Alderley FZE

Section C - INSTALLATION AND COMMISSIONING INSTRUCTIONS

C.1 SAFETY PROCEDURES

PRIOR TO SKID OPERATION
Prior to starting any work on any equipment listed or detailed in this manual, it is essential that
the following actions are taken.
 This manual is read and understood.
 Check that the system is safe to work on. The system has been isolated and all
pressure removed prior to any items being removed or worked on.
 Prior to starting any work, the necessary permits should be obtained and all safety
interlocks placed in position by the operator.

HEALTH & SAFETY

All AFZE metering systems are inherently safe to use provided that they are handled by
competent, trained staff, in accordance with recognized engineering practices and in
accordance with the instructions provided by the manufacturers.
The following notes are offered as a guide to operators:
 The electrical power supplies required by the system are specified in the utilities
schedule. Never carry out any maintenance work unless power supplies have been
isolated at source, or a valid permit to work on live equipment has been obtained. Great
care should be taken when working on live equipment.

 Ensure that interconnecting pipe work is adequate in strength and that the system is
never operated outside its design limitations.

 Never screw down a pipe union that is under pressure. Never screw down a safety
valve beyond the manufacturer’s setting.

 Never unscrew or open a closure that is under pressure.

 Never attempt to straighten badly bent pipes or re-use damaged fittings. Never use
worn or damaged components that rely on threads for security, such as nuts, bolts,
nipples and threaded fittings.

 Ensure that all fittings are secure, to prevent undue pipe work vibration and possible
fracture under pressure.

 Beware of trapped pressure when removing pipe work / instrumentation

 Always work from safe access (i.e. grating or scaffolding). Never work on high level
equipment using a ladder unless other access cannot be provided. In the event that
ladder access must be used, always lash the ladder to prevent it from slipping or falling.

 It is of paramount importance for the safe operation of the systems that any piping
flange joints that are unbolted - for whatever reason - are remade using the correct
grade of gasket.

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 18 of 54 Package
IOM
Alderley FZE
C.2 DETAILS OF ANY SPECIAL RIGGING, TOOLS OR DESIRED INSTALLATION AIDS OR
SAFETY DEVICES TO BE INSTALLED OR REMOVED, INCLUDING LIFTING
EQUIPMENT AND LIFTING POINTS

The system delivered is preserved using a dry fogging powder (VpCl 309/609). When contacted
with water, this powder forms a reddish brown gel, which, on casual inspection, resembles rust. It
will continue to act as a corrosion inhibitor when damp. The preservation does have a limited life
and recommendations will have been made for renewal frequency.

Correction Protection powder

When the system is de-preserved (for connecting up to piping not supplied by Alderley) there may
be reddish brown deposits found in the spools. If this is the case, wipe gently with a lint free cloth
and the corrosion inhibitor deposits should wipe away easily.

Warning Label is placed on each tie-in point containing warnings & precautions.

Prior to start up, the Cortec powder can be removed by fresh water flushing or blowing with
compressed air (preferred and most effective is water flushing).

C.3 CALIBRATION METHODS WHERE APPLICABLE

Normally, calibration of field instruments does not take please on site. Field instruments can be
tested and if a problem is found with them, can be sent back to the manufacturer for
repair/replacement.

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 19 of 54 Package
IOM
Alderley FZE
The following is the procedure for the meter calibration by using the skid master meter:

The following procedure can be used to initiate a proof and accept/reject the new meter factor
from the Supervisory Computer.

The operational meter and the master meter shall be interconnected and process fluid circulated
through the system prior to the test.

1. Ensure only one stream is flowing and allow the temperature, pressure and flow rate to
stabilise.

2. Initiate a proof at the supervisory computer.

3. Ensure the valve sequence, to align the Master Meter, is correct.

4. Verify the sequence of operation, i.e. stable conditions established, run data is as expected
etc.

5. Verify that repeatable results are achieved.

6. Accept the new meter factor / meter K factor and verify the proof report is printed.
7. Deselect / re-align the stream from the Supervisory Computer.

8. Repeat steps 1 - 7 for each meter on the system.

9. Ensure a prove report is generated / archived on completion of each set of prove runs.

10. Ensure the Flow computer uses the new factor.

The following is step-by-step procedure for calibrating the skid meters against the Krohne mobile
master meter:
Equipment:

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 20 of 54 Package
IOM
Alderley FZE
The above picture shows the power connection to the Krohne mobile prover. From the PDB
junction box DS001-MET-PDB-001, there is a 50-metre cable at the end of which an Ex’d’ plug will
be provided. Due to the long delivery of the plug, it will be shipped to site separately. The power
connector is a 5-pin Hawke receptacle (model: EXD40-S-BR-F-5x10-S-S-FRC-A).

The above picture shows the signal connection to the mobile prover. There is a 50-metre cable at
the end of which an Ex’d’ plug will be provided. Due to the long delivery of the plug, it will be
shipped to site separately. The signal connector is a 31-pin Hawke receptacle (model: EXD40-S-
BR-F-30x1, 5-S-C-FRC-A).

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 21 of 54 Package
IOM
Alderley FZE

The above images show the four switches on the metering panel which operate both the skid
master metering and the Krohne mobile proving operation.

In the default position shown above, the stream 3 flow meter can be used as a master meter to
prove the stream 1 and 2 meters.

The following are the steps to prove any of the 3 stream meters with the Krohne mobile prover
trailer.

1. Connect the Ex’d’ power and signal cables to the Krohne mobile prover. At this point, the
density signal is being transmitted to the Krohne prover.

2. Turn the switch of the stream to be proved to the ‘ON’ position. Also turn the Switch 4 to the
‘Mobile Prover’ position. The example below is shown for stream 1. At this point, the temperature
and pressure signals are being transmitted to the Krohne prover.

3. On the flow computer, select Operator -> Stream X -> Stream X Status -> (Scroll right to) Raw
Pulse. Change ‘Clear’ to ‘Set’. At this point, the Stream ‘X’ USM signal is being transmitted to the
Krohne prover.

4. Now the density, stream pressure, stream temperature and stream meter signals are all being
transmitted to the Krohne prover and the proving operation can be carried out from the trailer.
Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 22 of 54 Package
IOM
Alderley FZE
5. Once the proving operation is completed, change the raw pulse back to ‘Clear’ in the S600.
Move the switches back to the default ‘OFF’ positions and the switch 4 back to ‘Master Meter’
position. Disconnect the cables from the Krohne trailer.

C.4 PRE-COMMISSIONING CHECK LISTS

The Metering skid has been tested before leaving AFZE works using simulated signals for all
permissive and control signals. The complete Site Acceptance Test (SAT) can be referred in the
document no. 5123/1519.

In this section, a few important commissioning points will be listed. These must be carried out prior
to initial start-up of Metering Skid.

S. No. Item Yes No

1 Instrument manifolds should be turned completely open or closed as

required for operation
□ □
2 Spectacle blinds to be in correct position for operation.
□ □
3 Cable terminations to be tightened.
□ □
4 Grounding lugs/clamps to be tightened.
□ □
5 Skid Nuts/bolts to be verified as tight.
□ □
6 All instruments & tubing to be properly supported (no vibrations).
□ □
Before the Metering Skid is put into operation, it is assumed that the following tests have been
successfully completed:

 All process connections, pipe and instruments are sound and have been pressure tested.
 All instruments and equipment operate correctly
 The control systems are correctly set up and tested

C.5 ALLOWABLE FLANGE LOADINGS

C.5.1 Pipe Stress Calculation for Oil Metering

Please E.4.5.

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 23 of 54 Package
IOM
Alderley FZE
C.6 LIST OF CONSUMABLE REQUIREMENTS DURING ERECTION AND PRE-
COMMISSIONING

1. Spanner ( 6mm – 22mm)

2. Cutting Plier
3. Screwdriver (Adjustable)
4. Connector
5. Multi-meter
6. Clamping tools (Adjustable)

C.7 COMMISSIONING INSTRUCTIONS

C.7.1 Initial Inspection
Once the site induction training is completed and access gained access to the site, the first task is
to carry out a visual inspection of the control panel and skid installations. The purpose of this is
twofold.

• Familiarize yourself with the system, as this may be the first time you have seen it.

• To check that the system has been installed in a satisfactory way without damage to the
equipment.

The Site Acceptance Test Procedure document should be used to record all your inspection and
test results during the commissioning process. A separate log of System Query Reports should
also be kept.

C.7.2 Skid Inspection

The installation of the skid must be to be verified for correct mounting of the skid and installation of
the fixings to the ground or structure. Items to consider include skid earth, Instrument Air
connection, installation of the drains and inlet /outlet headers. Physically inspect the field cable
installation to the junction boxes and instruments where appropriate. Check the workmanship and
verify that installation has been completed to a satisfactory standard. Use the Alderley loop sheet
drawing as a reference. Tagging of field cables is often a problem - so verify that all cables are
correctly identified. Verify also that the screens have been properly terminated. None should be
connected to ground in the field; panel end only is the preferred method.
Check all components on the skid for transport/installation damage and report any findings to the
Client and Alderley immediately. This is important. Failure to do this soon after commencement of
the visit may result in a dispute over who is responsible for the damage and, more importantly,
who is going to pay for the repairs. Shipping companies, for example, typically will not accept a
claim for damage six months after delivery of the equipment

C.7.3 Panel Inspection

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 24 of 54 Package
IOM
Alderley FZE
The physical inspection of the control panel is similar to the skid. You must verify acceptable
installation quality and workmanship. Look for damage to the panel, panel mountings to the floor
or wall and field cable routing and terminations.

It is common to find field cable installation still on-going when you arrive at site. In addition, some
panel items may not be installed if they are shipped separately. Flow computers, PCs and printers
are usually shipped separately. You may have to unpack them and install them yourself.
As with the skid inspection, report any damage or missing items as soon as possible.

C.7.4 Initial Panel Tests

The first task for the panel testing phase is to verify correct connection of the panel earth and the
incoming power supplies. Power supplies must not be switched on until after the earth connections
have been verified.

Verify that the panel earth is correct and that all earth bars are connected to the site earth system
with suitable cable. A minimum 25mm² should be used.

Alderley usually include a panel earth (chassis), sometimes called dirty earth; an instrument earth
and an intrinsically safe earth. These must be segregated ‘in the field’ but, there may be a direct
connection between them in the panel or adjacent earth point.

Perform earth connection check for the field cables and screens associated with them. It is normal
practice to connect the screens to earth at the panel end only – this must be verified. The earth
bar cable should not be connected while you do this test.

Check each field cable in turn by measuring the resistance between the field cable screen and the
panel earth bars. If everything is ok then you insulation resistance of at least 2 me ohms between
the screen and the earth bars should be measured. If this is not the case the screen connections
in the field must be checked.

The usual reason for low resistance is cable screens that have been connected to ground in the
field junction boxes or instruments. Damage to the screens during installation is also common and
shows up as low insulation resistance. Inspect cables where they have been connected via cable
glands.
The majority of Clients provide evidence that cable testing has been carried out. If they have
correctly performed insulation and continuity checks this makes your job easier. However,
ALWAYS perform a random number of verification checks.

C.7.5 First Power Up

Once earth tests have been successfully completed then the incoming power supply connections
can be tested. Before commencing any tests, ensure that all MCBs and fuses associated with
these supplies are open. Ensure all the internal 24 volt DC fuses are open and all field cable
connections isolated at the field terminals (spades lifted).

Using the panel drawings for reference, verify the incoming supplies are correct in both voltage
level and polarity, where appropriate. Most panels will consist of a mix of low voltage DC, usually

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 25 of 54 Package
IOM
Alderley FZE
24 Volts, and either 110v or 220v AC (sometimes both). Take extra care when measuring the AC
voltages. Be aware of the risk of electrical shock.

Once the incoming supplies are verified, the isolators can be closed and power applied to the
distribution boxes. The individual MCBs can now be closed and individual circuits powered up.
Verify the correct voltage level and polarity of the internal panel 24 volt DC supply before powering
up any internal equipment. This should be ok as it should have been tested during the FAT - but it
is a good idea to double check.

The panel equipment should be powered up progressively. Any problems encountered should be
cured before moving on to the next item. It is recommended that the field loops are not powered
up until they are ready for loop testing.
Once all the panel equipment is powered up and seen to be running ok then loop testing can begin

C.7.6 Loop Testing

Due to differences in project design, you will encounter many different types of field instruments.
You must carry out basic commissioning work on most of these. This equipment includes
temperature and pressure transmitters, flow transmitters, densitometers, pumps, samplers, MOVs,
FCV’s and meter provers etc.

Each individual field loop must be tested and verified as working ok. The installation electrical
contractor may be responsible for this work. In this case Alderley provides supervision and
support. On some projects the installation contractor will install and connect the field cables but
the checking of each loop will be Alderley responsibility.

It is normal for loop checking to be performed in 3 steps. Cable insulation/continuity test, cold loop
check then finally hot loop test with power applied to the device. The Client may require loop check
sheets to be completed as each step of the tests is carried out. It is good practice to record the
test results in the SAT document for our own reference.

Step 1 verifies that the insulation of the cable is acceptable. It normally consists of checking the
insulation between the cable screen and all of the individual cores. Some Clients may also wish
core to core measurements to be taken.

Step 2 consists of checking that the field cable cores are connected to the correct terminals in the
field junction box and control panel. Installation contractors will, more often than not, assume that
the connections between the field junction boxes (skid mounted) and the instruments are correct
as they are part of the skid and they have been tested at the Factory Acceptance Test (FAT)
stage. This is generally true but do not be fooled into thinking the skid wiring is 100% correct. It is
preferred to conduct loop checks from the panel terminals to the instrument to verify the complete
loop.

Once steps 1 and 2 are completed you can power up the loops one at a time and verify correct
operation of the instrument. Pressure and temperature transmitters should be tested over their
entire ranges using suitable test equipment. (Site installation contractor may supply test
equipment, but this is not always the case.) The Site Acceptance Test (SAT) Procedure will
provide details for each test. It may be required that test equipment, used to carry out these tests,

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 26 of 54 Package
IOM
Alderley FZE
has current certification. However, generally the procedure requires a function test of each device
only and not a full calibration.

If the Client stipulates that a full calibration of the field devices is required then they may be
calibrated in-situ or removed to a workshop for bench calibration. As can be seen, Client
requirements vary so check with the project team or your manager if clarification is needed. If the
field equipment was supplied more than 6 months prior to commissioning then the Client may
insist on re-calibration.

Some items of field equipment cannot be functionally tested until put into service. These include
automatic grab samplers, fast loop circulation pumps. These items may have cold loop checks
performed until they are put into service. Density inputs to flow computers are normally tested by
using simulation. Before performing these tests remember to enter appropriate K Factors etc. to
suit the test.
Some field equipment requires special power up and commissioning procedures to be followed. The
SAT Procedure may not provide full details, so it becomes necessary to refer to the manufactures
commissioning procedure.

C.7.7 Panel Function Testing

Once loop tests are completed then the panel functionality must be checked. It is usually accepted
by Clients that complete panel functionality testing was conducted during Factory Acceptance
testing. Therefore, only some of the panel functions will require Site Acceptance tests. The system
Function Design Specification document provides full details of all functions of the system.

The following tests are typically conducted during SAT: Instrument calibration / functionality tests,
limited calculation checks, valve sequencing, sampler tests, fast loop tests, totalizer tests and
prover functionality. Note that some tests cannot be completed until process fluids are introduced
to the system. In some cases, field input simulation must be used to allow the system to operate
as if it was actually under flowing condition.

Care should be taken when carrying out certain tests as some equipment can be damaged by dry
operation. Typical examples are automatic grab samplers and fast loop pumps. It is worth
mentioning at this point that samplers and fast loop pumps should not be tested until clean product
is available. Do not attempt to fill the fast loop until product has been flowing through the skid for
24 hours. Dirty product will damage the grab sampler.

If any field equipment is to be operated then it is always advisable to talk to the operations team
before starting any work. There may be restrictions in place on valve movements, for example,
where opening a valve may cause an unwanted effect on running plant. If in doubt, ask.

The Site Acceptance Test document will give you details of the tests to be carried out to ensure
the system is working correctly. The Client may also wish to carry out some additional tests. Be
patient with the Client and assist as best you can.

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 27 of 54 Package
IOM
Alderley FZE
The majority of our systems will include at least 1 communications link to the Client DCS system. It is
usually serial modbus but may also include some network connections for such things as time
synchronization from the site timeserver. Details of these communication links and the data that is
being transferred is detailed in the Functional Design Specification document. Serious problems with
the communications links may require assistance from Alderley Systems department.

C.7.8 Introduction of Product (Liquid)

Once the dry commissioning phase of the job has been completed the next stage involves the
introduction of process fluids into the skid. This operation is overseen by the operations
department and Alderley is usually there to advise and assist only – and to verify correct operation
of the various components.

It is often the case that the skid is purged with nitrogen before any fluids are introduced.
Operations department will take care of that work but you may be asked to assist with valve line-
up before purging begins.

Once the purging is completed then process fluids will be introduced. Some things to watch out for
during this phase of the job are as follows:

Reset the totalizers and print a current report.

Ensure all drains and vents are in the position that operations want them. Drains will normally be
closed but some vents may initially be left open to allow nitrogen to escape as the process fluids
fill the skid.

Monitor the skid during the initial filling and keep a look out for anything unusual. The skid should
have been leak-tested as part of the mechanical installation, so there should not be any major
leaks. Some minor leaks, however, may become apparent once fluids are introduced. Be ready
with your adjustable spanner as simple tubing leaks can be cured easily. More serious leaks may
require the filling process to be stopped until the leak can be fixed.

Fill the skid slowly as an inrush of fluid may cause damage to delicate instruments. Turbine
systems do not like a sudden rush of liquid as this may cause the turbine to spin at high speed.
Nice and slow is the key to successful filling operations.

As well as monitoring for leaks, keep an eye on the skid pressure. You have no control over the
pressure, but be aware of what is happening. Be prepared to halt the filling operation if the
pressure is seen to be exceeding the expected maximum value.

Fast loop systems are best left isolated during the initial filling of a system. As stated earlier it is
advisable to flow fluids through the skid for 24 hours before opening the fast loop isolation valves.
This is intended to prevent ‘start-up debris’ from being pushed into the fast loop and thus risking
damage to the sampler grab mechanism.

Thoroughly vent the fast loop before starting the pump. The pumps are not designed to be run dry
so make certain the loop is full of fluid before the pump is run. Note that a bump test should be
carried out on the pump first to ensure correct rotation direction. Have the electrician swap 2
phases over if it goes the wrong way.

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 28 of 54 Package
IOM
Alderley FZE
As the downstream pipe work etc. is being filled, there may be a mixture of liquids and gas
passing through the system so initial flow indications should not be considered accurate. Monitor
the indicated flow as the system fills and vent at regular intervals to clear the skid of entrained air
and gas. Be careful with turbine meter systems as the meters may be damaged by slugs of gas /
air passing through the system at high velocity.

Once the system is filled and flow has been established, the system will be under the control of
operations department. From this point onwards, commissioning of the main metering elements
may be considered to be completed. The systems performance should be monitored to ensure all
devices are functioning as expected.

Review the process conditions. Process parameters approximate to original design conditions.
Indicated flow rates should be noted and compared to ‘expected’ figures that the Client’s
operations department advise. Monitor the DP instrumentation associated with strainers if fitted. A
high DP indicates the filters are blocked and require cleaning. Forcing flow through a blocked
strainer can result in a burst strainer and a harmful slug of debris being passed through
downstream equipment (including meters).

Strainers are routinely installed on turbine meter systems as these can be damaged easily by
debris.

Much attention is given to the metered indication after start up. That indication, however, can be
misleading. Flow rate is often unstable following start up. Be aware that often this instability comes
from sources upstream of the skid. In addition ‘apparent’ instability will be noted at very low flow
rates which are typical at this time. Coriolis meters are particularly susceptible to instability at flow
rates below 10% of their maximum flow rate.
Prover functionality tests may commence once stable flow is established. This may take some time
on a new system so do not expect to start prover trials straight away. It can lead to misleading results
and subsequent lack of confidence in the meters / prover.

C.7.9 Job Completion

Once the job has been completed and no further work is required for this visit then the close out
paper work must be completed.

The Alderley site report must be completed and signed by the Client. Make sure that timesheets
are also signed including Client supplied timesheets if these are needed.

If there is a punch list of outstanding items, get a copy from the Client and discuss with them the
remaining issues. A copy signed by both Alderley and the Client is the best option. If not available,
make sure your site report contains a list of the punch items as part of the summary section at the
end. This also provides Alderley with a quick reference of what is still outstanding. Make your site
report summary as clear as possible so that Alderley and the Client are fully aware of what the
status of the job is. Your manager will not want to have to read through your entire report to get a
picture of what the status is.

If any materials have been delivered to site or handed to the Client then obtain a signed delivery
note. Some of these materials may be chargeable and the Client may not pay unless proof of
delivery can be provided.

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 29 of 54 Package
IOM
Alderley FZE
All as-built drawings and documents must be copied and passed to the Client. Make sure your
mark ups are clear and easily readable. Sign any as-built drawings so the Alderley drawing office
knows where they came from. (Unsigned as-built drawings may not be accurate). If you are
confident of the changes you are making to any drawing or document then sign and date it.

Make a backup of the system software and leave a copy with the Client. Make a copy of this
backup for Alderley Systems department and hand it to them on your return.

Return any site passes that have been supplied by the Client as well as any special PPE that may
have been lent to you.

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 30 of 54 Package
IOM
Alderley FZE
Section D - OPERATING INSTRUCTIONS AND INFORMATION

D.1 PURPOSE
The purpose of this metering skid is to meet the oil metering specifications for Early Production
System (EPS) and Brown Field Facilities; comprising of Field Station (DS-2) and Central station
(DS-1) for Majnoon Oil Field.

D.2 BASIC CONSTRUCTION

The package consists of 1 x metering skid and 1 x CCR. The metering skid is made up of 4 parts.

Metering skid system consists of 24” inlet and outlet headers and three 14” metering runs with 10”
ultrasonic meters.

Just before the inlet header there is a static mixer. This device ensures that there is adequate
mixing in order to perform correct sampling as per ISO 3170 & 3171.

At the inlet header there is a sampling system (fast loop) consisting of pumps, density meters,
BS&W and grab sampler. The sampler can be set to sample the flow in flow interval or time
interval modes.

Each metering run consists of inlet hand valves, strainer, flow meters with flow conditioning plate,
outlet FCV’s & MOV’s and transmitters to measure pressure & temperature.

The Containerised Control Room (CCR) that is supplied with the metering skid package consists
of Airlock Room - which is the main entrance, Control Room – where the Operator can work from,
Battery Room – to house the UPS batteries and HVAC Skid which contains the redundant HVAC
units.

The CCR is an insulated housing, designed to maintain the temperature at 22 degrees C

(Operator configurable through thermostat). It consists of complete UPS, F&G and HVAC
integrated facilities. Note that while the Airlock and the Control Rooms are considered as “safe
area”, the Battery Room is a hazardous area due to the production of hydrogen gas by the
batteries (Ex’d’ IIB+H2).

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 31 of 54 Package
IOM
 Alderley FZE
D.3 DESCRIPTION OF THE SYSTEMS COMPRISING THE PLANT OR EQUIPMENT

Master Meter
takeoff

Sample Cabinet

Inlet header

The above image shows the inlet portion of the skid. The inlet header is 24” in size and just before
it the static mixer needs to be installed at site (not shown above). Sample cabinet is visible at the
side of the image. Each stream has a take-off valve to the master meter stream (stream 3).

Flow Control
Valves

Ultrasonic
Meters

Strainers

Stream 1 Stream 2 Stream 3

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 32 of 54 Package
IOM
Alderley FZE
The above image shows a close up view of the three meter runs. At the inlet side are the three
16” basket strainers with 20 mesh size. These help to remove all the debris from the line prior to
metering and prevent damage to the meter internals.

Further downstream are the three Caldon Ultrasonic flow meters. These are 8-path USM’s and are
considered one of the best in the industry.

At the far side of the image are the three Flow Control Valves. These are manufactured by Severn
Glocon and make use of Thermo-Fisher positioner. These are globe type control valves and help
regulate the flow as per the desired set point. The set point can be maintained in the Citect HMI in
the CCR.
BS&W

Density Meters
Grab Sampler

Sample Cans

The above image shows the interior of sample cabinet. It consists of redundant density meters, 1 x
BS&W (water cut meter) and grab sampler complete with 2 x 10 litres sample cans for automatic
sampling and 1 x 10 litres sample can for manual sampling.

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 33 of 54 Package
IOM
 Alderley FZE

Interconnection
JB for HVAC,
F&G Panel BFAS and UPS
(BFAS)

UPS
Lighting
Distribution
Board

UPS Battery
Breakers

The above is inside the control room of the CCR. The BFAS panel monitors for the presence of
smoke, heat, H2 and CH4 gases and takes appropriate actions to ensure safety of personnel and
equipment. The complete Cause & Effect chart is given in Section D.6. The complete method of
operation can be referenced in the sub-vendor IOM in Section E4.3.

The Lighting Distribution Board controls all the lighting in the CCR. Some of the lighting has
battery backup in the event of power failure.

UPS

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 34 of 54 Package
IOM
Alderley FZE
The UPS & UPS battery breakers can be seen in the above images. The UPS system is complete
with bypass section, battery backup and redundancy in case of failure of 1 UPS. The complete
method of operation can be referenced in the sub-vendor IOM in Section E4.3.

Flow
Computers

Prover
Monitor Interface
Switches

Keyboard
& Mouse

The metering panel is shown in the above image. It is complete with Monitor, keyboard & mouse,
flow computers and prover interface switches. These switches are used while proving the skid
meters against the Krohne mobile master meter. The complete details of this metering panel can
be referenced in the FDS in Section A2.1.

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 35 of 54 Package
IOM
Alderley FZE
D.4 SET POINTS, CALIBRATIONS AND SUPPLY PARAMETERS
Minimum Maximum LOW
Calibration Calibration HIGH
INSTRUMENT TYPE Range Range UNIT ALARM ALARM
STRAINER D/P TRANSMITTER 0 1 bar(g) 0.18 0.26
STRAINER D/P TRANSMITTER 0 1 bar(g) 0.18 0.26
STRAINER D/P TRANSMITTER 0 1 bar(g) 0.18 0.26
PRESSURE TRANSMITTER 0 50 bar(g) 14.4 17.6
PRESSURE TRANSMITTER 0 50 bar(g) 14.4 17.6
PRESSURE TRANSMITTER 0 50 bar(g) 14.4 17.6
PRESSURE TRANSMITTER 0 50 bar(g) 14.4 17.6
TEMPERATURE TRANSMITTER 0 100 deg C 50 60
TEMPERATURE TRANSMITTER 0 100 deg C 50 60
TEMPERATURE TRANSMITTER 0 100 deg C 50 60
TEMPERATURE TRANSMITTER 0 100 deg C 50 60
3
ULTRASONIC METER FLOW PULSES 164 1224 m /hr 693 847
3
ULTRASONIC METER FLOW PULSES 164 1224 m /hr 693 847
3
ULTRASONIC METER FLOW PULSES 164 1224 m /hr 693 847
3
DENSITOMETER 0 3000 kg/m - -
3
DENSITOMETER 0 3000 kg/m - -

D.5 PROCEDURES FOR SAFE INITIAL AND NORMAL START-UP, OPERATION STREAM
SWITCHING, MASTER METERING AND SHUTDOWN INCLUDING FLOW CHARTS
AND SYSTEM BLOCK DIAGRAMS WHERE NECESSARY

D.6 CHECKLIST TOR ALARMS AND SHUTDOWN FUNCTIONS

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 36 of 54 Package
IOM
 AFZE Ref: 5129
EARLY PRODUCTION FACILITIES PROJECT MAJNOON, SOUTHERN IRAQ Company Job No. : SIPD-024
Petrofac Job No. : JI-2002

0 30/11/11 NF RSV Issued for Information

CLOSE FRESH AIR DAMPER IN THE RUNNING HVAC UNIT

REV. DATE Prepared By Approved by REVISIONS

FUNCTION PERFORMED (EFFECT)

FIRE CONFIRMED ALARM TO CLIENT (SMOKE/HEAT)

JOB NO. DOCUMENT NO.
5129 5129-1772

CLOSE DAMPER 2 (CONTROL & BATTERY ROOM)

CLOSE DAMPER 3 (CONTROL & AIRLOCK ROOM)

SWITCH ON ALARM BELL IN CONTROL ROOM

SWITCH ON ALARM BELL IN AIR LOCK ROOM

ESD TO PDB (CUT POWER TO PANEL, HVAC)

FIRE CONFIRMED ALARM TO CLIENT (MCP)

SHUTDOWN UPS BATTERY CHARGING

GAS CONFIRMED ALARM TO CLIENT

H2 CONFIRMED ALARM TO CLIENT
START STANDBY EXTRACT FAN

SWITCH ON BEACON/SOUNDER
OPEN STANDBY FAN DAMPER

COMMON ALARM TO CLIENT

FIRE PRE ALARM TO CLIENT

GAS PRE ALARM TO CLIENT
H2 PRE-ALARM TO CLIENT
TITLE

BFAS Cause & Effect Chart

SCALE CLIENT DOCUMENT NO. STATUS REV.

SHEET
NTS
1 of 1
0

PROCESS COMPONENT (CAUSE)

H2 DETECTION SIGNAL 1 out of 2 Groups (20%)

Voting Group 1: DS001-7301-HD-555A X X X X X X X
Voting Group 2: DS001-7301-HD-553B

H2 DETECTION SIGNAL 2 out of 2 Groups (40%)

Voting Group 1: DS001-7301-HD-555A X X X X X X X X
Voting Group 2: DS001-7301-HD-553B

HVAC GAS DETECTION 1 out of 4 Groups (20%)

Voting Group 1: DS001-7301-GD-559A
Voting Group 2: DS001-7301-GD-559B X X X
Voting Group 3: DS001-7301-GD-559C
Voting Group 4: DS001-7301-GD-559D

HVAC GAS DETECTION 2oo4 Groups (40%)

Voting Group 1: DS001-7301-GD-559A
Voting Group 2: DS001-7301-GD-559B X X X X X X X
Voting Group 3: DS001-7301-GD-559C
Voting Group 4: DS001-7301-GD-559D

SMOKE OR HEAT 1oo2 Groups

Voting Group 1: DS001-7301-SD-554A, DS001-7301-SD-554C, DS001-7301-HD-555A X X X
Voting Group 2: DS001-7301-SD-554B, DS001-7301-SD-554D, DS001-7301-HD-555B

SMOKE OR HEAT 2oo2 Groups

X X X X X
Voting Group 1: DS001-7301-SD-554A, DS001-7301-SD-554C, DS001-7301-HD-555A
Voting Group 2: DS001-7301-SD-554B, DS001-7301-SD-554D, DS001-7301-HD-555B

MCP 1oo1 Groups

X X X X X
Voting Group 1: DS001-7301-MAC-556A, DS001-7301-MAC-556B, DS001-7301-MAC-556C

ANY DETECTION ALARM OR DETECTOR FAULT OR BFAS SYSTEM FAULT X

Notes:
Alderley FZE
Section E - MAINTAINENCE INSTRUCTIONS & PROCEDURES

E.1 PERSONNEL PROTECTIVE EQUIPMENT REQUIRED

1. Coverall
2. Safety Helmet
3. Safety Shoes
4. Earplugs
5. Safety Glasses
6. Safety Gloves

E.2 MAINTENANCE SCHEDULES COMPRISING:

E.2.1 Scheduled preventative maintenance at regular intervals e.g. monthly/ 6
monthly/ 12 monthly

Equipment to be Maintenance Description

Maintained Interval
Strainer Basket 1 Month Strainer basket to be cleared of debris, strainer
Cleaning / Inspection gasket & ‘O’-ring to be checked for any damage

Pumps & Drives Everyday Oil level to be checked/refilled as required.

Grab Sampler
All skid mounted
calibrated
instrumentation, egg.
temperature elements
Enclosures
Temperature /Pressure
Instrumentation
Pipe Clamps
All System Electrical
Connections
Instrument Piping and
fittings
3 Months Check that Bolts are Tight
3 Months Check pump for alignment
1 week Check the grab sampler actuation is
functioning/not jammed
3 month Visually inspect the instruments. Check all of the
electrical circuits. Regular check calibrations
should be performed to ensure continued integrity
of measurement.
3 months Check condition of door seals and visual inspection
1 month Check for any drift from the acceptable limits, by
using Druck or similar handheld test instruments
1 Year Check tightness of pipe attachment clamps
1 Year Visual Inspection; Check integrity
1 Year Check condition of all instrument piping and fittings

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 37 of 54 Package
IOM
Alderley FZE
Equipment to be Maintenance Description
Maintained Interval
All valves 1 Year Check for leaks / faulty operation. Inspect stem
packing.
General 1 Year Check for general deterioration due to
environmental conditions and treat accordingly

E.3 SPARE PARTS LISTS

Please refer overleaf

Majnoon Oilfield
Brownfield EPS Metering Skid March 2013
Doc. No.: 5129/1521 38 of 54 Package
IOM