 Produced Water Outlet

7.3.1 Heater Treater Interface Level Control

The Heater Treater is separated into two sections via a spill-over weir.
This creates two separate compartments which each maintain oil-water
interface levels independent of one another. Interface level control is
accomplished in each to different sections of the Heater Treater by
independent LCV’s and an associated Level Transmitter. The first section
(heater section), which functions as a heating and free water knock out
section, will handle much of the produced water. The second section
(coalescing section), which contains the coalescing plate pack, will handle
additional produced water mostly due to the coalescing.

The position of the level control valve associated with the heating/FWKO
section of the Heater Treater, LCV-1H400-03, is modulated by applying 4-
20 mA signal to LY-1H400-03. 0%, once calibrated and set, will
correspond to 4 mA and fully closed position. 100%, once calibrated and
set, will correspond to 20mA and fully open position. LCV opening, travel,
and Cv shall be per control valve manufacturer operating manual.

LIT-1H400-02 provides monitoring and alarming for the interface level in

the BPCS for the Heater Treater 1-H-400. LIT-1H400-02 also provides
the PV for LIC-1H400-02 in which the CV modulates LCV-1H400-03 by
means of LY-1H400-03. This level transmitter is located on the Heater
Treater. Refer to Cause & Effect for associated actions. Please refer to
section 7.6 for information related to set points.
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There is a 2” globe valve in a bypass line around LCV-1H400-03 that is

intended for continuous operation if maintenance of the LCV is needed.

SDY-1H400-03 is installed on the IA and is controlled by the SSS as a

permissive solenoid. When de-energized it will fully close LCV-1H400-03.
Please refer to section 7.6 for information related to set points.

LIT-1H400-01 provides monitoring and LALL/LAHH safety protection and

is connected to the SSS system. Please refer to section 7.7 for
information related to shutdown set points.

The position of the level control valve associated with the coalescing
section of the Heater Treater, LCV-1H400-02, is modulated by applying a
4-20 mA signal to LY-1H400-02. 0%, once calibrated and set, will
correspond to 4 mA and fully closed position. 100%, once calibrated and
set, will correspond to 20mA and fully open position. LCV opening, travel,
and Cv shall be per control valve manufacturer operating manual.

There is a 2” globe valve in a bypass line around LCV-1H400-02 that is

intended for continuous operation if maintenance of the LCV is needed.

LIT-1H400-05 provides monitoring and alarming for the interface level in

the BPCS for the Heater Treater 1-H-400. LIT-1H400-05 also provides
the PV for LIC-1H400-03 in which the CV modulates LCV-1H400-02 by
means of LY-1H400-02. This level transmitter is located on the Heater
Treater. Please refer to section 7.6 for information related to control set
points.

SDY-1H400-02 is installed on the IA and is controlled by the SSS as a

permissive solenoid. When de-energized will fully close LCV-1H400-02.
Please refer to section 7.6 for information related to control set points.

LIT-1H400-06 provides monitoring and LALL/LAHH safety protection in

the SSS. Please refer to section 7.7 for information related to shutdown
set points.

An ultrasonic flow meter, FIT-1H400-01, will be installed on the produced

water line 3”-PW-A2-CPF1-152A to skid edge. FIT-1H400-01 provides
monitoring for all the produced water in the BPCS from the Heater
Treater 1-H-400.

LSHH-1H400-01 provides LSHH safety protection in the SSS for overall

level in the heater section. Please refer to section 7.7 for information
related to shutdown set points.

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LSLL-1H400-01 provides LSLL safety protection in the SSS for overall

level in the heater section. Please refer to section 7.7 for information
related to shutdown set points.

7.4 Crude Oil Outlet

7.4.1 Heater Treater Oil Level Control

Treated oil is isolated from produced water falling out in the coalescing
section by means of an oil bucket located in the rear of the Heater
Treater. Oil Level Control is accomplished by means of a LCV and an
associated level transmitter.

The position of the heater treater oil level control valve, LCV-1H400-01, is
modulated by applying 4-20 mA signal to LY-1H400-01. 0%, once
calibrated and set, will correspond to 4 mA and fully closed position.
100%, once calibrated and set, will correspond to 20mA and fully open
position. LCV opening, travel, and Cv shall be per control valve
manufacturer operating manual.

There is a 2” globe valve in a bypass line around LCV-1H400-01 that is

intended for continuous operation if maintenance of the LCV is needed.

LIT-1H400-03 provides monitoring and alarming for oil level in the BPCS
for the Heater Treater 1-H-400. LIT-1H400-03 also provides the PV for
LIC-1H400-03 in which the CV modulates LCV-1H400-02 by means of
LY-1H400-02. This level transmitter is located on the Heater Treater.
Please refer to section 7.6 for information related to control set points.

LIT-1H400-04 provides monitoring and LALL/LAHH safety protection in

the SSS. Please refer to section 7.7 for information related to shutdown
set points..

SDY-1H400-04 is installed on the IA and controlled by the SSS as a

permissive solenoid. When de-energized will it fully close LCV-1H400-01.
Please refer to section 7.7 for information related to shutdown set points.

7.5 Burners

Heat is added to the process separation by means of two (2) 5 MMBTU/hr forced
draft burners using #2 fuel oil / diesel.

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7.5.1 Burner Control

The intended control and safety shutdown arrangement of burners “A”

and “B” for the heater treater is as follows:

For burner “A”, a temperature sensing transmitter, TIT-1H400-01A, is

used to measure temperature and is wired to the SSS system. TIT-
1H400-02A provides monitoring and TALL/TAHH safety protection in the
SSS. Please refer to section 7.7 for information related to shutdown set
points.

For burner “A”, TE-1H400-01A (an RTD), is used to sense the

temperature at in the vessel and is wired to a temperature controller (TIC-
1H400-01A) which is responsible for vessel temperature control via
burner throttling. The intended controller is to be a Honeywell 2500.

For burner “B”, an identical setup is used with the differing tag suffixes
ending with a “B” instead of an “A”.

All burner related I/O points, with exception to TIT-1H400-02A/B, do not

travel through the BPCS and SSS junction boxes mounted near the
equipment.

For additional guidance on burner operation, please consult the relevant

manufacturer’s literature on proper operation, etc.

7.6 BPCS Alarms and Control Set Points – Heater-Treater (1-H-400)

NOTE: Refer to latest P&ID to verify set points. This chart is based on Revision 0

Logic Tag No. Service Set Point High Alarm Low Alarm
PIC-1H400-01 Treater Pressure Control 60 psig 80 psig 40 psig
Temperature Control,
TIC-1H400-01A 240°F 275°F 230°F
Burner #1
Temperature Control,
TIC-1H400-01B 240°F 275°F 230°F
Burner #2
LIC-1H400-01 Oil Bucket Level Control 104.5” 108.5” 100.5”
Oil-Water Interface Level
LIC-1H400-02 54” 66” 48”
Control (Coalescing)
Oil-Water Interface Level
LIC-1H400-03 15.25” 19.25” 11.25”
Control (Heating)

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7.7 SSS Shutdown Set Points – Heater-Treater (1-H-400)

NOTE: Refer to latest P&ID to verify set points. This chart is based on Revision 0

Logic Tag No. Service Set Point Action

Shut SDV-1H400-01
LAHH-1H400-04 Oil Bucket High Shutdown 112.5”
Shut Down Burners
Shut LCV-1H400-01
LALL-1H400-04 Oil Bucket Low Shutdown 97.5”
Shut Down Burners
Oil-Water Interface High
LAHH-1H400-06 82” Shut SDV-1H400-01
Level Shutdown (Coalescing)
Oil-Water Interface Low Level
LALL-1H400-06 24” Shut LCV-1H400-02
Shutdown (Coalescing)
Oil-Water Interface Level
LAHH-1H400-01 34” Shut SDV-1H400-01
Control (Heating)
Oil-Water Interface Level
LALL-1H400-01 7.25” Shut LCV-1H400-03
Control (Heating)
Vessel Overall High Level Shut SDV-1H400-01
LSHH-1H400-01 112.5”
Shutdown Shut Down Burners
Vessel Heating Section
Shut LCV-1H400-03
LSLL-1H400-01 Overall Oil Low Level 97.5”
Shut Down Burners
Shutdown
Shut SDV-1H400-01
Vessel High Pressure
PAHH-1H400-01 90 PSIG Shut PCV-1H400-01
Shutdown
Shut Down Burners
Shut SDV-1H400-01
Vessel Low Pressure Shut LCV-1H400-02
PALL-1H400-01 35 PSIG
Shutdown Shut LCV-1H400-03
Shut LCV-1H400-01
Vessel High Temperature
TAHH-1H400-02A 285°F Shut Down Burners
Shutdown, Burner A
Shut SDV-1H400-01
Vessel Low Temperature
TALL-1H400-02A 220°F Shut SDV-1H400-04
Shutdown, Burner A
Shut Down Burners
Vessel High Temperature
TAHH-1H400-02B 285°F Shut Down Burners
Shutdown, Burner B
Shut SDV-1H400-01
Vessel Low Temperature
TALL-1H400-02B 220°F Shut SDV-1H400-04
Shutdown, Burner B
Shut Down Burners
Valve SDV-1H400-01 Close
ZIC-1H400-01 SDV-1H400-01 Operation
Close Signal
Valve SDV-1H400-01 Open
ZIO-1H400-01 SDV-1H400-01 Operation
Open Signal

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7.8 Operating Ranges – Heater-Treater (1-H-400)

Location Fluid Parameter Expected Range Units

Temperature 170 °F
Pressure 50-75 PSIG
Produced Gas
Flow 0.0-0.1 MMSCFD
Specific Gravity 0.89 []
Temperature 170 °F
Pressure 50-75 PSIG
Treater Inlet Produced Oil
Flow 0-5000 BBL/Day
API Gravity 17-19 °
Temperature 170 °F
Produced + Pressure 50-75 PSIG
Dilution Water Flow 0-3000 BBL/Day
Salinity ≤ 90,000 mg/L
Temperature 230-240 °F
Pressure 40-60 PSIG
Oil Outlet Produced Oil
Flow 0-5000 BBL/Day
BS&W ≤2 % H2O

For information regarding the inlet and outlet specifications of the crude oil, please consult the
process guarantee and Installation, Operation, and Maintenance Manual.

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