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MAERSK CURLEW - Book B: Oil Processing Facilities

Cover Page 002 / MAY 2010

Book B Oil Processing


Facilities
MAERSK CURLEW

This manual is the property of the Companies within Maersk FPSOs


and is for the use of designated staff only.

THIS IS A CONTROLLED PUBLICATION

Revision requests and comments should be forwarded to:

http://siriusportal.apmoller.net

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MAERSK CURLEW - Book B: Oil Processing Facilities
Table of Contents 002 / MAY 2010

Cover Page 002 / MAY 2010


Table of Contents 002 / MAY 2010

1 Introduction 002 / MAY 2010


.01 Objectives for this Manual 002 / MAY 2010
.02 Administration 002 / MAY 2010
.03 Manual Structure 002 / MAY 2010
.04 Definition 002 / MAY 2010
2 System Overview 002 / MAY 2010
.01 Introduction 002 / MAY 2010
.02 Process Flow Summary 002 / MAY 2010
3 Process Description 002 / MAY 2010
.01 Subsea System - Overview 002 / MAY 2010
.02 Test and Production Manifolds 002 / MAY 2010
.03 Test Separator V-1005 002 / MAY 2010
.04 HP Separator V-1001 002 / MAY 2010
.05 HP Crude Oil Heater E-1001 002 / MAY 2010
.06 MP Separator V-1002 002 / MAY 2010
.07 MP Crude Oil Heater E-1002 002 / MAY 2010
.08 LP Separator V-1003 002 / MAY 2010
.09 Produced Water Transfer Pumps P-1002A/B 002 / MAY 2010
.10 Crude Oil Transfer Pumps P-1001A/B 002 / MAY 2010
.11 Electrostatic Coalescer V-1004 002 / MAY 2010
.12 Export Crude Oil Cooler E-1004 002 / MAY 2010
4 Equipment Description 002 / MAY 2010
.01 Test and Production Manifolds 002 / MAY 2010
.02 Test Separator V-1005 002 / MAY 2010
.03 HP Separator V-1001 002 / MAY 2010
.04 HP Crude Oil Heater E-1001 002 / MAY 2010
.05 MP Separator V-1002 002 / MAY 2010
.06 MP Crude Oil Heater E-1002 002 / MAY 2010
.07 LP Separator V-1003 002 / MAY 2010
.08 Produced Water Transfer Pumps P-1002A/B 002 / MAY 2010
.09 Crude Oil Transfer Pumps P-1001A/B 002 / MAY 2010
.10 Electrostatic Coalescer V-1004 002 / MAY 2010
.11 Export Crude Oil Cooler E-1004 002 / MAY 2010
5 Operating Procedures 002 / MAY 2010
.01 Cold Start-up of the Oil Processing Facilities 002 / MAY 2010
.02 Hot Start-up of the Oil Processing Facilities 002 / MAY 2010
.03 Normal Running 002 / MAY 2010

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MAERSK CURLEW - Book B: Oil Processing Facilities
Table of Contents 002 / MAY 2010

.04 Planned Shutdown of the Oil Processing Facilities 002 / MAY 2010
.05 Process and Emergency Cause and Effect Charts 002 / MAY 2010
.06 Pressure Safety Valve Five Key Interlock Operations 002 / MAY 2010
6 Isolation/Reinstatement Procedures 002 / MAY 2010
.01 Oil Processing Facilities, Boundary Isolation, Flushing,
Draining and Nitrogen Purging Operations 002 / MAY 2010
.02 Test Separator V-1005 002 / MAY 2010
.03 HP Separator V-1001 002 / MAY 2010
.04 HP Crude Oil Heater E-1001 002 / MAY 2010
.05 MP Separator V-1002 002 / MAY 2010
.06 MP Crude Oil Heater E-1002 002 / MAY 2010
.07 LP Separator V-1003 002 / MAY 2010
.08 Produced Water Transfer Pumps P-1002A/B 002 / MAY 2010
.09 Crude Oil Transfer Pumps P-1001A/B 002 / MAY 2010
.10 Electrostatic Coalescer V-1004 002 / MAY 2010
.11 Export Crude Oil Cooler E-1004 002 / MAY 2010
.12 Oil Processing Facilities Boundary Reinstatement 002 / MAY 2010

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MAERSK CURLEW - Book B: Oil Processing Facilities
Introduction 002 / MAY 2010

Introduction

1.01 Objectives for this Manual


1.02 Administration
1.03 Manual Structure
1.04 Definition

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MAERSK CURLEW - Book B: Oil Processing Facilities
Introduction 002 / MAY 2010

1.01 The objective of this Operating Procedures Manual is to provide the


Objectives for Plant Operators with detailed information and instructions for the safe
this Manual and efficient operation of the process facilities on the Curlew Field
Floating, Production, Storage and Offloading (FPSO) vessel.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Introduction 002 / MAY 2010

1.02 This document is a controlled publication and all revision requests


Administration and suggestions should be submitted via the SIRIUS portal under:
http://siriusportal.apmoller.net

Language The English version prevails if conflicts are found between different
language versions.

Controlled Publication This means that the manual is identified by a distinct document
number and a track record is kept regarding the below:
Manuals Edition number and issue date
Language version
Number of Volumes of the manual

Revisions Revision Requests must be in the English language.


To submit a revision request for this document go to the SIRIUS
portal under http://siriusportal.apmoller.net and find the document
by using the search options.
Open a model where the document is attached and right-click,
which will open a drop-down menu. Click on Request revision to
open the revision request form.

Fill in and submit the form as per included instructions.


Shortly after submitting the revision you will receive an email con-
taining the unique number given to your request to use for queries
and updates. You will be notified upon completion or rejection.
Weekly status updates on revisions will be sent to the OIM of each
offshore unit.
Progress on all open revisions can be followed under:
http://drilling-fpsos.apmoller.net/sirius

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MAERSK CURLEW - Book B: Oil Processing Facilities
Introduction 002 / MAY 2010

1.03 The Operating Procedures Manual for the Curlew FPSO comprises two
Manual Structure Volumes; Volume 1 Process and Volume 2 Marine. Each Volume is sub-
divided into a series of standalone Books, each addressing one or more
associated systems, as follows:

Volume 1 Process Book A Subsea Facilities


Book B Oil Processing Facilities
Book C Gas Processing Facilities
Book D Produced Water and Sand Jetting Facilities
Book E Water Injection Facilities (Not Used - Future)
Book F Flare and Vent Systems
Book G Main Power Generation and Distribution
Book H Cooling Medium System
Book I Heating Medium System
Book J Compressed Air and Nitrogen Systems
Volume 1 Process Book K Fuel Gas System
(Continued) Book L Seawater System
Book M Chemical Injection Systems
Book N Export Pipelines (Not Used)
Book O Laboratory Procedures
Book P Glycol Regeneration System
Book Q Drainage Systems

Volume 2 Marine Book A Crude Oil Storage and Offloading


Book B Ballast Systems
Book C Crude Oil Washing
Book D Marine Power Generation (Not Used)
Book E Compressed Air
Book F Seawater Service Systems
Book G Freshwater Systems
Book H Main Boiler Systems
Book I Fuel Oil (Not used)
Book J Diesel Oil
Book K Lube Oil
Book L Bilge and Sludge Systems
Book M Soil System
Book N Stern Thruster (Not Used)
Book O Main Engine System (Not Used)
Book P Deck Equipment
Book Q Inert Gas Facilities

Each Volume provides a description of the system and its associated


equipment and provides detailed start-up, operation and shutdown
procedures. In addition, isolation/reinstatement procedures are also
included in Volume 1 for all of the main process plant.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Introduction 002 / MAY 2010

1.04 Definition of this Manual is in accordance with the ISO 8402 Standard.
Definition Those definitions which are not included in that standard are in
accordance with the terms of ISO 9004 or the Companys
own definitions.

Approval Statement or signature from an authorised person that a product or


service complies with specified requirements or that a defined series of
planned actions may be initiated.

Area Manager The person designated to manage the activities of Maersk FPSOs -
Floating Production Division in a specific area.

Maersk Operational The organisational unit designated by the Operations Manager to


Documentation Control conduct the control of documents and publications issued under the
Maersk FPSOs - Floating Production Division Operational
Documentation Management System.

Company Policy Any of the policies stated within the framework of the Management
System Manuals and explicitly authorised by the Maersk FPSOs -
Floating Production Division Operations Manager.

Offshore Installation Manager That person on an offshore unit who has the highest authority (in some
(OIM) publications this person may be referred to as the Person in Charge).

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MAERSK CURLEW - Book B: Oil Processing Facilities
System Overview 002 / MAY 2010

System Overview

2.01 Introduction
2.02 Process Flow Summary

Figure

2.01 Topsides Processing Facilities Overview

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MAERSK CURLEW - Book B: Oil Processing Facilities
System Overview 002 / MAY 2010

2.01 The Curlew FPSO is designed to accept well fluids from the Curlew
Introduction subsea wells and process fully stabilised or dead crude for cargo tank
storage with export via shuttle tankers. The Curlew subsea development
includes the Curlew D field, a gas/condensate field in Block 29/7 of the
Western Central Graben and Curlew B field, an under-saturated oil
reservoir located approximately 4km west of Curlew D. Total Curlew
production is currently from Curlew D wells as Curlew B is no longer
producing and all indications are that it is dead.

The topsides process facilities include the oil stabilisation plant, gas
compression train, dehydration equipment for sales gas export and the
produced water treatment package. Produced water treatment facilities
are provided to clean up the produced water from the well stream fluids
enabling the polished produced water to be discharged overboard.
Detailed information on the Produced Water Treatment facilities is
provided in Volume 1 Book D of the Operating Procedures Manuals.

Figure 2.01 provides an overall simplified schematic of the main topsides


oil processing facilities.

Topside production routing is configured such that Curlew D wells


production is routed to the HP Separator and the Curlew B well
production to the MP Separator.

The oil stabilisation facilities consist of a single separation train with


three stages of flash separation and an electrostatic coalescer which
reduces the water content in the crude oil to 0.5% (volume). A single gas
compression train is provided configured as three stages with a single
train of gas dehydration between the 2nd and 3rd stages of
compression. Detailed information on the Gas Processing facilities is
provided in Volume 1 Book C of the Operating Procedures Manuals.

The Oil Stabilisation Facilities are located in areas M01, M02, and M03
of the Process Deck and comprise the following main items of
equipment:

Test Separator, V-1005

HP Separator, V-1001

HP Crude Oil Heater, E-1001

MP Separator, V-1002

MP Crude Oil Heater, E-1002

LP Separator, V-1003

Produced Water Transfer Pumps, P-1002A/B

Crude Oil Transfer Pumps, P-1001A/B

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MAERSK CURLEW - Book B: Oil Processing Facilities
System Overview 002 / MAY 2010

2.01 Electrostatic Coalescer, V-1004


Introduction (Continued)
Coalescer Power Pack, L-1001

Export Crude Oil Cooler, E-1004

2.02 Well fluids from the Curlew B and D flow, via subsea flowlines and
Process Flow Summary flexible risers, to the FPSO turret. Individual production choke valves,
operated from the Central Control Room (CCR) are located at the
subsea xmas trees and within the turret to control the flow from
each well.

The individual well design flowrates are 20,000bpd of fluids with a


minimum operational flowrate of 13,000bpd. The well flowlines are
designed for bullheading of scale inhibitor squeeze chemicals back from
the FPSO to each well with a maximum pump discharge pressure of
356barg which exceeds the maximum shut-in wellhead pressure of
327barg for the Curlew B well and 354barg for the Curlew D wells.
Although sand production is not anticipated, sandwashing connections
are provided for all separation vessels included in the oil processing
facilities. Chemical injection points are provided on the topsides flowlines
to enable methanol, demulsifier, antifoam and corrosion inhibitor to be
injected (refer to Volume 1, Book M of the Operating Procedures
Manuals).

The arrival temperature of the Curlew fluids under normal operation is


designed to be a minimum of 60C, this temperature being set by the
cloud point temperature of the live crude to minimise the possibility of
wax deposition.

Production and test manifolds within the turret collect fluids from all
wells. The two flowlines from the Curlew D subsea production facilities
are either routed directly through a dedicated production manifold in the
swivel to the HP production separator or directed to the test manifold.
The fluids from the test manifold pass through a separate path within the
swivel to the Test separator in the Oil Stabilisation Facilities.

In the event of any problems with the Test or Production swivels,


crossover between the HP and Test production manifold is provided to
facilitate an alternative back-up production flowpath via the redundant
Water Injection Swivel, thus allowing continued operation of the Curlew
field. The operation of this crossover is further detailed in Sections 3.02
and 4.02.

Due to its lower wellhead pressure the single Curlew B flowline is routed
through the swivel to either the MP separator or the Test separator via
separate manifolds.

The Oil Processing Facilities are designed to handle 75,000BPD of


fluids, with a maximum oil rate of 45,000BOPD, a maximum water rate of
30,000BWPD and a maximum gas export rate of 110MMSCFD.

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MAERSK CURLEW - Book B: Oil Processing Facilities
System Overview 002 / MAY 2010

2.02 The oil production train comprises three stages of separation, namely
Process Flow Summary the HP Separator V-1001, MP Separator V-1002 and LP Separator
(Continued) V-1003. Curlew fluids are routed to the HP Separator, V-1001. Partially
stabilised crude from Curlew then enters the MP Separator, V-1002,
for further stabilisation. Each vessel is equipped to achieve three-phase
separation of gas, hydrocarbon liquid and produced water. Produced
gas from the vessels flows under pressure control to the gas
compression facilities.

Demulsifier and anti-foam injection points are provided on the inlet


headers to the Test separator, HP separator and MP separator to
enhance the separation process.

Crude oil heating is provided between the separation stages. The HP


Crude Oil Heater E-1001 is installed on the oil outlet from the
HP separator (upstream of tie in with Test separator fluids) and the MP
Crude Oil Heater E-1002 is located on the outlet from the MP separator.
The HP crude oil heater is a shell and tube heat exchanger and the MP
crude oil heater is designed as plate type heat exchanger. Both heaters
use heating medium to increase the temperature of the crude oil to the
desired temperature to enhance separation.

The HP, MP, LP and Test separators are designed so that the liquid
carryover in the gas outlet stream from the vessels does not exceed 0.10
US gals per MMSCF. If the Oil Processing Facilities are operating
efficiently, the water content in the oil outlet streams from these vessels
should not exceed 2.0% (volume).

The fully stabilised crude oil from the LP separator, together with any
produced water carried over from the vessel, is pumped to the
electrostatic coalescer.

The coalescer operates at a pressure approximately 5barg greater than


the LP separator and is designed to ensure that the water content of the
crude is reduced to less than 0.5% (volume). If required, the crude oil
passing through the coalescer can be dehydrated to a BS&W of 0.3% as
the salt content of the crude oil export must not exceed 500mg/lt.
However, it is anticipated that the salt content of the crude oil will be less
than 300mg/lt if the electrostatic coalescer is set to reduce the water
content of the crude to less than 0.5%.

The water removed in the coalescer is returned under level control to the
MP crude oil heater. The dehydrated crude from the coalescer flows
through the Export Crude Oil Cooler E-1004 before entering the FPSO
storage facilities. The cooler is a plate type exchanger which uses
cooling medium to cool the fully stabilised crude to 30oC for storage.

The separators, crude oil heaters and coalescer included in the oil
processing facilities ensure that the stabilised crude oil exported to the
shuttle tankers has a maximum True Vapour Pressure (TVP) of 0.83barg
at 26.67oC. A design margin has been incorporated into the capacity of
the HP and MP crude oil heaters to ensure that the TVP can be
achieved during conditions of variable flow.

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MAERSK CURLEW - Book B: Oil Processing Facilities
System Overview 002 / MAY 2010

2.02 Well Testing is performed using the Test separator.


Process Flow Summary
(Continued) Existing vortex meters located on the oil outlet of the first stage
separators (HP and Test) are utilised as part of new facility for
production allocation metering. This will comprise a fast loop crude
sampling pump system incorporating in-line density and BS&W meters.

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Figure 2.01: Topsides Processing Facilities Overview
MAERSK CURLEW - Book B: Oil Processing Facilities
Process Description 002 / MAY 2010

Process Description

3.01 Subsea System Overview


3.02 Test and Production Manifolds
3.03 Test Separator V-1005
3.04 HP Separator V-1001
3.05 HP Crude Oil Heater E-1001
3.06 MP Separator V-1002
3.07 MP Crude Oil Heater E-1002
3.08 LP Separator V-1003
3.09 Produced Water Transfer Pumps P-1002A/B
3.10 Crude Oil Transfer Pumps P-1001A/B
3.11 Electrostatic Coalescer V-1004
3.12 Export Crude Oil Cooler E-1004

Figures

3.01 Production Subsea Tree with Umbilical Interface (Curlew Well DP1 - Typical)
3.02 Turret Process and Control Interface Schematic
3.03 Oil Stabilisation Train Schematic Process Facilities

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MAERSK CURLEW - Book B: Oil Processing Facilities
Process Description 002 / MAY 2010

3.01 Wells have been drilled at two subsea locations (the Curlew B and D
Subsea System Overview Drilling Centres). Crude oil flows from the remaining subsea wells, via
subsea flowlines and flexible risers to the FPSO turret. Each production
well is connected to the FPSO by a single flowline with a production
choke mounted within the FPSO turret. A subsea choke is fitted to the
xmas trees for all wells.

The Subsea Control System is a multiplexed electro-hydraulic system.


The subsea facilities are monitored and controlled from the Local
Equipment Room (LER), via the Process Control System (PCS).

All electrical monitoring and control signals are performed from the
Master Control Station (MCS) located in the LER. The MCS interfaces
with the Integrated Control and Safety System (ICSS) to allow the control
of the subsea facilities to be transferred to the PCS.

Valves operated at each production xmas tree are as follows:

Production Wing Valve (PWV)


Annulus Wing Valve (AWV)
Production Upper Master Valve (PUMV)
Annulus Master Valve (AMV)
Annulus Crossover Valve (AXOV)
Subsurface Safety Valve (SSSV) [Downhole Safety Valve]
Methanol Injection Valve (MIV)
Subsea Choke Valve

The system also provides constant monitoring of the following functions


at each well:

Downhole Pressure
Downhole Temperature
Annulus Bore Pressure
Wellhead Pressure
Wellhead Temperature
Flowline Pressure
Subsea Choke Position
Topsides Choke Position

The ICSS controls all the riser Emergency Shutdown Valves (ESDVs)
located in the turret. These shutdown valves are the first barrier on the
FPSO from the subsea wells.

All safety critical ESD signals to the turret are hardwired across a slip
ring system incorporated at the swivel in the turret. Data monitoring and
non-critical functions are operated via high security telemetry between
the CCR and the turret turntable.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Process Description 002 / MAY 2010

3.01 Further details of the subsea wellheads and controls are provided in
Subsea System Overview Volume 1, Book A Subsea Facilities. Refer also to the following figures
(Continued) at the end of this Section:

Figure 3.01: Production Subsea Tree with Umbilical Interface


(Typical)

Figure 3.02: Turret - Process and Control Interface Schematic

3.02 Well fluids from any subsea production well flow through its subsea
Test and Production flowline and riser to the FPSO turret. The riser enters the base of the
Manifolds turret and passes vertically up through the turret to its riser emergency
(Refer to Figure 3.03) shutdown valve. The pipework for the well then leads the well fluids
through a downstream HIPS valve on the flowline to the remotely
operated choke valve. The Curlew flowlines are then divided into
separate feeds for the test and production turret located manifolds. Each
supply to the manifolds is fitted with a manual diverter valve.

Under normal conditions, when the production swivels are trouble and
leakage-free, the Curlew D production fluids are routed to the HP
Separator and the Curlew B wellfluids routed to the Test Separator.

When producing Curlew through the HP swivels to the Test separator via
the crossover manifold, the terminations to the routing switches on the
Curlew routing valves 07-XV-110 and 07-XV-402 (flowline DP2) as well
as 07-XV-210 and 07-XV-403 must be switched over. This is to ensure
that the shutdown signal from the Test separator is correctly routed.

The turret located manifolds are constructed circumferentially around the


centrally positioned facility termed the swivel. The swivel receives crude
from each manifold into its lower-most inlet ports, transferring the well
fluids upwards through internal concentric annuli to the upper outlet
ports. The outlet ports are arranged one upon another, maintaining
isolated flowpaths for the test and production crude, and link directly
across to the respective test and production manifolds which are part of
the FPSO structure.

The uppermost section of the swivel, which contains the outlet ports, is
free to rotate with the FPSO, while its lowermost inlet ports are attached
to the turret and therefore fixed in relation to the seabed.

The swivel also provides the link between the FPSO and turret for the
gas export and water injection manifolds, however the water injection
manifold is not normally in use.

The test and production manifolds on the FPSO transfer the well fluids to
the test, HP or MP separators respectively for the three-phase separation
of crude oil, produced water and gas.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Process Description 002 / MAY 2010

3.02 Chemical injection facilities are provided on the FPSO to direct the
Test and Production following chemicals into the inlet headers for the test, HP and MP
Manifolds separators downstream of the turret:
(Continued) Demulsifier
(Refer to Figure 3.03) Antifoam

Chemical injection facilities are provided on the FPSO to direct the


following chemicals into the production facilities within the turret and
subsea wellheads:

Methanol
Corrosion Inhibitor
Wax Inhibitor
Scale Inhibitor

Details of all chemical injection facilities on the FPSO are provided in


Volume 1 Book M.

3.03 The Test separator is no longer utilised as a well testing facility and is
Test Separator V-1005 dedicated solely for production of Curlew fluids. The function of the Test
(Refer to Figure 3.03) separator is to receive Curlew D production fluids from the subsea well(s)
and conduct three-phase separation of the reservoir fluid into the
following constituent parts:

Crude Oil
Produced Water
Produced Gas

The Test separator operates at 39barg and 60 to 70oC and is designed to


process up to 20,000BOPD. Crude oil from the test manifold enters the
Test separator and is immediately subjected to a reduction in pressure
and velocity in the vessel.

The reduction in pressure and the retention time of the Test separator
facilitates an efficient three-phase separation to take place within the
vessel. An internal weir has been installed to aid separation, and the
instrumentation which controls the oil/water interface in the bulk side of
the separator is used to increase (or decrease) the residence time of the
well fluids. The oil and produced water components are drawn off either
side of the weir from within their respective operating levels for further
processing.

The off-gas leaves the Test separator from the outlet nozzle positioned
on top of the vessel. A Vortex Meter, 10-FT-0515, is installed in the gas
outlet line and data from this instrument is transmitted to the PCS. The
gas then commingles with the process gas from the HP separator and
passes forward to the Gas Compression Facilities for further processing.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Process Description 002 / MAY 2010

3.03 The crude oil from the Test separator is measured by a Vortex Meter, 10-
Test Separator V-1005 FT-0519 with data transmitted to the PCS. The crude then passes
(Continued) forward to the MP separator for partial stabilisation or on to the process
(Refer to Figure 3.03) inlet for the MP crude oil heater for preheating prior to entering the LP
separator for full stabilisation.

The produced water from the Test separator is measured by a Vortex


Meter, 10-FT-0521 with data transmitted to the PCS. The produced water
then passes directly to the test hydrocyclone in the Produced Water
Package for clean-up. However, a crossover has been provided between
the Test separator and HP Hydrocyclone. When Curlew produced water
rates are in excess of 5000 BWPD, repositioning of spectacle blinds and
adjustment of control switch, 40-HS-4001A, allows produced water from
the Test separator to be routed to the HP Hydrocyclone.

The oil, gas and produced water metering facilities at the Test separator
allow Curlew fluids to be measured for the purpose of metering
allocation.

Sampling of the incoming crude to the Test separator provides the Base
Sediment and Water readings (BS&W).

Sampling and analysis of the produced gas exiting the Test separator
provides the Carbon Dioxide (CO 2 ), Hydrogen Sulphide (H 2 S) and
composition of the gas.

3.04 The function of the HP separator is to receive production fluids from the
HP Separator V-1001 subsea well(s) and conduct three-phase separation of the reservoir fluid
(Refer to Figure 3.03) into the following constituent parts:

Crude Oil
Produced Water
Produced Gas

The HP separator operates at approximately 39barg and 35oC to 60oC


and is designed to process up to 37000BOPD. Crude oil enters the
separator and is immediately subjected to a reduction in pressure and
velocity in the vessel.

The designed retention time of the HP separator allows three-phase


separation to take place within the vessel. An internal weir has been
installed in V-1001 to aid separation, and the instrumentation which
controls the oil/water interface in the bulk side of the separator is used to
increase (or decrease) the residence time of the well fluids. The oil and
produced water components are drawn off either side of the weir from
within their respective operating levels for further processing.

The flowrates of crude oil, produced water and produced gas from the HP
separator are accurately measured by vortex meters on leaving the vessel.
The crude from the HP separator passes to the HP crude oil heater for
pre-heating prior to entering the MP separator.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Process Description 002 / MAY 2010

3.04 The produced water from the HP separator is directed to the HP


HP Separator V-1001 hydrocyclone in the produced water package for clean-up. Conversely to
(Continued) the arrangement with the Test separator, produced water from the HP
(Refer to Figure 3.03) separator can be routed to the Test hydrocyclone. When Curlew
production is less than 5000 BWPD, the HP hydrocyclone is used.

The produced gas leaves the HP separator from the outlet nozzle
positioned at the top end of the vessel. Downstream of the HP separator
the produced gas passes to the inlet gas cooler included in the Gas
Compression Facilities for further processing.

3.05 The HP crude oil heater is a conventional shell and tube heat exchanger
HP Crude Oil Heater designed to raise the temperature of the partially stabilised crude from the
E-1001 HP separator.
(Refer to Figure 3.03)
The warmed crude oil leaving the crude oil heater is fed to the MP
separator for further processing.

3.06 The MP separator is provided to receive the well fluids from the Curlew B
MP Separator V-1002 subsea well and semi-dry, preheated crude oil from the HP crude oil
(Refer to Figure 3.03) heater. Well fluids from the Curlew D subsea wells, the partially stabilised
crude from the Test separator, is also directed to
V-1002. In addition, the 2in common discharge line from the produced
water transfer pumps is hardpiped to the MP separator to dispose of the
produced water from these facilities.

Three-phase separation of the fluids occurs inside the MP separator into


the following components:

Crude Oil
Produced Water
Produced Gas

The MP separator operates at approximately 10barg and 48 to 67oC and is


designed to process up to 49000BOPD. Wellfluids, produced water and
Crude oil enter the separator and are immediately subjected to a reduction
in pressure and velocity in the vessel.

The designed retention time of the MP separator allows three-phase


separation to take place within the vessel. An internal weir has been
installed in V-1002 to aid separation, and the instrumentation which
controls the oil/water interface in the bulk side of the separator is used to
increase (or decrease) the residence time of the well fluids. The oil and
produced water components are drawn off either side of the weir from
within their respective operating levels for further processing.

The flowrates of crude oil, produced water and produced gas from the MP
separator are accurately measured by vortex meters on leaving the vessel.
The partially stabilised crude from the MP separator passes to the MP
crude oil heater for pre-heating prior to entering the LP separator for full
stabilisation.

ID: M-CPH-1171-01417_EN_Section_3.doc Page 6 / 12


MAERSK CURLEW - Book B: Oil Processing Facilities
Process Description 002 / MAY 2010

3.06 The produced water from the MP separator is directed to the MP


MP Separator V-1002 hydrocyclone in the produced water package for clean-up.
(Continued)
(Refer to Figure 3.03) The produced gas leaves the MP separator from the outlet nozzle
positioned at the top end of the vessel. Downstream of the MP separator
the produced gas passes to the MP compressor suction cooler in the Gas
Compression Facilities for further processing.

3.07 The MP crude oil heater is a conventional plate heat exchanger designed
MP Crude Oil Heater to raise the temperature of the crude flowing to the downstream LP
E-1002 separator. This is essential, as the LP separator must be capable of
(Refer to Figure 3.03) producing fully stabilised crude oil suitable for storage on the FPSO and
export to the shuttle tankers.

Typically, the crude temperature is raised to 65 to 68oC when passing


through the cold side of the heater by heating medium at 5barg and 120oC
passing through the hot side of the exchanger.

3.08 The LP separator is provided to receive the preheated crude oil from the
LP Separator V-1003 MP crude oil heater and conduct three-phase separation of the fluids into
(Refer to Figure 3.03) the following components:

Crude Oil
Produced Water
Produced Gas

The LP separator vessel has a design pressure and temperature of


16barg and -30/+85oC respectfully, and normally operates at 1.1barg and
67oC. Preheated crude oil enters the second stage separator and is
subjected to a further reduction in pressure and velocity in the vessel.

The designed retention time of the LP separator allows three phase


separation to take place within the vessel. An internal weir has been
installed in V-1003 to aid separation, and the instrumentation which
controls the oil/water interface in the bulk side of the separator is used to
increase (or decrease) the residence time of the fluids. The oil and
produced water components are drawn off either side of the weir from
within their respective operating levels for further processing.

The crude oil recovered in the LP separator passes out of the bottom of
the vessel and flows to the oil transfer pumps which are located directly
below the separator.

The produced water from the LP separator is directed to the produced


water transfer pumps also located beneath the separator.

The evolved gas leaves the vessel from a single outlet nozzle at the top of
the vessel and flows under pressure control to the LP compressor cooler
in the Gas Compression Facilities for further processing.

ID: M-CPH-1171-01417_EN_Section_3.doc Page 7 / 12


MAERSK CURLEW - Book B: Oil Processing Facilities
Process Description 002 / MAY 2010

3.09 The produced water transfer pumps are provided to receive the produced
Produced Water Transfer water from the LP separator at a pressure of 1.1barg and pump the liquids
Pumps P-1002A/B back to the MP separator at a discharge pressure of approximately
(Refer to Figure 3.03) 11barg.

The produced water transfer pumps are single stage, centrifugal pumps
driven by 18.5kW electric motors. Each pump is rated at 16.5m3/hr.
The two pumps operate on a duty/standby basis.

3.10 The crude oil transfer pumps draw the wet crude from the LP separator at
Crude Oil Transfer Pumps a pressure of 1.1barg and pump the crude to the electrostatic coalescer for
P-1001A/B further processing at a discharge pressure of approximately 7barg.
(Refer to Figure 3.03)

The two identical crude oil transfer pumps are single stage, centrifugal
pumps driven by 90kW electric motors. Each pump is rated at 326m3/hr.
The 100% capacity pumps operate on a duty/standby basis.

A dedicated flow control valve 10-FCV-0328 is fitted on the common


discharge line from both crude oil transfer pumps to provide minimum flow
protection to the Transfer Pumps by recycling a controlled flow of crude oil
via 10-FICA-0328 back to the LP separator.

3.11 The coalescer is designed to reduce the water-in-oil content of the crude
Electrostatic Coalescer oil for export/storage to 0.5% (volume).
V-1004
(Refer to Figure 3.03) The demulsifier which can be injected into the test and production
manifolds at the turret helps break down the oily film around water
molecules in the upstream separation trains, but further treatment in the
coalescer is required to complete the operation.

The coalescer operates by breaking down oil/water emulsions with the use
of a high voltage electric field.

Note: An emulsion can be depicted as water molecules surrounded by a


thin film of oil, held together by surface tension. The oil film requires
to be broken to allow the water molecules to coalesce.

The coalescer operates in a completely flooded condition at all times. The


crude oil and water emulsion enters the coalescer at the bottom and is
ducted to below the electrostatic grids where it is then evenly distributed
along the length of the vessel.

As the crude/emulsion moves vertically towards the outlet collector tray it


passes between the high voltage grids where an intense electrostatic field
exists.

This results in suspended water droplets within the crude becoming


charged and distended. The charged water particles are attracted to each
other at opposite poles and as they collide they coalesce to form larger
droplets. These larger water droplets fall towards the bottom of the vessel
against the general direction of flow.

ID: M-CPH-1171-01417_EN_Section_3.doc Page 8 / 12


MAERSK CURLEW - Book B: Oil Processing Facilities
Process Description 002 / MAY 2010

3.11 The dry crude oil passes out of the top of the coalescer and is fed to the
Electrostatic Coalescer export crude oil cooler for further processing.
V-1004
(Continued) The produced water passes out of the bottom of the coalescer and is
(Refer to Figure 3.03) directed back to the MP crude oil heater.

3.12 The export crude oil cooler is a plate type exchanger provided to cool the
Export Crude Oil Cooler dehydrated crude oil from the electrostatic coalescer to 30oC before its
E-1004 arrival at the cargo oil storage tanks on the FPSO.
(Refer to Figure 3.03)
The cooler utilises cooling medium (70% / 30% water/glycol) as the heat
exchange material. The outlet temperature of the crude leaving the coolers
is controlled by a temperature control valve located on the cooling medium
return line.

ID: M-CPH-1171-01417_EN_Section_3.doc Page 9 / 12


Figure 3.01 Production Subsea Tree with Umbilical Interface (Curlew Well DP1 - Typical)
Figure 3.02: Turret Process and Control Interface Schematic
Figure 3.03: Oil Stabilisation Train Schematic Process Facilities
MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

Equipment Description

4.01 Test and Production Manifolds


4.02 Test Separator V-1005
4.03 HP Separator V-1001
4.04 HP Crude Oil Heater E-1001
4.05 MP Separator V-1002
4.06 MP Crude Oil Heater E-1002
4.07 LP Separator V-1003
4.08 Produced Water Transfer Pumps P-1002A/B
4.09 Crude Oil Transfer Pumps P-1001A/B
4.10 Electrostatic Coalescer V-1004
4.11 Export Crude Oil Cooler E-1004

ID: M-CPH-1171-01417_EN_Section_4.doc Page 1 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.01 During normal operation reservoir fluids from Curlew D and Curlew B
Test and Production production wells flow through individual risers to the turret before passing
Manifolds on to the test and production manifolds. Production from DP3 can pass
(Refer to P&ID Drgs through either the DP1 or DP2 flowlines; normal production from DP3
CUR-MAS-PB-20022-001, would pass through DP2 flowline.
CUR-MAS-TP-42002-001
and Well fluids from Curlew DP1 production line pass to the turret through an
CUR-MAS-TP-42035-001) 8in riser and flowline which is provided with the following flow control and
shutdown isolation valves:

Riser Shutdown Valve - 07-XV-200


Flowline Shutdown Valve - 07-XV-205
Choke Valve - 07-PCV-209
Production Diverter Valve - 07-XV-210
Test Diverter Valve - 07-XV-403

Well fluids from Curlew DP2 production line pass to the turret through an
8in riser and flowline which is provided with the following flow control and
shutdown isolation valves:

Riser Shutdown Valve - 07-XV-100


Flowline Shutdown Valve - 07-XV-105
Choke Valve - 07-PCV-109
Production Diverter Valve - 07-XV-110
Test Diverter Valve - 07-XV-402

Well fluids from Curlew BP1 production line pass to the turret through a
6in riser and 8in flowline which is provided with the following flow control
and shutdown isolation valves:

Riser Shutdown Valve - 07-XV-300


Flowline Shutdown Valve - 07-XV-305
Choke Valve - 07-PCV-309
Production Diverter Valve - 07-XV-310
Test Diverter Valve - 07-XV-404

The spare production line passes to the turret as a 12in riser and 12in
flowline which is provided with the following flow control and shutdown
isolation valves:

Riser Shutdown Valve - 07-XXV-0500


Flowline Shutdown Valve - 07-XV-0505
Choke Valve - 07-PCV-0509
Isolation Valve - 07-XV-0510

ID: M-CPH-1171-01417_EN_Section_4.doc Page 2 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.01 Crossover lines are provided to facilitate flow from the spare production
Test and Production line to be routed through the water injection swivel, when there are
Manifolds (Continued) problems with the production or test swivels. During this time Curlew D
production will remain to be through the production or test swivel to allow
positive isolation and maintenance of whichever swivel requires it.

During the utilisation of the water injection swivel, a further crossover is


installed outside of the turret to the spare production line to be routed to
HP separator and Curlew fluids routed to the Test separator.

At this time, there is no need for any crossover outside of the turret.
Curlew D production is via the production swivel to the HP separator and
well testing is via the test swivel to the Test separator.

Refer to Figure 3.8 Crude Production Flowline System Valves and


Spectacle Blind Status.

All four production risers are protected by a series of layers of armoured


protection with an inner carcass. The inner carcass is not pressure
retaining and is designed to prevent the collapse of the pressure sheath
on top of it. Any pressure in the carcass is safely vented to atmosphere
via two dedicated carcass vent lines located upstream of the riser valves.
Any leakage from the carcass passes through these vent lines which are
permanently locked open to an atmospheric vent header.

The Riser Shutdown Valve is hydraulically actuated and is located


upstream of the topsides flowline shutdown valve to provide positive
isolation from the well in accordance with SI 1029. The riser valve is
reset locally and can be partially closed to 25% of its full travel for test
purposes. The riser valves are controlled by the PSD System and are
normally only closed on the occurrence of a Level C General Facilities
Shutdown or in the event of Level A or B Emergency Shutdowns.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 3 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.01 Note: An Emergency Shutdown button is located in the CCR which


Test and Production allows the riser PSD valves to be closed manually.
Manifolds (Continued)

The riser valves are also closed on activation of the flowline High
Integrity Protection System (HIPPS). This protection system is provided
because the shut-in pressure of the Field pipelines may exceed the
design pressure of the separation system vessels. The HIPPS System
operates on a two-out-of-three voting system and is independent of the
PSD System.

Provision is made downstream of the riser valves to inject the following


chemicals if required:

Methanol: can be used to prevent hydrate formation during


start-up/shutdown operations

Corrosion Inhibitor: can be used to prevent corrosion in the topsides


pipework

Squeeze Chemicals: to chemically treat or kill the well during well


servicing operations

Isolation of the four oil production flowlines is provided downstream of


the riser valves by the Flowline Shutdown Valves. All flowline valves are
hydraulically actuated and controlled through the PSD System. The
flowline valves are normally open but will close on the occurrence of a
Level D Production Shutdown or in the event of a Level D General
Facilities Shutdown or Level A or B Emergency Shutdowns.

As with the riser valves, the flowline valves are also closed on activation
of the flowline High Integrity Protection System (HIPPS).

A Low Low Pressure Shutdown System is provided on each flowline


upstream of the flowline valve utilising individual pressure transmitters.
Activation of any of these instruments initiates a PSD to protect the Oil
Processing Facilities from dangerously low pressures.

Motorised choke valves are installed on all three Curlew production


flowlines downstream of the flowline valves to control the flowrate of well
fluids from the wells.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 4 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.01 All choke valves are remotely operated from the PCS system. The
Test and Production position of the choke valve is accessed via the PCS system and a
Manifolds (Continued) shutdown signal automatically closes the choke on the occurrence of a
process shutdown or in the event of a Level C General Facilities
Shutdown or Level A or B Emergency Shutdown.

As the shut-in pressure of the Curlew Field pipelines and risers may
exceed the design pressure of the separation vessels included in the Oil
Processing Facilities, a High Integrity Protection System (HIPS) has
been provided for each of the DP1 and 2 and Spare flowlines. Each
comprises three independent pressure transmitters which operate in a
two-out-of-three voting system.

The BP1 flowline is equipped with two sets of three of HIPS transmitters.
As with the other HIPS transmitters, each set comprises three
independent pressure transmitters which operate in a two-out-of-three
voting system.

The HIPS facilities are located downstream of the topsides choke valves
and operate independently of the PSD System.

Provision is made downstream of the choke valves to inject Corrosion


Inhibitor to prevent corrosion of the flowlines and downstream test and
production manifolds.

Temperature and pressure transmitters located upstream and


downstream of the topsides choke valves continuously monitor the
operating temperature and pressure of the oil flowlines in the swivel.
Signals from each transmitter provides pressure/temperature indication
on the PCS. Each indicator is equipped with high and low alarms which
annunciate on the PCS.

Manually operated diverter valves are positioned on the Curlew flowlines


in the turret to direct the well fluids to the Test or Production Manifolds.
Position indicators are provided for the diverter valves which relay the
status of the each valve to the PCS.

Opening or closing the correct sequence of spectacle blinds on the spare


flowline allows the well fluids to be directed to the production, test or
water injection swivel.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 5 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.01 Note:
Test and Production A valve status interlock is provided for the topsides choke valve which
Manifolds (Continued) prevents the choke from opening unless a permissive is obtained from
the PCS. A permissive is only obtained if the position indicators for the
diverter valves, flowline PSD valve and riser PSD valve indicate that a
valid route is available to the test or production separation train.

The production manifold for the Curlew BP1 well is 8in in diameter and is
mounted around the base of the turret. During normal operation the
production manifold for the Curlew D wells is 8in in diameter and located
beneath the Curlew B manifold. The test manifold is positioned below the
production manifolds and is 8in in diameter. The Curlew D manifold is
provided with two nozzles, one for Riser DP1 and the other for DP2.

Cause and Effect Charts The Cause and Effect Charts associated with the test and production
manifolds are System 07, 27 and 34 CUR-MAS-PB-20655.

4.02 Curlew well fluids enter the Test separator through 10in pipework from
Test Separator V-1005 the test manifold. Demulsifier and defoamer injection points are
(Refer to P&ID Drg No hardpiped to the Test separator inlet pipework to allow the injection of
CUR-MAS-PM-20048-501) chemicals to improve the separation process.

On entering the Test separator the flow of reservoir fluids is distributed


throughout the vessel by a distribution plate fitted at the fluid inlet nozzle.
This also reduces the velocity of the flow to aid separation.

Separation takes place within the main hold-up area of the separator
which contains two perforated baffle plates. The baffle plates are
installed in a cross and longitudinal configuration and are designed to
reduce the velocity of the reservoir fluids and minimise the effects of any
surging.

A corrugated plate coalescing pack assembly is fitted in between the two


baffle plates to encourage coalescence and therefore enhance
separation of the oil and water phases.

Produced gas fills the vapour space of the vessel and the oil and
produced water liquids collect on the bottom of the Test separator. The
gas leaves the top of the separator through 10in gas outlet pipework after
passing through a parallel plate vane mist eliminator which removes any
liquids from the gas stream.

The vane mist eliminator reduces the gas velocity and allows any
entrained droplets to separate out by gravity, impinge on the parallel
plates and fall back to the vessel. The eliminator is designed to ensure
that the gas outlet stream contains a maximum of
0.1USgal/MMSCF and a maximum particle size of 10microns.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 6 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.02 The flow of gas exiting the Test separator is metered by Vortex Meter 10-
Test Separator V-1005 FT-0515. This provides flow indication on PCS through Flow Indicator
(Continued) 10-FI-0515.

A local sample point is situated adjacent to 10-FT-0515. This allows gas


samples to be taken to determine the hydrocarbon composition of the
Test separator off-gas. H 2 S scavenger is injected downstream of the
sample point to ensure no build up of H 2 S in the system. Further details
regarding chemical injection can be found in POPM Volume N41M3.

Pressure within the Test separator is monitored through Pressure


Transmitters 10-PT-0507, 10-PT-0508 and 10-PT-0509. Signals from 10-
PT-0507 are relayed to Pressure Controller 10-PIC-0507 which
maintains the Test separator pressure. Signals from the other pressure
transmitters provide input signals to the PSD system to protect the Test
separator against high and low pressures.

Pressure within the Test separator is controlled through Pressure


Controller 10-PIC-0507. This controller operates on split range control
and modulates Pressure Control Valves 10-PCV-0507A and B as
required to maintain the control setpoint.

Gas from the Test separator co-mingles with the gas outlet from the HP
separator at the Inlet Cooler E-2201 in the Gas Compression Facilities
under pressure control through 10-PCV-0507A for further processing. If
the pressure in the Test separator rises and 10-PCV-0507A is fully open,
then 10-PCV-0507B opens to control the pressure, directing the gas flow
from the separator to the HP Flare System for safe disposal.

The 10in gas outlet line contains Gas Outlet Shutdown Valve
20-XV-1191 located downstream of the Pressure Control Valve
10-PCV-0507A.

This is a pneumatically actuated valve which fails closed on loss of


instrument air supply. The valve is controlled through the PSD System
and is equipped with open and closed position switches on the valve
stem. These provide open and closed position indication on PCS through
20-ZI-1191. The valve is reset by the control room operator in the CCR
after confirmation from the field operator that it is safe to do so.

A contingency wet fuel gas supply facility is provided from the gas outlet
line of the Test separator to the Fuel Gas Cooler. This source of fuel gas
is normally locked closed and is only used if the normal source of fuel
gas from the glycol contactor is unavailable.

The retention time of the liquids flowing through the Test separator is
such that oil and water separation occurs in the bulk side of the vessel,
with the less dense oil phase accumulating above the water layer.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 7 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.02 The interface level in the vessel is maintained by the Interface Level
Test Separator V-1005 Control Valve 10-LCV-0511 located on the clean water outlet from the
(Continued) Test separator hydrocyclone. This level control valve is controlled by an
Interface Level Controller 10-LIC-0511 on signals from Level Transmitter
10-LT-0511. The level controller is equipped with PCS generated high
and low level alarms through 10-LAH-0511 and
10-LAL-0511 respectively.

Alternatively, when the Curlew produced water rate is 5000BWPD and


above, control signal 40-HS-4001A allows Test separator to be lined up
with the HP Hydrocyclone. In this instance the interface level in the Test
separator is maintained by Interface Control Valve 10-LCV-0111, located
on the clean water outlet from the HP Hydrocyclone. This level control
valve is controlled by an Interface Level Controller 10-LIC-0111 on
signals from Level Transmitter 10-LT-0511. The level controller is
equipped with PCS generated high and low level alarms through 10-
LAH-0511 and 10-LAL-0511 respectively.

Level Transmitter 10-LT-0511 is located on top of the Test separator with


its displacer located in a still well within the vessel to reduce motion
effects.

Produced water leaves the Test separator through 4in pipework


containing Manual Isolation Valve HV-10281 to Test separator
Hydrocyclone V-4003, or HP Hydrocyclone V-4001.

The 4in produced water outlet pipework is insulated and heat traced for
freeze protection.

The flow of produced water to the Test Hydrocyclone, which is either


from the Test separator or the HP Separator, is metered downstream of
the shutdown valve by Vortex Meter 10-FT-0521. This provides produced
water flow indication on PCS through 10-FI-0521.

A chemical injection point is provided downstream of the vortex meter


which can be utilised for the injection of scale inhibitors to prevent scaling
of the produced water pipework or reverse demulsifiers to improve the
performance of the Test separator hydrocyclone.

Oil level in the Test separator is maintained by Level Control Valve


10-CV-0514 located on the oil outlet line from the vessel. This level
control valve is controlled by Level Controller 10-LIC-0514 on signals
from Level Transmitter 10-LT-0514. The level transmitter displacer is
located in a still well within the vessel to reduce motion effects. The level
controller is equipped with PCS generated high and low level alarms 10-
LAH-0514 and 10-LAL-0514 respectively.

A normally isolated 3in bypass line is provided around the level control
valve for use in the event of control valve maintenance.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 8 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.02 The Test separator is protected against high and low oil levels through
Test Separator V-1005 Level Transmitters 10-LT-0512 and 10-LT-0513 respectively. Activation
(Continued) of either switch is relayed to the PSD System.

Crude oil leaves the Test separator through 6in pipework to the MP
Separator V-1002 or MP Heater E-1002 for further processing.

The 6in oil outlet pipework contains Oil Outlet Shutdown Valve 10-XV-
0518. This is pneumatically actuated valve which fails closed on loss of
instrument air supply. The valve is controlled through the PSD System
and is equipped with open and closed position switches on the valve
stem. These provide open and closed position indication on PCS through
10-ZI-0518.

The oil outlet valve is reset by the control room operator in the CCR after
confirmation from the field operator that it is safe to do so.

A local sample point situated upstream of the shutdown valve enables


crude oil samples to be obtained for analysis.

The flow of crude oil from the Test separator is metered downstream of
the shutdown valve by Vortex Meter 10-FT-0519. This provides oil outlet
flow indication on PCS through 10-FI-0519.

For future use the Test separator is provided with a sandwash facility
This will be utilised to remove any deposited solids from the bottom of
the separator by the introduction of seawater.

A hose connection is fitted to the sandwash pipework to facilitate the


transfer of deaerated seawater from the water injection or flushing water
from the utility seawater system to the Test separator.

When in use the sandwash water will be introduced to the Test separator
through three high velocity jetting nozzles with the vessel on-line.
Sandwash water will enter the base of the separator through individual
valves fitted on the jetting lines. Any deposits from the bottom of the
vessel will be directed to the skid drip pan through the belly drain lines for
safe disposal to the Hazardous Open Drain.

The following pressure and level trip signals are provided as inputs to the
PSD system from transmitters on the Test separator:

10-LT-0510 Oil/Water Interface Level Low Low


10-LT-0512 Oil Level Low Low
10-LT-0513 Liquid Level High High
10-PT-0508 Pressure Low Low
10-PT-0509 Pressure High High

ID: M-CPH-1171-01417_EN_Section_4.doc Page 9 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.02 Overpressure protection of the Test separator is provided by Pressure


Test Separator V-1005 Safety Relief Valves, 10-PSV-0503A and 10-PSV-0503B, located on a
(Continued) line routed from the Test separator to the HP flare header. Both valves
are set to relieve at 45.0barg and are fitted with a valve interlock system
that ensures that one relief valve is on-line at all times.

A normally isolated 1in line is provided around the PSV set which allows
the Test separator to be manually depressurised to HP Flare.

The Test separator may be automatically depressurised to HP Flare


through 3in blowdown pipework containing Blowdown Valve
10-XV-0501. The blowdown valve is pneumatically actuated and fails
open on loss of instrument air supply.

The blowdown valve is controlled through the PSD system and is opened
on activation of a Level C-Fire (C-F) - General Facilities Shutdown on
Confirmed Fire.

The rate of depressurisation is limited by Flow Orifice 10-FO-0502


installed downstream of the blowdown valve. The flow is restricted to
ensure that the separator is depressurised within fifteen (15) minutes
under fire conditions.

The separator may also be manually depressurised through a 1in line


upstream of the blowdown valve. This line is normally isolated and
depressurises the separator to LP Flare.

Local Instrumentation The following local instrumentation is provided on and around the Test
separator:

10-LG-0517 Oil/Gas Interface Level


10-LG-0516 Oil/Water Interface Level
10-TG-0505 Vessel Temperature
10-TG-0528 Produced water outlet temperature
10-PG-0506 Vessel Pressure

Technical Data Dimensions: 2200mm ID x 4900mm TT


Design Pressure: Full Vac/45barg
Design Temperature: -30C/+100C

Cause and Effects The Cause and Effect Chart associated with the Test separator is
System 10.2 CUR-MAS-PB-20655.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 10 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.03 Reservoir fluids from the Curlew production wells enter the HP separator
HP Separator V-1001 through 14in pipework from the turret swivel. Demulsifier and defoamer
(Refer to P&ID Drg No injection points are hardpiped to the HP separator inlet pipework allowing
CUR-MAS-PM-20041-501) the injection of chemicals to improve the separation process.

On entering the HP separator the flow of reservoir fluids is distributed


throughout the vessel by a distribution plate fitted at the fluid inlet nozzle.
This also reduces the velocity of the flow to aid separation.

Separation takes place within the main hold-up area of the separator
which contains four perforated baffle plates. The baffle plates are
installed in a cross and longitudinal configuration and are designed to
reduce the velocity of the reservoir fluids and minimise the effects of any
surging.

A corrugated plate coalescing pack assembly is installed downstream of


the perforated baffle plates to encourage coalescence and therefore
enhance separation of the oil and water phases.

Produced gas fills the vapour space of the vessel and the oil and
produced water liquids collect on the bottom of the HP separator. The
separated gas flow leaves the separator through 12in pipework after
passing through a parallel plate vane mist eliminator which removes any
entrained liquids from the gas stream.

The vane mist eliminator reduces the gas velocity and allows any
entrained droplets to separate out by gravity, impinge on the parallel
plates and fall back to the vessel. The eliminator is designed to ensure
that the gas outlet stream contains a maximum of 0.1USgal/MMSCF and
a maximum particle size of 10microns.

The flow of gas exiting the HP separator is metered by Vortex Meter 10-
FT-0115. This provides flow indication on PCS through Flow Indicator
10-FI-0115.

A local sample point is situated adjacent to 10-FT-0115. This allows gas


samples to be obtained to determine the hydrocarbon composition of the
HP separator off-gas. H 2 S scavenger is injected downstream of the
sample point to ensure no build up of H 2 S in the system. Further details
regarding chemical injection can be found in POPM Volume N41M3.

Pressure within the HP separator is monitored through Pressure


Transmitters 10-PT-0107. 10-PT-0108 and 10-PT-0109. Signals from 10-
PT-0107 are relayed to Pressure Controller 10-PIC-0107 which vents
excess pressure from the HP separator to HP Flare through Pressure
Control Valve 10-PCV-0107. Signals from the other pressure transmitters
provide input signals to the PSD system to protect the HP separator
against high and low pressures.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 11 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.03
HP Separator V-1001 Pressure within the HP separator is normally controlled by the load
(Continued) control setpoint for Export Compressor K-2001.

Gas is routed from the top of the HP separator through 10in pipework
and normally passes to the Inlet Cooler E-2201 through Inlet Cooler Gas
Supply Valve 22-XV-1051.

This is a pneumatically actuated valve which fails closed on loss of


instrument air supply. The valve is controlled through the PSD System
and is equipped with switches on the valve stem. These provide open
and closed position indication on PCS through 22-ZI-1051.

The inlet cooler is provided with a 2in pressurisation bypass line


containing Pressurisation Valve 22-XV-1052.

This is a pneumatically actuated valve which fails closed on loss of


instrument air supply. The valve is controlled through the PSD System
and is equipped with position switches on the valve stem. These provide
open and closed position indication on PCS through 22-ZI-1052. The
valves are reset by the control room operator in the CCR after
confirmation from the field operator that it is safe to do so.

A contingency supply of wet fuel gas supply is provided from the gas
outlet line of the HP separator to the fuel gas cooler. This source of fuel
gas is normally isolated and is only in use if the normal source of fuel gas
from the glycol contactor is unavailable.

The retention time of the liquids flowing through the HP separator is such
that oil and water separation occurs in the bulk side of the vessel, with
the less dense oil phase accumulating above the water layer.

The interface level in the vessel is maintained by the Interface Level


Control Valve 10-LCV-0111 located on the clean water outlet from the
HP separator hydrocyclone. This level control valve is controlled by an
Interface Level Controller 10-LIC-0111 on signals from Level Transmitter
10-LT-0111. The level controller is equipped with PCS generated high
and low level alarms through 10-LAH-0111 and
10-LAL-0111 respectively.

Alternatively when the Curlew produced water rate is 5000BWPD and


above, control signal switch 40-HS-4001A allows HP Separator to be
lined up with the Test Hydrocyclone. In this instance the interface level in
the HP Separator is maintained by Interface Level Control Valve 10-LCV-
0511, located on the clean water outlet from the Test Hydrocyclone. This
level control valve is controlled by an Interface Level Controller 10-LIC-
0511 on signals from Level Transmitter 10-LT-0111. The level controller
is equipped with PCS generated high and low level alarms through 10-
LAH-0111 and 10-LAL-0111 respectively.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 12 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.03
HP Separator V-1001 Level Transmitter 10-LT-0111 is located on top of the HP separator with
(Continued) its displacer located in a still well within the vessel to reduce motion
effects.

Produced water leaves the HP separator through 6in pipework containing


Manual Isolation Valve HV-10046 to HP Hydrocyclone
V-4001, or Test Hydrocyclone V-4003.

The 6in produced water outlet pipework is insulated and heat traced for
freeze protection.

The flow of produced water to the HP Hydrocyclone, which is either from


the HP Separator or the Test separator, is metered downstream of the
outlet valve HV-10046 by Vortex Meter 10-FT-0121. This provides flow
indication on PCS through Flow Indicator 10-FI-0121.

A chemical injection point is provided downstream of the vortex meter


which can be utilised for the injection of scale inhibitors to prevent scaling
of the produced water pipework or reverse demulsifiers to improve the
performance of the HP separator hydrocyclone.

Oil level in the HP separator is maintained by Level Control Valve


10-LCV-0114 located on the oil outlet line from the HP crude oil heater.
This level control valve is controlled by Level Controller 10-LIC-0114
on signals from Level Transmitter 10-LT-0114. The level transmitter
displacer is located in a still well within the vessel to reduce motion
effects. The level controller is equipped with PCS generated high and low
level alarms 10-LAH-0114 and 10-LAL-0114 respectively.

Crude oil leaves the HP separator through 6in pipework to the HP Crude
Oil Heater E-1001 for further processing.

The 6in crude oil outlet pipework contains Oil Outlet Shutdown Valve 10-
XV-0118. This is a pneumatically actuated valve which fails closed on
loss of instrument air supply. The valve is controlled through the PSD
System and is equipped with open and closed position switches on the
valve stem. These provide open and closed position indication on PCS
through 10-ZI-0118.

The oil outlet valve is reset from the control room after confirmation from
the field that it is safe to do so.

A local sample point situated upstream of the shutdown valve enables


crude samples to be taken for analysis.

The flow of crude oil from the HP separator is metered downstream of


the shutdown valve by Vortex Meter 10-FT-0119. This provides flow
indication on PCS through Flow indicator 10-FI-0119.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 13 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.03 For future use the HP separator is provided with a sandwash facility
HP Separator V-1001 which will be utilised to remove any deposited solids from the bottom of
(Continued) the separator by the introduction of seawater.

A hose connection is fitted to the sandwash pipework to facilitate the


transfer of deaerated seawater from the water injection or flushing water
from the utility seawater system to the HP separator.

When in use the sandwash water will be introduced to the HP separator


through three high velocity jetting nozzles with the vessel on-line.
Sandwash water will enter the base of the separator through individual
valves fitted on the jetting lines. Any deposits from the bottom of the
vessel will be directed to the skid drip pan through the belly drain lines for
safe disposal to the Hazardous Open Drain.

The following pressure and level trip signals are provided as inputs to the
PSD system from transmitters on the vessel:

10-LT-0110 Oil/Water Interface Level Low Low


10-LT-0112 Oil Level Low Low
10-LT-0113 Liquid Level High High
10-PT-0108 Pressure Low Low
10-PT-0109 Pressure High High

Overpressure protection of the HP separator is provided by Pressure


Safety Relief Valves, 10-PSV-0103A and 10-PSV-0103B located on a
line routed from the HP separator to the HP flare header. Both valves are
set to relieve at 45.0barg and are fitted with a valve interlock system that
ensures that one relief valve is on-line at all times.

A normally isolated 1in line is provided around the PSV set which allows
the HP separator to be manually depressurised to HP Flare.

The HP separator may be automatically depressurised to HP Flare


through 4in blowdown pipework containing Blowdown Valve
10-XV-0101. The blowdown valve is pneumatically actuated and fails
open on loss of instrument air supply.

The blowdown valve is controlled through the PSD system and is opened
on activation of a Level C-Fire (C-F) - General Facilities Shutdown on
Confirmed Fire.

The rate of depressurisation is limited by Flow Orifice 10-FO-0102


installed downstream of the blowdown valve. The flow is restricted to
ensure that the separator is depressurised within fifteen (15) minutes
under fire conditions.

The separator may also be manually depressurised through a 1in line


upstream of the blowdown valve. This line is normally isolated and
depressurises the separator to LP Flare.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 14 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.03
HP Separator V-1001
(Continued)

Local Instrumentation The following local instrumentation is provided on and around the HP
Separator:

10-LG-0117 Oil/Gas Interface Level


10-LG-0116 Oil/Water Interface Level
10-TG-0105 Vessel Temperature
10-PG-0106 Vessel Pressure

Technical Data Dimensions: 2900mm ID x 7000mm TT


Design Pressure: Full Vac/45barg
Design Temperature: -30C/+100C

Cause and Effects The Cause and Effect Chart associated with the HP separator is System
10.1 CUR-MAS-PB-20655.

4.04
HP Crude Oil Heater Partially stabilised crude oil from the HP separator flows through a
E-1001 manual isolation valve to the HP crude oil heater inlet. The HP crude oil
(Refer to P&ID Drg CUR- heater is a horizontally mounted shell and tube heat exchanger located in
MAS-PM-20042-501) the HP separation train.

Crude oil is passed through the tube bundle of the exchanger where it is
heated to between 55 and 75oC by heat exchange with the heating
medium flowing through the shellside. The heated crude leaves the
exchanger through a 6in connection fitted to the tube head and passes
on to the MP separator for further stabilising.

The flow of crude oil through the exchanger is controlled through Level
Control Valve 10-LCV-0114 located on the oil outlet line. The control
valve controls the oil level in the HP separator on signals from Level
Controller 10-LIC-0114.

The level control valve is pneumatically operated and fails closed on loss
of instrument air supply. A normally isolated 3in bypass line is provided
around the level control valve for use in the event of control valve
maintenance.

The 30% TEG/70% freshwater solution utilised for heating purposes


flows through a 4in supply line from the heating medium circuit to the
shellside of the HP crude oil heater. The heating medium then passes
through the exchanger where heat is exchanged with the crude oil
passing through the tubeside of the unit. After giving up its heat to the
crude oil, the heating medium passes out of the exchanger through
Temperature Control Valve 10-TCV-0155 and downstream Shutdown
Valve 44-XV-2017 before flowing to the heating medium return circuit.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 15 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.04 The shutdown valve is a pneumatically actuated valve which fails closed
HP Crude Oil Heater on loss of instrument air supply. The valve is controlled through the PSD
E-1001 (Continued) system and is equipped with position switches on the valve stem. These
provide open and closed indication on PCS through 44-ZI-2017. The
valve is reset by the control room operator in the CCR after confirmation
from the field operator that it is safe to do so.

Heating medium flow through the exchanger is controlled by


Temperature Control Valve 10-TCV-0155. This temperature control valve
is regulated by Temperature Controller 10-TIC-0155 on signals from
Temperature Transmitter 10-TT-0155 located on the heater oil outlet line.
The temperature controller is equipped with PCS generated high and low
temperature alarms through 10-TAH-0155 and 10-TAL-0155
respectively.

The following temperature and pressure trip signals are provided as


inputs to the PSD System from transmitters located on the crude oil and
heating medium outlets from the heater:

10-TT-0154 Crude oil outlet temperature high high


44-PT-2016 Heating Medium outlet pressure high high

In the unlikely event of tube bundle rupture, the heating medium circuit is
protected from overpressurisation by Pressure Transmitter 44-PT-2016
fitted to the heating medium outlet from the HP crude oil heater.
Activation of 44-PT-2016 initiates a PSD shutdown which isolates the
flowrate of crude through the heater.

Overpressure protection of the tubeside of the HP crude oil heater is


provided by Pressure Safety Valve 10-PSV-0153 located on the oil outlet
line. This relief valve is set at 45barg and relieves excess pressure to the
HP Flare header.

Overpressure protection of the shellside of the HP crude oil heater is


provided by Pressure Safety Valve 44-PSV-2013 located on the heating
medium outlet line. This relief valve is set at 16barg and relieves excess
pressure to the LP Flare.

Local Instrumentation The following local instrumentation is provided on and around the HP
crude oil heater:

10-TG-0151 Crude oil to E-1001 temperature


10-TG-0156 Crude oil from E-1001 temperature
10-PG-0157 Crude oil from E-1001 pressure
44-TG-2011 Heating Medium to E-1001 temperature
(at heating medium circuit)
44-PG-2012 Heating Medium to E-1001 pressure
(at heating medium circuit)
44-TG-2015 Heating medium from E-1001 temperature
(at heating medium circuit)
44-PG-2014 Heating medium from E-1001 pressure
(at heating medium circuit)

ID: M-CPH-1171-01417_EN_Section_4.doc Page 16 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.04 Dimensions: 4500mm TT


HP Crude Oil Heater Design Pressure (oil side): 45barg
E-1001 (Continued) Design Pressure
(heating medium side): 16barg
Design Temperature (oil side): -30oC to 120oC
Design Temperature
Technical Data (heating medium side): 130oC
Design Duty: 1509KW

Cause and Effects The Cause and Effect Chart associated with the HP crude oil heater is
System 10.1 CUR-MAS-PB-20655.

4.05 Reservoir fluids from the Curlew B Production Well BP1 enter the MP
MP Separator V-1002 separator through 10in pipework from the turret swivel. Demulsifier and
(Refer to P&ID Drg No defoamer injection points are hardpiped to the MP separator inlet header
CUR-MAS-PM-20043-001) for dosing with chemicals to improve the separation process.

Fluids from the following sources are also directed to the MP separator
inlet header:

Pre-heated crude oil from the HP Crude Oil Heater E-1001

Curlew crude oil from the Test separator V-1005

Produced water from the common discharge of the Produced Water


Pumps P-1002A/B

Condensates recovered from the Export Gas Scrubber V-2001 and


Glycol Contactor C-2201

On entering the MP separator the flow of reservoir fluids is distributed


throughout the vessel by a distribution plate fitted at the fluid inlet nozzle.
This also reduces the velocity of the flow to aid separation.

Separation takes place within the main hold-up area of the separator
which contains four perforated baffle plates. The baffle plates are
installed in a cross and longitudinal configuration and are designed to
reduce the velocity of the reservoir fluids and minimise the effects of any
surging.

A corrugated plate coalescing pack assembly is installed downstream of


the perforated baffle plates to encourage coalescence and therefore
enhance separation of the oil and water phases.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 17 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.05 Produced gas fills the vapour space of the vessel and the oil and
MP Separator V-1002 produced water liquids collect on the bottom of the MP separator. The
(Continued) separated gas flow leaves the separator through 10in pipework after
passing through a parallel plate vane mist eliminator which removes any
entrained liquids from the gas stream.

The vane mist eliminator reduces the gas velocity and allows any
entrained droplets to separate out by gravity, impinge on the parallel
plates and fall back to the vessel. The eliminator is designed to ensure
that the gas outlet stream contains a maximum of 0.1USgal/MMSCF.

The flow of gas exiting the MP separator is metered by Vortex Meter 10-
FT-0215. This provides flow indication on PCS through Flow Indicator
10-FI-0215.

A local sample point is situated adjacent to 10-FT-0215. This allows gas


samples to be obtained to determine the hydrocarbon composition of the
MP separator off-gas.

Pressure within the MP separator is monitored through Pressure


Transmitters 10-PT-0207. 10-PT-0208 and 10-PT-0209. Signals from 10-
PT-0207 are relayed to Pressure Controller 10-PIC-0207 which vents
excess pressure from the MP separator to HP Flare through Pressure
Control Valve 10-PCV-0207B. Signals from the other pressure
transmitters provide input signals to the PSD system to protect the MP
separator against high and low pressures.

Pressure Control Valve 10-PCV-0207B is a pneumatically operated valve


which fails closed on loss of instrument air supply.

Pressure within the MP separator is normally controlled by the load


control setpoint for MP Compressor K-2002.

Gas is routed from the top of the MP separator through 10in pipework
and passes to the MP Compressor Suction Cooler E-2002 through MP
Compressor Suction Cooler Gas Supply Valve 20-XV-1201.

This is a pneumatically actuated valve which fails closed on loss of


instrument air supply. The valve is controlled through the PSD System
and is equipped with switches on the valve stem. These provide open
and closed position indication on PCS through 20-ZI-1201.

The MP compressor suction cooler is provided with a 2in pressurisation


bypass line containing Pressurisation Valve 20-XV-1202.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 18 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.05 This is a pneumatically actuated valve which fails closed on loss of


MP Separator V-1002 instrument air supply. The valve is controlled through the PSD System
(Continued) and is equipped with position switches on the valve stem. These provide
open and closed position indication on PCS through 20-ZI-1202. The
valves are reset by the control room operator in the CCR after
confirmation from the field operator that it is safe to do so.

The retention time of the liquids flowing through the MP separator is such
that oil and water separation occurs in the bulk side of the vessel, with
the less dense oil phase accumulating above the water layer.

The interface level in the vessel is maintained by the Interface Level


Control Valve 10-LCV-0211 located on the clean water outlet from MP
Hydrocyclone V-4002.

This level control valve is controlled by an Interface Level Controller 10-


LIC-0211 on signals from Level Transmitter 10-LT-0211. The level
controller is equipped with PCS generated high and low level alarms
through 10-LAH-0211 and 10-LAL-0211.

Level Transmitter 10-LT-0211 is located on top of the MP separator with


its displacer located in a still well within the vessel to reduce motion
effects.

Produced water leaves the vessel through 6in pipework containing


Manual Isolation Valve HV-10112 to MP Hydrocyclone V-4002.

The 6in produced water outlet pipework is insulated and heat traced for
freeze protection.

The flow of produced water from the MP separator is metered


downstream of HV-10112 by Vortex Meter 10-FT-0221. This provides
flow indication on PCS through Flow Indicator 10-FI-0221.

Oil level in the MP separator is maintained by Level Control Valve


10-LCV-0214 located on the 8in crude oil outlet line. This level control
valve is controlled by Level Controller 10-LIC-0214 on signals from Level
Transmitter 10-LT-0214. The level transmitter displacer is located in a
still well within the vessel to reduce motion effects. The level controller is
equipped with PCS generated high and low level alarms 10-LAH-0214
and 10-LAL-0214 respectively.

Crude oil leaves the MP separator through 8in pipework to the MP Crude
Oil Heater E-1002 for further processing.

The 8in crude oil outlet pipework contains Oil Outlet Shutdown Valve 10-
XV-0218. This is pneumatically actuated valve which fails closed on loss
of instrument air supply. The valve is controlled through the PSD System
and is equipped with open and closed position switches on the valve
stem. These provide open and closed position indication on PCS through
10-ZI-0218.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 19 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.05 The oil outlet valve is reset from the control room after confirmation from
MP Separator V-1002 the field that it is safe to do so.
(Continued)

A local sample point situated upstream of the shutdown valve enables a


crude samples to be taken for analysis.

The flow of crude oil from the MP separator is metered downstream of


the shutdown valve by Vortex Meter 10-FT-0219. This provides flow
indication on PCS through Flow indicator 10-FI-0219.

For future use the MP separator is provided with a sandwash facility This
will be utilised to remove any deposited solids from the bottom of the
separator by the introduction of seawater.

A hose connection is fitted to the sandwash pipework to facilitate the


transfer of deaerated seawater from the water injection or flushing water
from the utility seawater system to the MP separator.

When in use the sandwash water will be introduced to the MP separator


through five high velocity jetting nozzles with the vessel on-line.
Sandwash water will enter the base of the separator through individual
valves fitted on the jetting lines. Any deposits from the bottom of the
vessel will be directed to the skid drip pan through the belly drain lines for
safe disposal to the Hazardous Open Drain.

The following pressure and level trip signals are provided as inputs to the
PSD system from transmitters on the vessel:

10-LT-0210 Oil/Water Interface Level Low Low


10-LT-0212 Oil Level Low Low
10-LT-0213 Liquid Level High High
10-PT-0208 Pressure Low Low
10-PT-0209 Pressure High High

Overpressure protection of the MP separator is provided by Pressure


Safety Relief Valves, 10-PSV-0203A and 10-PSV-0203B located on a
line routed from the MP separator to the LP flare header. Both valves are
set to relieve at 16.0barg and are fitted with a valve interlock system that
ensures that one relief valve is on-line at all times.

A normally isolated 1in line is provided around the PSV set which allows
the MP separator to be manually depressurised to LP Flare.

The MP separator may be automatically depressurised to LP Flare


through 4in blowdown pipework containing Blowdown Valve
10-XV-0201. The blowdown valve is pneumatically actuated and fails
open on loss of instrument air supply.

The blowdown valve is controlled through the PSD system and is opened
on activation of a Level C-Fire (C-F) - General Facilities Shutdown on
Confirmed Fire.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 20 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.05 The rate of depressurisation is limited by Flow Orifice 10-FO-0202


MP Separator V-1002 installed downstream of the blowdown valve. The flow is restricted to
(Continued) ensure that the separator is depressurised within fifteen (15) minutes
under fire conditions.

Local Instrumentation The following local instrumentation is provided on and around the
MP Separator:

10-LG-0217 Oil/Gas Interface Level


10-LG-0216 Oil/Water Interface Level
10-TG-0205 Vessel Temperature
10-PG-0206 Vessel Pressure

Technical Data Dimensions: 3200mm ID x 7200mm TT


Design Pressure: 16barg
Design Temperature: -30oC/+100oC

Cause and Effects The Cause and Effect Chart associated with the MP separator is System
10.1 CUR-MAS-PB-20655.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 21 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.06
MP Crude Oil Heater Partially stabilised crude from the oil outlet line of the MP separator flows
E-1002 through 8in pipework which increases to a 16in line downstream of Level
(Refer to P&ID Drg No Control Valve 10-LCV-0214. The crude oil stream is then routed to the
CUR-MAS-PM-20044-501) inlet of the MP crude oil heater.

Fluids from the following sources are also directed to the inlet header for
the MP crude oil heater:

Curlew crude oil from Test separator V-1005

Produced water from Electrostatic Coalescer V-1004

Condensate recovered from the LP and MP Compressor Suction


Scrubbers

Condensate recovered from the Fuel Gas Scrubber V-5201 and


Glycol Regeneration Package A-2201

Liquids from the LP and HP Flare KO drums

A manually operated isolation ball valve is provided on the process inlet


to the MP crude oil heater. This valve is always in the open position as
the MP crude oil heater is in continuous service.

Crude oil passes through the MP crude oil heater where the temperature
of the oil is increased to 65 to 68oC by heat exchange with heating
medium. The heated oil flows out of the plate type exchanger and
combines with the reject oil flow from the HP, MP and Test
Hydrocyclones before passing onwards to the LP separator for full
stabilisation.

The 30% TEG/70% freshwater solution utilised for heating purposes


flows through a 6in supply line to the hot side of the MP crude oil heater
from the heating medium circuit. The heating medium passes through the
plate type exchanger where heat is exchanged with the crude.

After giving its heat to the crude oil, the heating medium passes out of
the MP crude heater through 6in pipework containing Temperature
Control Valve 10-TCV-0255.

The temperature control valve is a pneumatically operated valve which


fails closed on loss of instrument air supply. The valve is provided with a
normally isolated 4in bypass line for use in the event of control valve
maintenance.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 22 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.06 Heating medium flow through the MP crude oil heater is controlled by
MP Crude Oil Heater Temperature Control Valve 10-TCV-0255. This temperature control valve
E-1002 (Continued) is regulated by Temperature Controller 10-TIC-0255 on signals from
Temperature Transmitter 10-TT-0255 located on the heater oil outlet line.
The temperature controller is equipped with PCS generated high and low
temperature alarms through 10-TAH-0255 and 10-TAL-0255 respectively.

The following temperature trip signal is provided as an input to the PSD


System from an independent transmitter located on the oil outlet from the
MP crude oil heater:

21-TT-0254 Crude oil temperature high high

Overpressure protection of the crude oil side of the MP crude oil heater is
provided by a Pressure Safety Relief Valve 10-PSV-0253 located on the
oil inlet line. This relief valve is set at 16barg and relieves excess
pressure to the LP flare header.

Local Instrumentation The following local pressure and temperature instrumentation is provided
on and around the MP crude oil heater:

10-TG-0251 Crude oil to E-1002 temperature


10-PG-0250 Crude oil to E-1002 pressure
10-TG-0256 Crude oil from E-1002 temperature
10-PG-0257 Crude oil from E-1002 pressure
44-TG-2021 Heating medium to E-1002 temperature
44-PG-2022 Heating medium to E-1002 pressure
44-TG-2025 Heating medium from E-1002 temperature
44-PG-2024 Heating medium from E-1002 pressure

Technical Data Overall Dimensions: 1828m (L) x 1060mm (W)


x 1985mm (H)
Design Pressure (Oil Side): 16.0barg
Design Pressure
(Heating Medium Side): 16.0barg
Design Temperature (Oil Side): -30oC to 120oC
Design Temperature
(Heating Medium Side): 130oC
Duty: 6288KW

Cause and Effects The Cause and Effect Chart associated with the heater is
System 10-1 CUR-MAS-PB-20655.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 23 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.07 Pre-heated crude enters the LP separator through 20in pipework from
LP Separator V-1003 the MP crude oil heater.
(Refer to P&ID Drg No
CUR-MAS-PM-20045-001) On entering the vessel the crude oil flow is distributed throughout the
vessel by a distribution plate fitted at the fluid inlet nozzle. This also
reduces the velocity of the flow to aid separation.

Separation takes place within the main hold-up area of the separator
which contains four perforated baffle plates. The baffle plates are
installed in a cross and longitudinal configuration and are designed to
reduce the velocity of the reservoir fluids and minimise the effects of any
surging.

A corrugated plate coalescing pack assembly is installed downstream of


the perforated baffle plates to encourage coalescence and therefore
enhance separation of the oil and water phases.

Produced gas fills the vapour space of the vessel and the oil and
produced water liquids collect on the bottom of the LP separator.
The separated gas leaves the separator through 16in pipework after
passing through a parallel plate vane mist eliminator which removes any
entrained liquids from the gas stream.

The vane mist eliminator reduces the gas velocity and allows any
entrained droplets to separate out by gravity, impinge on the parallel
plates and fall back to the vessel. The eliminator is designed to ensure
that the gas outlet stream contains a maximum of
0.1USgal/MMSCF and a maximum particle size of 10microns.

The flow of gas exiting the LP separator is metered by Vortex Meter 10-
FT-0315. This provides flow indication on PCS through Flow Indicator
10-FI-0315.

A local sample point is situated adjacent to 10-FT-0315. This allows gas


samples to be obtained to determine the hydrocarbon composition of the
LP separator off-gas.

Pressure within the LP separator is monitored through Pressure


Transmitters 10-PT-0307. 10-PT-0308 and 10-PT-0309.

Signals from 10-PT-0307 are relayed to Pressure Controller 10-PIC-0307


which vents excess pressure from the LP separator to LP Flare through
Pressure Control Valve 10-PCV-0307B. This pressure controller is
equipped with PCS generated high and low pressure alarms through 10-
PAH-0307 and 10-PAL-0307 respectively. The controller also provides
an input signal to True Vapour Pressure (TVP) Relay 10-XY-0307.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 24 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.07 Signals from the other pressure transmitters provide input signals to the
LP Separator V-1003 PSD system to protect the LP separator against high and low pressures.
(Continued)

Pressure Control Valve 10-PCV-0307B is a pneumatically operated valve


which fails closed on loss of instrument air supply.

Pressure within the LP separator is normally controlled by the load


control setpoint for LP Compressor K-2003.

Gas is routed from the top of the LP separator to the inlet of LP


Compressor Cooler E-2003 through 16in pipework containing Shutdown
Valve 20-XV-1221.

This is a pneumatically actuated valve which fails closed on loss of


instrument air supply. The valve is controlled through the PSD System
and is equipped with position switches on the valve stem. These provide
open and closed position indication on PCS through 20-ZI-1221. The
shutdown valve is reset by the control room operator from the CCR after
confirmation from the field that it is safe to do so.

The retention time of the liquids flowing through the LP separator is such
that oil and water separation occurs in the bulk side of the vessel, with
the less dense oil phase accumulating above the water layer.

The interface level in the LP separator is maintained by the Interface


Level Controller 10-LIC-0311 on signals from Level Transmitter 10-
LT-0311. The level controller operates in an on/off control configuration
and controls the interface level by starting and stopping the duty
Produced Water Transfer Pump P-1002A/B located beneath the vessel.
The level controller is equipped with high and low level alarms which on
activation annunciate on PCS through 10-LAH-0311 and 10-LAL-0311
respectively.

Level Transmitter 10-LT-0311 is located on top of the LP separator with


its displacer located in a still well within the vessel to reduce motion
effects.

Produced water leaves the LP separator through 3in pipework and is


routed to the suction of Produced Water Transfer Pumps
P-1002A/B. These facilities return the produced water from the LP
separator to the MP separator and are detailed in Paragraph 4.08 of
this Volume.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 25 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.07 The 3in produced water outlet pipework is insulated and heat traced for
LP Separator V-1003 freeze protection and contains Produced Water Outlet Valve 10-XV-
(Continued) 0334. This is a pneumatically actuated valve which fails closed on loss of
instrument air supply. The valve is controlled through the PSD System
and is equipped with position switches on the valve stem. These provide
open and closed indication on PCS through 10-ZI-0334. The produced
water outlet valve is reset from the control room after confirmation from
the field that it is safe to do so.

The flow of produced water from the LP separator is metered


downstream of the produced water transfer pumps by Vortex Meter 10-
FT-0321. This provides flow indication on PCS through Flow Indicator
10-FI-0321.

Oil level in the LP separator is maintained by Level Control Valve


10-LCV-0314 located on the oil outlet line from the Export Crude Oil
Cooler E-1004. This level control valve is controlled by Level Controller
10-LIC-0314 on signals from Level Transmitter
10-LT-0314. The level transmitter displacer is located in a still well within
the vessel to reduce motion effects. The level controller is equipped with
PCS generated high and low level alarms
10-LAH-0314 and 10-LAL-0314 respectively.

Crude oil leaves the LP separator through 12in pipework to the suction of
Crude Oil Transfer Pumps P-1001A/B. These facilities direct the crude
recovered in the LP separator to the Electrostatic Coalescer V-1004 for
further processing. Full details on the operation and control of the crude
oil transfer pumps are provided in Paragraph 4.09 of this Volume.

The 12in crude oil outlet pipework contains Oil Outlet Shutdown Valve
10-XV-0335. This is pneumatically actuated valve which fails closed on
loss of instrument air supply. The valve is controlled through the PSD
System and is equipped with open and closed position switches on the
valve stem. These provide open and closed position indication on PCS
through 10-ZI-0335.

The oil outlet valve is reset from the control room after confirmation from
the field that it is safe to do so.

A local sample point situated downstream of the shutdown valve enables


crude samples to be taken for analysis.

For future use the LP separator is provided with a sandwash facility This
will be utilised to remove any deposited solids from the bottom of the
separator by the introduction of seawater.

A hose connection is fitted to the sandwash pipework to facilitate the


transfer of deaerated seawater from the water injection or flushing water
from the utility seawater system to the LP separator.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 26 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.07 When in use the sandwash water will be introduced to the LP separator
LP Separator V-1003 through five high velocity jetting nozzles with the vessel on-line.
(Continued) Sandwash water will enter the base of the separator through individual
valves fitted on the jetting lines. Any deposits from the bottom of the
vessel will be directed to the skid drip pan through the belly drain lines for
safe disposal to the Hazardous Open Drain.

The following pressure and level trip signals are provided as inputs to the
PSD system from transmitters on the vessel:

10-LT-0310 Oil/Water Interface Level Low Low


10-LT-0312 Oil Level Low Low
10-LT-0313 Liquid Level High High
10-PT-0308 Pressure Low Low
10-PT-0309 Pressure High High

Overpressure protection of the LP separator is provided by Pressure


Safety Relief Valves, 10-PSV-0303A and 10-PSV-0303B. These relief
valves are set at 16barg and relieve excess pressure to the LP flare
header. The PSV sets are fitted with a valve interlock system which
ensures that one of the relief valves is on-line at all times.

A normally isolated 1in line is provided around the PSV set which allows
the LP separator to be manually depressurised to LP Flare.

The LP separator may be automatically depressurised to LP Flare


through 4in blowdown pipework containing Blowdown Valve
10-XV-0301. The blowdown valve is pneumatically actuated and fails
open on loss of instrument air supply.

The blowdown valve is controlled through the PSD system and is opened
on activation of a Level C-Fire (C-F) - General Facilities Shutdown on
Confirmed Fire.

The rate of depressurisation is limited by Flow Orifice 10-FO-0302


installed downstream of the blowdown valve. The flow is restricted to
ensure that the separator is depressurised within fifteen (15) minutes
under fire conditions.

Local Instrumentation The following local instrumentation is provided on and around the LP
Separator:

10-LG-0317 Oil/Gas Interface Level


10-LG-0316 Oil/Water Interface Level
10-TG-0305 Vessel Temperature
10-PG-0306 Vessel Pressure

ID: M-CPH-1171-01417_EN_Section_4.doc Page 27 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

Technical Data Dimensions: 2900mm ID x 6650mm TT


Design Pressure: Full Vac/16barg
Design Temperature: -30oC/+85oC

Cause and Effects The Cause and Effect Chart associated with the LP separator is System
10.2 CUR-MAS-PB-20655.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 28 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.08
Produced Water Transfer Produced water is routed from the LP separator to the individual suction
Pumps P-1002A/B lines for the produced water transfer pumps through 3in pipework
(Refer to P&ID Drg No containing Produced Water Outlet Shutdown Valve
CUR-MAS-PM-20045-501) 10-XV-0334.

Both suction lines are fitted with a manual isolation valve and a
downstream strainer. The in-line strainer is provided to remove any
material from the produced water stream which could damage the pump
internals.

The transfer pumps and associated suction and discharge pipework is


insulated and heat traced for freeze protection.

The suction pressure available at the produced water transfer pump is a


combination of LP separator pressure and positional head and is in order
of 1.1barg. An allowance has been made to compensate for spurious
reductions in static head due to vessel motion to ensure that the
minimum suction pressure for safe operation of the duty produced water
transfer pump is always maintained.

The produced water transfer pumps are electric single stage centrifugal
pumps manufactured by Howmar. The function of the duty pumps is to
increase the pressure of the produced water recovered from the LP
separator to around 11barg. This provides the necessary pressure to
direct a 16.5m3/hr flowrate of produced water back to MP Separator V-
1002. The produced water transfer pumps are rated for 100% duty and
operate on a duty/standby basis.

The water return pumps are driven by 18.5KW motors through direct
flanged couplings. The pumps are controlled remotely via the Interface
Level Controller 10-LIC-0311 for the LP separator but can be shutdown
locally through individual emergency stop pushbuttons provided at the
pump skids. PSD inputs to the produced water transfer pump control
system provide remote pump shutdowns in the event of an emergency.

Note: Before the duty produced water transfer pump can be remotely
controlled from the PCS the pump must be set for Remote
Operation in the MAERSK FPSOS HEADQUARTERS.

Produced water leaves the discharge nozzle of each pump through 2in
pipework to the common discharge header and back to the MP
separator. Each discharge line is fitted with a non-return valve to prevent
reverse flow and a manually operated block valve to facilitate pump
isolation.

Minimum flow protection for the duty produced water transfer pump is
provided by recycling produced water from the common discharge
through a 2in minimum flow bypass line back to the LP separator.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 29 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.08 The produced water discharge flowrate is monitored through Vortex


Produced Water Transfer Meter 10-FT-0321 installed in the common discharge header from the
Pumps P-1002A/B produced water transfer pumps. This provides flow indication on PCS
(Continued) through Flow Indicator 10-FI-0321. Signals from 10-FT-0321 are relayed
to Produced Water Transfer Pump Minimum Flow Controller 10-FIC-
0321. This controller modulates Flow Control Valve 10-FCV-0321 located
in the 2in minimum flow bypass line.

Local Instrumentation The following local instrumentation is provided on and around the
produced water transfer pumps:

10-PG-0326 P-1002A Discharge Pressure


10-PG-0327 P-1002B Discharge Pressure

Technical Data Design Capacity: 16.5m3/hr


Design Pressure: 12barg
Discharge Pressure: 11barg
Power Installed: 18.5KW per pump

Cause and Effects The Cause and Effect Chart associated with the Produced Water
Transfer Pumps are the same as those for the LP separator and are
detailed on System 10.2 CUR-MAS-PB-20655.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 30 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.09 Fully stabilised crude oil is routed from the LP separator to the individual
Crude Oil Transfer Pumps suction lines for the crude oil transfer pumps through 12in pipework
P-1001A/B containing Oil Outlet Shutdown Valve 10-XV-0335. Both suction lines are
(Refer to P&ID Drg No fitted with a manual isolation block valve and downstream strainer. The
CUR-MAS-PM-20045-001) in-line strainer is provided to remove any material from the crude oil
which could damage the pump internals.

The suction pressure available at the pump is a combination of LP


separator pressure and positional head and is in the order of 1.1barg
under normal conditions. An allowance has been made to compensate
for spurious reductions in static head due to vessel motion to ensure that
the minimum suction pressure for the duty crude oil transfer pump is
always maintained.

The crude oil transfer pumps are electric single stage centrifugal pumps
manufactured by Howmar. The function of the duty crude oil transfer
pump is to increase the pressure of the crude recovered from the LP
separator to around 7barg. The duty crude oil transfer pump provides the
necessary pressure to direct 326m3/hr crude to the Electrostatic
Coalescer V-1004 for further processing. The crude oil transfer pumps
are rated for 100% duty and operate on a duty/standby basis.

The crude oil transfer pumps are driven by 90 KW motors through direct
flanged couplings. The pumps are started and stopped remotely from the
CCR but can be shutdown locally through individual emergency stop
pushbuttons 10-HS-0324 and 10-HS-0325 at Crude Oil Transfer Pumps
P-1001A and B respectively. PSD inputs to the crude oil transfer pump
control system provide remote pump shutdowns in the event of an
emergency.

Crude oil leaves the discharge nozzle of each pump through 8in
discharge pipework and forms a common discharge header. Oil is then
routed from the discharge header to the electrostatic coalescer. Each
pump discharge line is fitted with a non-return valve to prevent reverse
flow and a manually operated block valve to facilitate pump isolation.

Minimum flow protection for the duty crude oil transfer pump is provided
by recycling crude from the common discharge through a 4in minimum
flowline back to the LP separator.

The discharge flow from the crude oil pumps is monitored through Flow
Transmitter 10-FT-0328. Signals from the flow transmitter are relayed to
Crude Oil Transfer Pump Minimum Flow Controller
10-FIC-0328. This controller modulates Flow Control Valve
10-FCV-0328 located in the 4in minimum flow pipework.

The minimum flow controller is normally set in auto control mode with the
setpoint adjusted to provide adequate pump protection against low flow
to prevent cavitation.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 31 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.09
Crude Oil Transfer Pumps
P-1001A/B (Continued)

Technical Data Design Capacity: 326m3/hr


NPSH: 1.7Metres
Head: 92.3Metres
Power Installed: 90KW per pump

Local Instrumentation The following local instrumentation is provided on and around the crude
oil transfer pumps:

10-PG-0322 P-1001A Discharge Pressure


10-PG-0323 P-1001B Discharge Pressure

Cause and Effects The Cause and Effect Chart associated with the Crude Oil Transfer
Pumps are the same as those for the LP separator and are detailed on
System 10.2 CUR-MAS-PB-20655.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 32 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.10 The electrostatic coalescer is designed to operate completely full of liquid


Electrostatic Coalescer and is used to separate crude oil and water by gravity and with the aid of
V-1004 an electrostatic field. The vessel may also be used to desalt the crude oil
(Refer to P&ID Drg No flow if required by the addition of industrial water to dilute the saline
CUR-MAS-PM-20046-001) formation water.

Fully stabilised crude from the duty crude oil transfer pump enters the
bottom of the electrostatic coalescer through 8in pipework. The crude oil
inlet pipework is fitted with a manual mixing valve upstream of the crude
oil inlet nozzle. This is designed for use when the coalescer is being
used to desalt the crude oil flow.

When used for desalting the crude oil saline solution is diluted by the
addition of industrial water through a hose connection on the crude oil
inlet pipework. The flow of industrial water is monitored locally through
Flow Gauge 10-FG-0415. The industrial water is mixed with the oil using
a manual mixing valve fitted downstream of the industrial water
connection. To ensure mixing, the mixing valve is partially closed to
create a differential pressure across the valve. The differential pressure
is monitored locally through Differential Pressure Gauge 10-PDG-0416.

On entering the coalescer, the crude oil flow passes to a distribution pipe
installed in the lower section of the vessel, below the grid formed by two
electrode plates. The electrode plates are installed one above the other
at or near to the vessel centre line to provide the maximum area of
electrical field.

As the crude outlet is on the top of the vessel, oil flows upward passing
between the electrode plates. As the flow passes through the electrode
plates the smaller water droplets entrained in the oil are encouraged to
coalesce on receiving positive or negative charge from the electrodes.
The small water droplets then combine to form larger water droplets
which fall by gravity to the bottom of the vessel.

The electrical field is generated by Power Unit L-1001. This is a


3:2 phase power unit which incorporates two single phase transformers
each rated for 75kV. The two transformers are connected in a single
case to provide two high voltage outputs which are connected to the two
electrode grids.

The power supply to the 75kV transformers fitted to the coalescer power
pack is controlled from a remote control box. The power unit is started
and stopped at the coalescer power pack control panel using start/stop
switches 10-HS-0407 and 10-HS-0408 respectively.

To prevent the formation of vapour inside the coalescer a back pressure


is maintained within the vessel through LP Separator Oil Level Control
Valve 10-LCV-0314 located downstream of Export Crude Oil Cooler E-
1004.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 33 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.10 Crude oil at stock tank specification leaves the top of the coalescer
Electrostatic Coalescer through 8in outlet pipework and flows through a manual isolation valve
V-1004 (Continued) directly to the Export Crude Oil Cooler E-1004 for further processing.

Separated water leaves the bottom of the vessel through 3in pipework
and is returned to the inlet of MP Crude Oil Heater
E-1002.

The interface level in the coalescer is maintained by Interface Level


Control Valve 10-LCV-0401 located on the water outlet line from the
electrostatic coalescer to the MP crude oil heater. This level control valve
is controlled through Interface Level Controller 10-LIC-0401 on signals
from Level Transmitter 10-LT-0401. The level controller is equipped with
PCS generated high and low level alarms which annunciate on PCS
through 10-LAH-0401 and 10-LAL-0401 respectively.

To allow the interface level to be manually checked five trycocks are


provided at different intervals on the vessel. These allow a sample of the
crude oil to be taken for analysis. The crude oil sample is drawn through
2in pipework which is routed through a trycock cooler.

To prevent the risk of explosion the coalescer is provided with Low Level
Switch 10-LSLL-0406 installed in the top of the vessel. This is designed
to detect a build-up of gas within the vessel as a result of a low level.
Activation of the switch trips the power unit, to remove a possible source
of ignition, and is annunciated on PCS through
10-LALL-0406.

Overpressure protection of the electrostatic coalescer is provided by


Pressure Safety Relief Valves 10-PSV-0403A/B which are set at 16barg
and relieve excess pressure to LP Flare. The valves are fitted with a
valve interlock system which ensures that one relief valve is on line at all
times.

Local Instrumentation The following local instrumentation is provided on and around the
electrostatic coalescer:

10-LG-0414 Oil/Water interface level


10-PG-0405 Vessel pressure
10-TG-0404 Vessel temperature

Technical Data Dimensions: 2900mm ID x 9650mm TT


Design Pressure: 16.0barg/FV
Design Temperature: -30oC/+85oC

Cause and Effect Charts The Cause and Effect Chart associated with the electrostatic coalescer is
System 10.2 CUR-MAS-PB-20655.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 34 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.11 The export crude oil cooler is a plate type heat exchanger designed to
Export Crude Oil Cooler cool the crude oil flow to 30oC by heat exchange with cooling medium.
E-1004 Dehydrated crude from the oil outlet line of the electrostatic coalescer
(Refer to P&ID Drg No flows through 8in pipework to the inlet of the export crude oil cooler.
CUR-MAS-PM-20047-001)

The flow of crude entering the cooler is metered by Vortex Meter


10-FT-0459. This provides flow indication on PCS through Flow Indicator
10-FI-0459.

Temperature of the crude oil inlet flow is also monitored through


Temperature Transmitter 10-TT-0452 located downstream of the vortex
meter. This provides inlet temperature indication on PCS through
Temperature Indicator 10-TI-0452.

A manually operated isolation ball valve is fitted on the crude inlet to the
export crude oil cooler. This valve is always in the open position as the
export crude oil cooler is in continuous service unless a long term
shutdown of the Oil Processing Facilities is in progress, when the cooler
may be isolated for maintenance.

Crude oil passes through the plate internals of the export crude oil cooler
where the temperature of the oil is lowered to 30oC by heat exchange with
cooling medium. The cooled oil flows out of the exchanger where it
passes onwards to the cargo oil tanks for storage through Outlet
Shutdown Valve 10-XV-0458 and Level Control Valve 10-LCV-0314.

Outlet Shutdown Valve 10-XV-0458 is a pneumatically actuated valve


which fails closed on loss of instrument air supply and is provided with
position switches on the valve stem. These provide open and closed
position indication on PCS through 10-ZI-0458.

The flow of crude oil through the plate exchanger is controlled through
Level Control Valve 10-LCV-0314. This valve is controlled through Level
Controller 10-LIC-0314 on signals from Level Transmitter
10-LT-0314 located on the oil side of LP Separator V-1003.

Level Control Valve 10-LCV-0314 is pneumatically operated and fails


closed on loss of instrument air supply. A normally isolated 6in bypass line
is provided around the valve for use in the event of control valve failure.

Cooling medium is routed to the export crude oil cooler through 6in
pipework from the cooling medium supply header. The cooling medium
flow passes through the exchanger where heat is transferred from the hot
crude oil flow to the cooling medium.

After absorbing heat from the crude oil, the cooling medium passes out of
the export crude oil cooler through Temperature Control Valve
10-TCV-0455 before flowing on to the cooling medium return circuit.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 35 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Equipment Description 002 / MAY 2010

4.11 The flow of cooling medium through the export crude oil cooler is
Export Crude Oil Cooler controlled by Temperature Controller 10-TIC-0455 on signals from
E-1004 (Continued) Temperature Transmitter 10-TT-0455 located on the exchanger crude oil
outlet line. The temperature controller modulates 10-TCV-0455 as
required to maintain the control setpoint and is equipped with high and low
temperature alarms through 10-TAH-0455 and 10-TAL-0455 respectively.

The cooler is protected against high temperature through Temperature


Transmitter 10-TT-0454 located in the crude oil outlet line. This provides
crude oil outlet temperature indication on PCS through 10-TI-0454 and
also provides a high temperature shutdown of the cooler through 10-
TAHH-0454. Activation of the high temperature condition is relayed to the
PSD System.

A dedicated sample point for crude oil sampling is fitted to the oil outlet
line from the export crude oil cooler. Samples from this facility are taken
and the crude oil analysed to ensure that the TVP specification of
0.83barg (max) @ 26.67oC is not exceeded.

Local Instrumentation The following local instrumentation is provided on and around the export
crude oil cooler:

10-TG-0451 Crude oil to E-1004 temperature


10-PG-0450 Crude oil to E-1004 pressure
10-TG-0456 Crude oil from E-1004 temperature
10-PG-0457 Crude oil from E-1004 pressure
44-TG-2041 Cooling medium to E-1004 temperature
44-PG-2042 Cooling medium to E-1004 pressure
44-TG-2045 Cooling medium from E-1004 temperature
44-PG-2044 Cooling medium from E-1004 pressure

Technical Data Overall Dimensions: 2058m (L) x 626mm (W) x


2390mm (H)
Design Pressure (Oil Side): 16.0barg
Design Pressure
(Cooling Medium Side): 16.0barg
Design Temperature (Oil Side): -30oC to 85oC
Design Temperature
(Cooling Medium Side): 60oC
Duty: 4740KW

Cause and Effects The Cause and Effect Chart associated with the export crude oil cooler is
System 10-2 CUR-MAS-PB-20655.

ID: M-CPH-1171-01417_EN_Section_4.doc Page 36 / 36


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Operating Procedures

5.01 Cold Start-up of the Oil Processing Facilities


5.01.1 Preamble
5.01.2 Plant Status
5.01.3 Preconditions
5.01.4 Cold Start-up Valve Checklist
5.01.5 Start-up Overrides
5.01.6 Cold Start-up Procedure

5.02 Hot Start-up of the Oil Processing Facilities


5.02.1 Preamble
5.02.2 Preconditions
5.02.3 Hot Start-up PSD Valve Checklist
5.02.4 Hot Start-up Overrides
5.02.5 Hot Start-up Procedure

5.03 Normal Running

5.04 Planned Shutdown of the Oil Processing Facilities


5.04.1 Preamble
5.04.2 Preconditions
5.04.3 Planned Shutdown Procedure

5.05 Unplanned Shutdown of the Oil Processing Facilities


5.05.1 Preamble
5.05.2 Unplanned Shutdown Procedure

5.06 Process and Emergency Cause and Effect Charts

5.07 Pressure Safety Valve Five Key Interlock Operations

Figures

5.01 Interlocked Pressure Safety Valves

ID: M-CPH-1171-01417_EN_Section_5.doc Page 1 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01
Cold Start-up of the Oil
Processing Facilities

5.01.1 This procedure covers the case of starting up all Curlew wells to Curlew
Preamble FPSO as required to provide procedural coverage for all well start-ups.
The assumed routing is Curlew wells DP1, DP2, DP3 and DP4 started up
with commingling flow at the manifold through both Riser D1 and Riser
D2 to the HP Separator. Well BP1 is assumed to be started up to the
Test Separator through Riser B1. Procedure would need to be adapted
appropriately to perform other start-up cases.

The Curlew D wells are expected to be started up in the order DP1, DP2,
DP4 and then DP3. Potentially DP3 and BP1 wells will not be under
production.

If well testing a Curlew D well then production from this well would be
routed to the Test Separator. Well BP1 would not be produced if the Test
Separator is being used for a Curlew D well.

Based on erosional data results, if single riser production is used for all
Curlew D wells this will require production deferment, ie. choking back on
wells for initial years.

If production rates up both Curlew D risers do not achieve arrival


temperatures that exceed the wax appearance temperature of 35C then
Curlew D should be changed to single riser production, However,
commingling flow via both flowlines hydraulically unconstrains Curlew D
production as FTHPs decline.

Continuous wax inhibitor injection will be required if arrival temperatures


remain below the wax appearance temperature. The wax inhibitor
injection strategy would be provided by Production Engineering in this
late-field case.

Continuous scale inhibitor injection will be required when DP3 is


produced and is expected to be required a few months into production
from the DP4 well. The Scale Inhibition Strategy provides guidance and
input will be provided to operators from Production Engineering at this
stage.

Manifold crossover valve 03-XV-1003 should be retained open for


shutdowns/start-up if both flowlines are used during normal operation.
This is in order to prevent pressure differentials over it and unnecessary
damage to the valve seats from opening it. If changing to one flowline
operation then the crossover valve 03-XV-1003 should be closed.

The cold start-up procedure for the Oil Processing Facilities can be
summarised in the following major steps:

ID: M-CPH-1171-01417_EN_Section_5.doc Page 2 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.1 Line up the oil flow from the Curlew D subsea wells to the
Preamble - Continued HP Separator, MP Separator, MP Crude Oil Heater, LP
Separator, Crude Oil Transfer Pump and Electrostatic
Coalescer.

During start-up all gas produced is routed to the flares.

Line-up the produced water outlet from the HP and Test separators
to the HP and Test hydrocyclone using the keyswitch
selector and manual valves on water outlets to dispose of the
produced water.

Line-up the fully stabilised oil flow from the Electrostatic


Coalescer through the Export Crude Oil Cooler to the Crude
Storage Tanks until the oil processing facilities have
achieved stable operating conditions.

Ensure that Heating Medium is available to the HP and MP


Crude Oil Heaters.
.
Ensure that Cooling Medium is available to prepare the
Export Crude Oil Cooler to receive stabilised crude oil from
the Electrostatic Coalescer.
.
If the separators have been depressurised it should be
possible to repressurise them from produced gas. If
necessary the separators may be pressurised using nitrogen
for stability during start-up.

Commence methanol injection to each Curlew D well


sequentially to prevent the formation of hydrates in the
flowlines during well start-ups.
C ur l e w D H y dr a t e For ma t i on C ur v e s ( 1 C Sa f e t y Fa c t or )

120. 00

100. 00

80. 00

Condensed Wat er

60. 00 P r oduc ed Wat er

A r r i v al P r es sur e

40. 00

20. 00

0. 00
0. 00 5. 00 10. 00 15. 00 20. 00 25. 00 30. 00

T e mp e r a t u r e ( C )

ID: M-CPH-1171-01417_EN_Section_5.doc Page 3 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.1 Start up the Curlew Well DP1 to the HP separator by slowly


Preamble - Continued opening the subsea choke

Establish operating levels, pressures and temperatures in


the HP Separator, then the MP separator, and then establish
a flowrate through the MP Crude Oil Heater to the LP
Separator. Reset the shutdown valves on the liquid outlets
as the operating levels are established.

Start the duty Crude Oil Transfer Pump to fill the


Electrostatic Coalescer and start the duty Produced Water
Transfer Pump to direct any produced water recovered in the
Coalescer back to the MP separator for further processing

Start up the Curlew Well DP2 to the HP separator.

Reset the PSD shutdown valves for Riser D1 and slowly


open the topsides choke to start flowing through Riser D1 as
well.

Start up the Curlew well DP4 to the HP separator.

Start up the Curlew well DP3 to the HP separator.

If required to start-up well BP1 then visually check Riser B1


topsides chokes are in the closed position and line up the oil
flow from the well BP1 to the Test Separator.

Commence methanol injection and wax inhibitor to the


Curlew B subsea well to prevent the formation of hydrates
and wax deposition in the flowlines and topsides facilities
during start-up

Start up the Curlew Well BP1 to the Test separator.

Establish operating levels, pressures and temperatures in


the Test Separator.

Once the oil processing facilities have achieved stable operating


conditions and the crude oil has achieved export
specification of 0.83 barg (max) at 26.67oC direct the
flowrate of dead crude from the Export Crude Oil Cooler to
the Cargo Storage Tanks

ID: M-CPH-1171-01417_EN_Section_5.doc Page 4 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.1 This cold start-up procedure must be read in conjunction with the
Preamble - Continued cold start-up procedures of the following systems:

Volume 1 Book A - Subsea Facilities

Volume 1 Book C - Gas Processing Facilities

Volume 1 Book D - Produced Water Facilities

Volume 1 Book K - Fuel Gas System

Volume 1 Book M - Chemical Injection

Volume 2 Book A - Crude Oil Storage and Offloading

Limitations to Single The following details simulation results of the reduction in riser life
Riser Production Due to while producing through a single riser due to the effect of sand
Sand associated with production flow rates.

On observing sand measurements above 1.3lb/1000bbl liquid


consultation should be taken with Production Engineering to
determine optimal production rates.

Max Flow Rate 100 GOR 4,600 scf/bbl (819 m3/m3)


MMscfd Water cut 0%
Liquid rate 21,739 bbl/d (3,456 m3/d)
Arrival pressure 42 barg

Sand content Calculated Life (yrs)


10 lb/1000bbl for 6months then 0.5 + 3.75
5lb/1000bbl for residual service life
10 lb/1000bbl for 6months then 0.5 + 14.5
1.3lb/1000bl for residual service life

5.01.2 Following completion of all maintenance activities within the boundary


ID: M-CPH-1171-01417_EN_Section_5.doc Page 5 / 81
MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Plant Status isolation, as detailed in Procedure 6.15 Oil Processing Facilities Boundary
Reinstatement in Part 6 of this Volume, all equipment has now undergone
pre-start pressure testing to 95% of the relief valve lifting pressures.

It is only after successful pre-start pressure tests, as witnessed by the


Operations Supervisor, that the boundary isolation can be lifted and the
cold start-up procedure undertaken.

Various Cold Start-up and operating scenarios are possible, depending


on the level of shutdown and the status of the production flowlines and oil
processing facilities. A full listing of these is given in Section 2 of the MAS
Alliance Curlew Field Development Project - Oil and Gas Operability
Review (Document Number CUR-MAS-G-O-50030).

In later Curlew field life the following factors will change:

The expected flowrates of well fluids from the subsea production


wells

Line-up of the hydrocyclones in the produced water facilities

Depletion of produced gas from the oil processing facilities

Injection of increased quantities of methanol during the Cold Start-


up when the water cut of the well fluids has increased

This procedure is for starting the oil processing facilities from a cold start,
ie the facilities have been shut down for some time and the temperature of
the crude oil in the flowlines from the subsea production facilities has
achieved the minimum seabed temperature of 4C.

The D1 and D2 flowline pressures have been blown-down to 10 barg to


prevent hydrate formation on start-up. The B1 flowline pressure has been
blown-down to <2 barg to prevent hydrate formation and to help kick-off
the depleted well. If the shutdown was planned, then methanol has been
injected in the production flowlines.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 6 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.3 WARNING: ALL SYSTEM PRESSURE SAFETY RELIEF VALVES


Preconditions MUST BE LINED UP FOR NORMAL OPERATION.

(1) No Permits to Work or electrical isolations are in force which may


prohibit system start-up.

(2) The Fire and Gas Detection/Protection, Process Control System


(PCS) and Safety Related Systems (PSDs) are operational along
with the alarms, trips, and controllers.

(3) All spades and spectacle blinds are in the correct positions as per
the P&IDs.

(4) All drains, vents, integral double block and bleed assemblies,
sandwash valves, purge and sample points are closed and blanked
where necessary.

(5) All instrument and level bridle drain valves are closed.

(6) All instrument isolation valves are open.

(7) The following utility systems are available:

Electrical Power Distribution (including trace heating)

Instrument Air

Heating Medium

Cooling Medium (including cooling seawater)

(8) Chemical Injection Package including the availability of the


following chemicals, as required:

Methanol
Demulsifier

Anti-foam
Scale Inhibitor

Corrosion Inhibitor

Wax Inhibitor

HP Flare System (requires N 2 purge)

ID: M-CPH-1171-01417_EN_Section_5.doc Page 7 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.3
Preconditions- LP Flare System (requires N 2 purge)
Continued Hazardous Open Drains

(9) Ensure that the Gas Compression Facilities are prepared to


receive the process gas from the Test, HP, MP and LP separators
included in the Oil Processing Facilities.

(10) Ensure that Glycol Circulation has been initiated and the glycol is
up to temperature in the Gas Dehydration System.

Note that the Glycol system can be operated on the short loop,
Surge Drum to Flash Drum, whilst the plant is shutdown.

(11) The produced water disposal facilities are available for use.

(12) Communications have been established between all personnel


involved in this procedure.

(13) All HVAC and Turret Annulus Fans have been restarted.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 8 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.4 Refer to Figures 3.01 to 3.08 in Section 3 of this Volume and the P&IDs
Cold Start-up identified below.
Valve Checklist
(1) The System Operator should CHECK the following valves to
confirm the valve settings are as given below.

(2) Where the valves are found to be out of position, the operator
should satisfy himself that it is safe to move the valves before
doing so.

Subsea Production Well Curlew B (BP1) - Valve Checklist

Ref P&ID No (CUR-MAS-PB-20021-003)

Valve Tag Valve Description Setting

03-AMV-0204 Annulus Master Valve Well BP1 OPEN

03-ASV-0202 Annulus Swab Valve Well BP1 CLOSED

03-AXOV-0201 Annulus Crossover Valve Well BP1 CLOSED

03-SSSV-0211 Subsurface Safety Valve Well BP1 CLOSED

03-PUMV-0205 Production Upper Master Valve Well BP1 CLOSED

03-PSV-0203 Production Swab Valve Well BP1 CLOSED

03-PWV-0206 Production Wing Valve Well BP1 CLOSED

03-PCV-0208 Production Choke Valve Well BP1 CLOSED

03-MIV-0207 Methanol Injection Valve Well BP1 CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 9 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Subsea Production Well Curlew D (DP1) - Valve Checklist

Ref P&ID No (MAERSK DRILLING AUSTRALIA-CP692-B-20021-001 Rev C1)

Valve Tag Valve Description Setting

03-AMV-0004 Annulus Master Valve Well DP1 OPEN

03-ASV-0002 Annulus Swab Valve Well DP1 CLOSED

03-AXOV-0001 Annulus Crossover Valve Well DP1 CLOSED

03-SSSV-0011 Subsurface Safety Valve Well DP1 CLOSED

03-PUMV-0005 Production Upper Master Valve Well DP1 CLOSED

03-PSV-0003 Production Swab Valve Well DP1 CLOSED

03-PWV-0006 Production Wing Valve Well DP1 CLOSED

03-PCV-0008 Production Choke Valve Well DP1 CLOSED

03-MIV-0007 Methanol Injection Valve Well DP1 CLOSED

03-PTIV-0010 Production Test Isolation Valve Well DP1 CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 10 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Subsea Production Well Curlew D (DP2) - Valve Checklist

Ref P&ID No (MAERSK DRILLING AUSTRALIA-CP692-B-20021-002 Rev C1)

Valve Tag Valve Description Setting

03-AMV-0104 Annulus Master Valve Well DP2 OPEN

03-ASV-0102 Annulus Swab Valve Well DP2 CLOSED

03-AXOV-0101 Annulus Crossover Valve Well DP2 CLOSED

03-SSSV-0111 Subsurface Safety Valve Well DP2 CLOSED

03-PUMV-0105 Production Upper Master Valve Well DP2 CLOSED

03-PSV-0103 Production Swab Valve Well DP2 CLOSED

03-PWV-0106 Production Wing Valve Well DP2 CLOSED

03-PCV-0108 Production Choke Valve Well DP2 CLOSED

03-MIV-0107 Methanol Injection Valve Well DP2 CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 11 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Subsea Production Well Curlew D (DP3) - Valve Checklist

Ref P&ID No (MAERSK DRILLING AUSTRALIA-CP692-B-20021-004 Rev C1)

Valve Tag Valve Description Setting

03-AMV-0304 Annulus Master Valve Well DP3 OPEN

03-ASV-0302 Annulus Swab Valve Well DP3 CLOSED

03-AXOV-0301 Annulus Crossover Valve Well DP3 CLOSED

03-SSSV-0311 Subsurface Safety Valve Well DP3 CLOSED

03-PUMV-0305 Production Upper Master Valve Well DP3 CLOSED

03-PSV-0303 Production Swab Valve Well DP3 CLOSED

03-PWV-0306 Production Wing Valve Well DP3 CLOSED

03-PCV-0308 Production Choke Valve Well DP3 CLOSED

03-MIV-0307 Methanol Injection Valve Well DP3 CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 12 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Subsea Production Well Curlew D (DP4) - Valve Checklist

Ref P&ID No (MAERSK DRILLING AUSTRALIA-CP692-B-20021-005 Rev C1)

Valve Tag Valve Description Setting

03-AMV-1104 Annulus Master Valve Well DP4 OPEN

03-ASV-1102 Annulus Swab Valve Well DP4 CLOSED

03-AXOV-1101 Annulus Crossover Valve Well DP4 CLOSED

03-SSSV-1111 Subsurface Safety Valve Well DP4 CLOSED

03-PUMV-1105 Production Upper Master Valve Well DP4 CLOSED

03-PSV-1103 Production Swab Valve Well DP4 CLOSED

03-PWV-1106 Production Wing Valve Well DP4 CLOSED

03-PCV-1108 Production Choke Valve Well DP4 CLOSED

03-MIV-1107 Methanol Injection Valve Well DP4 CLOSED

03-CIV1-1113 Chemical Injection Valve CLOSED

03-CIV2-1114 Chemical Injection Valve CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 13 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Subsea Production Manifold Curlew D - Valve Checklist

Ref P&ID No (MAERSK DRILLING AUSTRALIA-CP692-U-20021-001 Rev C1)

Valve Tag Valve Description Setting

03-XV-1001 Riser D2 Manifold Isolation Valve OPEN

03-XV-1002 Riser D1 Manifold Isolation Valve OPEN

03-XV-1003 Crossover Isolation Valve OPEN

ID: M-CPH-1171-01417_EN_Section_5.doc Page 14 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Production Flowlines - Valve Checklist


Ref P&ID No (CUR-MAS-TP-42002-001 Rev C8)
Valve Tag Valve Description Setting
07-XXV-100 Curlew Riser D2 ESD Valve CLOSED (Set
for Start-up)

07- HV-002 Isolation Valve for Riser D2 carcass Vent No 1 LOCKED


OPEN

07-HV-003 Isolation Valve for Riser D2 carcass Vent No 2 LOCKED


OPEN

07-HV-004 Double block and bleed valves for Riser D2 low point drain CLOSED

07-HV-005 Double block and bleed valves for squeeze/diesel injection point for CLOSED
Riser D2

07-HV-006 Double block and bleed valves for methanol injection point for Riser CLOSED (Set
D2 for Start-up)

07-XV-105 Riser D2 ESD Valve CLOSED (Set


for Start-up)

07-PCV-109 Topsides Choke Valve Riser D2 CLOSED (Set


for Start-Up)

07-HV-008 Double block and bleed valves for corrosion inhibitor injection point OPEN
for Riser D2

07-HV-009 Double block and bleed valves for Riser D2 low point drain CLOSED

07-XV-402 Riser D2 Test Diverter Valve CLOSED (Set


for Start-Up)

07-XV-110 Riser D2 Production Diverter Valve CLOSED (Set


for Start-Up)

07-XXV-200 Curlew Riser D1 ESD Valve CLOSED (Set


for Start-up)

07-HV-012 Isolation Valve for Riser D1 carcass Vent No 1 LOCKED


OPEN

07-HV-013 Isolation Valve for Riser D1 carcass Vent No 2 LOCKED


OPEN

ID: M-CPH-1171-01417_EN_Section_5.doc Page 15 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Production Flowlines - Valve Checklist (Continued)


Valve Tag Valve Description Setting
07-HV-014 Double block and bleed valves for Riser D1 low point drain CLOSED

07-HV-015 Double block and bleed valves for squeeze/diesel injection point for CLOSED
Riser D1

07-HV016 Double block and bleed valves for methanol injection point for Riser CLOSED (Set
D1 for Start-up)

07-XV-205 Riser D1 ESD Valve CLOSED (Set


for Start-up)

07-PCV-209 Topsides Choke Valve Riser D1 CLOSED (Set


for Start-Up)

07-HV018 Double block and bleed valves for corrosion inhibitor injection point OPEN
for Riser D1

07-HV019 Double block and bleed valves for Riser D1 low point drain CLOSED

07-XV-403 Riser D1 Test Diverter Valve CLOSED (Set


for Start-Up)

07-XV-210 Riser D1 Production Diverter Valve CLOSED (Set


for Start-Up)

07-XXV-300 Riser B1 ESD Valve CLOSED (Set


for Start-up)

07-HV022 Isolation Valve for Riser B1 carcass Vent No 1 LOCKED


OPEN

07-HV-023 Isolation Valve for Riser B1 carcass Vent No 2 LOCKED


OPEN

07-HV-024 Double block and bleed valves for Riser B1 low point drain CLOSED

07-HV-025 Double block and bleed valves for squeeze/diesel injection point for CLOSED
Riser B1

07-HV-026 Double block and bleed valves for methanol injection point for Riser CLOSED (Set
B1 for Start-up)

07-XV-305 Riser B1 ESD Valve CLOSED (Set


for Start-up)

ID: M-CPH-1171-01417_EN_Section_5.doc Page 16 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Production Flowlines - Valve Checklist (Continued)

Valve Tag Valve Description Setting

07-PCV-309 Topsides Choke Valve Riser B1 CLOSED (Set


for Start-Up)

07-HV-028 Double block and bleed valves for corrosion inhibitor injection point OPEN
for Riser B1

07-HV-029 Double block and bleed valves for Riser B1 low point drain CLOSED

07-XV-404 Riser B1 Test Diverter Valve CLOSED (Set


for Start-Up)

07-XV-310 Riser B1 Production Diverter Valve CLOSED (Set


for Start-Up)

ID: M-CPH-1171-01417_EN_Section_5.doc Page 17 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Swivel Stack Leak Recuperation System - Valve Checklist


Ref P&ID No (CUR-MAS-TM-41096-001)

Valve Tag Valve Description Setting

07 HV-046 Three way valve for 8in Gas Swivel X-0701 (top seal ring) to the leak OPEN (Set for
recuperation tank Start-up)

07 HV-045 Three way valve for 8in Gas Swivel X-0701 (bottom seal ring) to the OPEN (Set for
leak recuperation tank Start-up)

07 HV-044 Three way valve for 8in Curlew B Production Swivel X-0704 (top seal OPEN (Set for
ring) to the leak recuperation tank Start-up)

07 HV-043 Three way valve for 8in Curlew B Production Swivel X-0704 (bottom OPEN (Set for
seal ring) to the leak recuperation tank Start-up)

07 HV-042 Three way valve for 8in Curlew D Production Swivel X-0703 (top OPEN (Set for
seal ring) to the leak recuperation tank Start-up)

07 HV-041 Three way valve for 8in Curlew D Production Swivel X-0703 (bottom OPEN (Set for
seal ring) to the leak recuperation tank Start-up)

07 HV-040 Three way valve for 8in Test Swivel X-0705 (top seal ring) to the leak OPEN (Set for
recuperation tank Start-up)

07 HV-039 Three way valve for 8in Test Swivel X-0705 (bottom seal ring) to the OPEN (Set for
leak recuperation tank Start-up)

07 HV-037 2in isolation valve for Leak Recuperation Tank T-0705 to the LOCKED
Hazardous Open Drains OPEN

ID: M-CPH-1171-01417_EN_Section_5.doc Page 18 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Test Separator - Valve Checklist


Ref P&ID No (CUR-MAS-PM-20048-501 and CUR-MAS-PB-20048-002)

Valve Tag Valve Description Setting

HV-10260/1 10in Isolation valves for the inlet header to the Test separator LOCKED
OPEN

HV-73007 in Isolation valve for the demulsifier dosing point at the Test OPEN (If
separator inlet required)

HV-73009 in Isolation valve for the anti-foam dosing point at the Test separator OPEN (If
inlet required)

HV- 10307 6in Isolation valve for the inlet to Pressure Safety Relief Valve 10-PSV- INTERLOCKED
0503A OPEN

HV-10243/4 6in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10-PSV-0503A to the HP Flare OPEN

HV- 10308 6in Isolation valve for the inlet to Pressure Safety Relief Valve 10-PSV- INTERLOCKED
0503B CLOSED

HV-10248/9 6in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10-PSV-0503B to the HP Flare OPEN

HV-10251 1st in line isolation valve on bypass line for 10-PSV-0503A and B CLOSED

HV-10250 2nd in line isolation valve on bypass line for 10-PSV-0503A and B CLOSED

10-XV-0501 Blowdown Valve to the HP Flare CLOSED

HV-10239 8in Isolation valve downstream of 10-XV-0501 LOCKED


OPEN

HV-10237 1st in line isolation valve on manual depressurisation line to LP Flare CLOSED

HV-10236 2nd in line isolation valve on manual depressurisation line to LP Flare CLOSED

HV-10253/4 Single twin seal valve downstream of 10-PCV-0507B on Test separator OPEN
gas outlet line to the HP flare

HV-10258/9 Single twin seal valve downstream of 10-PCV-0507A on Test separator OPEN
gas outlet line to gas compression

ID: M-CPH-1171-01417_EN_Section_5.doc Page 19 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Valve Tag Valve Description Setting

20-XV-1191 PSD isolation valve for Test separator gas outlet line CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 20 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Test Separator - Valve Checklist (Continued)


Valve Tag Valve Description Setting

HV-52003 10in Isolation ball valve downstream of 20-XV-1191 for Test separator gas to LOCKED
the fuel gas cooler E-5202 CLOSED

HV-20072 10in Isolation ball valve downstream of 20-XV-1191 for Test separator gas to CLOSED
MP Separator V-1002 (Set for
Start-up)

HV-20071 10in Isolation ball valve downstream of 20-XV-1191 for Test separator gas to CLOSED
the MP compressor cooler E-1002 (Set for
Start-up)

HV-20073 10in Isolation ball valve downstream of 20-XV-1191 for Test separator gas to CLOSED
the Inlet Cooler E-2201 (Set for
Start-up)

HV-10282 6in Manual isolation ball valve for Test separator oil outlet line OPEN

10-XV-0518 PSD Isolation valve for Test separator oil outlet line CLOSED

HV-10285 6in Isolation ball valve upstream of 10-LCV-0514 for Test separator oil outlet OPEN
line

HV-10286 6in Isolation ball valve downstream of 10-LCV-0514 OPEN

HV-10289 3in isolation globe valve for 10-LCV-0514 bypass line CLOSED

HV-10077 6in Isolation ball valve on the line from the Test separator oil outlet to the MP OPEN
separator (Set for
Start-up)

HV-10122 6in Isolation ball valve on the line from the Test separator oil outlet to the MP CLOSED
crude oil heater (Set for
Start-up)
HV-10281 4in Manual isolation ball valve for Test separator produced water outlet line OPEN

- Isolation valve(s) for the spare chemical injection point to the Test separator CLOSED
produced water outlet line

HV-10273 Manual Jetting Water Valve No 1 from the jetting water inlet manifold to CLOSED
the Test separator

HV-10275 Manual Jetting Water Valve No 2 from the jetting water inlet manifold to CLOSED
the Test separator

ID: M-CPH-1171-01417_EN_Section_5.doc Page 21 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Test Separator - Valve Checklist (Continued)

Valve Tag Valve Description Setting

HV-10277 Manual Jetting Water Valve No 3 from the jetting water inlet manifold to CLOSED
the Test separator

HV-10278 Isolation ball valve from the jetting water inlet manifold to the skid drip pan CLOSED

HV-10304 4in Isolation valve between the Test separator V-1005 and the Test OPEN
Hydrocyclone V-4003 (When
V-1005 is
Lined Up
to
V-4003)

HV-10305 4in Isolation valve between the HP Separator V-1001 and the Test CLOSED
Hydrocyclone V-4003 (When
V-1005 is
Lined Up
to
V-4003)

HV-10306 Low point drain valve in the produced water cross-over between the HP CLOSED
Separator and the Test Hydrocyclone

HV-10321 & 3in Isolation valve in the jet mix nozzle supply from the crude oil fast loop OPEN
HV-10322 sampling system (When
Hooked
Up)

HV-10319 & 4in Isolation valve in crude the supply line to the fast loop sampling system OPEN
HV-10320 (When
Hooked
Up)

HV-73316 Integrated DB&B and check valve for the H2S Scavenger injection OPEN

ID: M-CPH-1171-01417_EN_Section_5.doc Page 22 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

HP Separator - Valve Checklist


Ref P&ID Nos (CUR MAS-PMT-20041-501 and CUR-MAS-PB-20041-002)
Valve Tag Valve Description Setting
HV-10013/4 14in Isolation valve for the inlet header to the HP Separator LOCKED
OPEN

HV-73001 in Isolation valve for the demulsifier dosing point at the HP separator OPEN
inlet

HV-73002 in Isolation valve for the anti-foam dosing point at the HP separator OPEN
inlet

HV- 6in Isolation valve for the inlet to Pressure Safety Relief Valve INTERLOCKED
10019/20 10-PSV-0103A OPEN

HV-1023/4 8in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10-PSV-0103A to the HP Flare OPEN

HV-10025/6 6in Isolation valve for the inlet to Pressure Safety Relief Valve INTERLOCKED
10-PSV-0103B CLOSED

HV- 8in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10029/30 10-PSV-0103B to the HP Flare OPEN

HV-10032 1st in line isolation valve on bypass line for 10-PSV-0103A and B CLOSED

HV-10031 2nd in line isolation valve on bypass line for 10-PSV-0103A and B CLOSED

10-XV-0101 Blowdown Valve to the HP Flare CLOSED

HV-10033 10in Isolation valve downstream of 10-XV-0101 LOCKED


OPEN

HV-10015 1st in line isolation valve on manual depressurisation line to LP Flare CLOSED

HV-10017 2nd in line isolation valve on manual depressurisation line to LP Flare CLOSED

HV-10018 3rd in line isolation valve on manual depressurisation line to LP Flare CLOSED

HV-22001 Isolation ball valve downstream of 10-PCV-0107 on HP separator gas OPEN


outlet line to the HP flare

HV-52001 4in Isolation ball valve for the fuel gas supply from HP separator gas CLOSED
outlet line to the fuel gas cooler E-5202 (Set for
Start-up)

ID: M-CPH-1171-01417_EN_Section_5.doc Page 23 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

HP Separator - Valve Checklist (Continued)


Valve Tag Valve Description Setting
20-XV-1051 PSD Isolation Valve on HP separator gas outlet line CLOSED

20-XV-1052 Pressurisation Bypass Valve for Test separator gas outlet line CLOSED

HV-10048 6in Manual isolation ball valve for HP separator oil outlet line OPEN

10-XV-0118 PSD Isolation Valve for HP separator oil outlet line CLOSED

HV-10046 6in Manual isolation ball valve for HP separator produced water outlet line OPEN

- Isolation valve(s) for the spare chemical injection point to the HP separator CLOSED
produced water outlet line

HV-10037 Manual Jetting Water Valve No 1 from the jetting water inlet manifold to CLOSED
the HP separator

HV-10039 Manual Jetting Water Valve No 2 from the jetting water inlet manifold to CLOSED
the HP separator

HV-10041 Manual Jetting Water Valve No 3 from the jetting water inlet manifold to CLOSED
the HP separator

HV-10043 Manual Jetting Water Valve No 4 from the jetting water inlet manifold to CLOSED
the HP separator

HV-10060 Manual Jetting Water Valve No 5 from the jetting water inlet manifold to CLOSED
the HP separator

HV-10059 Isolation ball valve for the jetting water inlet manifold to the skid drip pan CLOSED

HV-10300 Low point drain valve in the produced water cross-over between the Test CLOSED
separator and the HP Hydrocyclone

HV-10301 6in Isolation valve between the Test separator V-1005 and the HP CLOSED
Hydrocyclone V-4001 (When
V-1001 is
Lined Up
to
V-4001)

HV-10302 4in Isolation valve between the HP Separator V-1001 and the Test CLOSED
Hydrocyclone V-4003 (When
V-1001 is
Lined Up
to

ID: M-CPH-1171-01417_EN_Section_5.doc Page 24 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Valve Tag Valve Description Setting


V-4001)

HP Separator - Valve Checklist (Continued)

Valve Tag Valve Description Setting

HV-10303 6in Isolation valve between the HP Separator V-1001 and the HP OPEN
Hydrocyclone V-4001 (When
V-1001 is
Lined Up
to
V-4001)

HV-10314 & 3in Isolation valve in the jet mix nozzle supply from the crude oil fast loop OPEN
HV-10317 sampling system (When
Hooked
Up)

HV-73322 Integrated DB&B and check valve for the H2S Scavenger injection CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 25 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

HP Crude Oil Heater - Valve Checklist

Ref P&ID No (CUR-MAS-PM-20042-501)

Valve Tag Valve Description Setting

HV-10061/2 6in Isolation ball valve on the crude inlet to the HP crude oil heater OPEN

HV-10063/4 6in Isolation ball valve on the crude outlet from the HP crude oil heater OPEN

HV-10065 4in Isolation ball valve on the crude bypass for the crude oil heater CLOSED

HV-10068/9 6in Double block and bleed valves upstream of 10-LCV-0114 on the oil OPEN
outlet line from the HP crude oil heater

HV-10070/1 10in Double block and bleed valves downstream of 10-LCV-0114 OPEN

HV-10073 3in Isolation globe valve on 10-LCV-0114 bypass line CLOSED

HV-10067 2in Isolation valve for 10-PSV-0153 discharge to the HP flare LOCKED
OPEN

HV-44054 4in Manual isolation valve for the Heating Medium Supply to the HP crude oil OPEN
heater

HV-44058 4in Isolation ball valve upstream of 10-TCV-0155 on the heating medium OPEN
outlet line from the HP crude oil heater

HV-44059 4in Isolation valve downstream of 10-TCV-0155 OPEN

HV-44062 3in Isolation globe valve on 10-TCV-0155 bypass line CLOSED

44-XV-2017 Shutdown valve for the Heating Medium Return from the HP crude oil heater CLOSED

HV-10313 & 4in Isolation valve in crude the supply line to the fast loop sampling system OPEN
HV-10316 (When
Hooked
Up)

ID: M-CPH-1171-01417_EN_Section_5.doc Page 26 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

MP Separator - Valve Checklist


Ref P&ID No (CUR-MAS-PM-20043501 and CUR-MAS-PB-20043-002)
Valve Tag Valve Description Setting
HV-10075 10in Isolation ball valve on the inlet header for the Curlew B well to the LOCKED
MP separator OPEN (Set
for Start-up)

HV-10076 10in Isolation ball valve on the inlet line from the HP crude heater to OPEN (Set
the MP separator for Start-up)

HV-10077 6in Isolation ball valve on the inlet line from the Test separator to the OPEN (Set
MP separator for Start-up)

HV-10078 2in Isolation ball valve on the discharge line from the produced water OPEN (Set
pumps to the MP separator inlet header for Start-up)

HV-73004 in Isolation valve for the demulsifier dosing point at the MP separator OPEN (If
inlet header required)

HV-73006 in Isolation valve for the anti-foam dosing point at the MP separator OPEN (If
inlet header required)

HV-10081 6in Isolation valve for the inlet to Pressure Safety Relief Valve INTERLOCKED
10-PSV-0203A OPEN

HV-10083 8in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10-PSV-0203A to the LP Flare OPEN

HV-10084 6in Isolation valve for the inlet to Pressure Safety Relief Valve INTERLOCKED
10-PSV-0203B CLOSED

HV-10086 8in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10-PSV-0203B to the LP Flare OPEN

HV-10088 1st in line isolation valve on bypass line for 10-PSV-0203A and B CLOSED

HV-10087 2nd in line isolation valve on bypass line for 10-PSV-0203A and B CLOSED

10-XV-0201 Blowdown Valve to the LP Flare CLOSED

HV-10079 12in Isolation valve downstream of 10-XV-0201 LOCKED


OPEN

HV-10090 Isolation ball valve downstream of 10-PCV-0207B OPEN

20-XV-1201 PSD isolation valve for MP separator gas outlet line CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 27 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Valve Tag Valve Description Setting

MP Separator - Valve Checklist (Continued)

Valve Tag Valve Description Setting

20-XV-1202 Pressurisation bypass valve for MP separator gas outlet line CLOSED

HV-10114 8in Manual isolation ball valve for MP separator oil outlet line OPEN

10-XV-0218 PSD Isolation Valve for MP separator oil outlet line CLOSED

HV-10118 8in Isolation ball valve upstream of 10-LCV-0214 on MP separator oil outlet OPEN
line

HV-10119 6in Isolation ball valve downstream of 10-LCV-0214 OPEN

HV-10080 4in Isolation globe valve on 10-LCV-0214 bypass line CLOSED

HV-10112 6in Manual isolation ball valve for MP separator produced water outlet line OPEN

HV-10102 Manual Jetting Water Valve No 1 from the jetting water inlet manifold to CLOSED
the MP separator

HV-10104 Manual Jetting Water Valve No 2 from the jetting water inlet manifold to CLOSED
the MP separator

HV-10106 Manual Jetting Water Valve No 3 from the jetting water inlet manifold to CLOSED
the MP separator

HV-10108 Manual Jetting Water Valve No 4 from the jetting water inlet manifold to CLOSED
the MP separator

HV-10110 Manual Jetting Water Valve No 5 from the jetting water inlet manifold to CLOSED
the MP separator

HV-10115 Isolation ball valve for the jetting water inlet manifold to the skid drip pan CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 28 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

MP Crude Oil Heater - Valve Checklist

Ref P&ID No (CUR-MAS-PM-20044-501)

Valve Tag Valve Description Setting

HV-10123 16in Isolation ball valve on the crude inlet to the MP crude oil heater OPEN

HV-10125 20in Isolation ball valve on the crude outlet from the MP crude oil heater OPEN

HV-10126 Isolation valve for 10-PSV-0253 outlet to the LP flare LOCKED


OPEN

HV-44064 6in Manual isolation valve for the Heating Medium Supply to the MP crude OPEN
oil heater (Set for
Start-up)

HV-44067 6in Isolation ball valve upstream of 10-TCV-0255 on the heating medium OPEN
outlet line from the MP crude oil heater

HV-44068 6in Isolation valve downstream of 10-TCV-0255 OPEN

HV-44071 4in Isolation globe valve on 10-TCV-0155 bypass line CLOSED

HV-44072 6in Manual isolation valve on the Heating Medium Return from the MP crude OPEN
oil heater (Set for
Start-up)

ID: M-CPH-1171-01417_EN_Section_5.doc Page 29 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

LP Separator, Crude Oil Transfer Pumps and Produced Water Transfer Pumps
Valve Checklist
Ref P&ID Nos (CUR-MAS-PM-20045-501 and
CUR-MAS-PB-20045-002)
Valve Tag Valve Description Setting
HV-10127 4in Isolation valve for the inlet to Pressure Safety Relief Valve INTERLOCKED
10-PSV-0303A OPEN

HV-10129 6in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10-PSV-0303A to the LP Flare OPEN

HV-10130 4in Isolation valve for the inlet to Pressure Safety Relief Valve INTERLOCKED
10-PSV-0303B CLOSED

HV-10132 6in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10-PSV-0303B to the LP Flare OPEN

HV-10134 1st in line isolation valve on bypass line for 10-PSV-0303A and B CLOSED

HV-10133 2nd in line isolation valve on bypass line for 10-PSV-0303A and B CLOSED

10-XV-0301 Blowdown Valve to the LP Flare CLOSED

HV-10135 10in Isolation valve downstream of 10-XV-0301 LOCKED


OPEN

HV-10136 Isolation ball valve downstream of 10-PCV-0307B OPEN

20-XV-1221 PSD isolation Valve for LP separator gas outlet line CLOSED

20-XV-334 PSD isolation Valve for LP separator produced water outlet line CLOSED

20-XV-335 PSD isolation Valve for LP separator crude oil outlet line CLOSED

HV-10140 Manual Jetting Water Valve No 1 from the jetting water inlet manifold CLOSED
to the LP separator

HV-10142 Manual Jetting Water Valve No 2 from the jetting water inlet manifold CLOSED
to the LP separator

HV-10144 Manual Jetting Water Valve No 3 from the jetting water inlet manifold CLOSED
to the LP separator

HV-10146 Manual Jetting Water Valve No 4 from the jetting water inlet manifold CLOSED
to the LP separator

ID: M-CPH-1171-01417_EN_Section_5.doc Page 30 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

LP Separator, Crude Oil Transfer Pumps and Produced Water Transfer Pumps
Valve Checklist (Continued)

Valve Tag Valve Description Setting

HV-10148 Manual Jetting Water Valve No 5 from the jetting water inlet manifold to CLOSED
the LP separator

HV-10170 Isolation ball valve for the jetting water inlet manifold to the skid drip pan CLOSED

HV-10162 12in Isolation ball valve for Crude Oil Transfer Pump P-1001A suction line OPEN

HV-10168 8in Isolation ball valve for P-1001A discharge line OPEN

HV-10165 12in Isolation ball valve for Crude Oil Transfer Pump P-1001B suction line OPEN

HV-10169 8in Isolation ball valve for P-1001B discharge line OPEN

HV-10174 3in Isolation ball valve for Produced Water Transfer Pump P-1002A OPEN
suction line

HV-10176 2in Isolation ball valve for P-1002A discharge line OPEN

HV-10171 3in Isolation ball valve for Produced Water Transfer Pump P-1002B OPEN
suction line

HV-10173 2in Isolation ball valve for P-1002B discharge line OPEN

ID: M-CPH-1171-01417_EN_Section_5.doc Page 31 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Electrostatic Coalescer - Valve Checklist


Ref P&ID No (CUR-MAS-PM-20046-501)
Valve Tag Valve Description Setting
- Mix valve on the discharge line from the crude oil transfer pumps to the FULLY
electrostatic coalescer OPEN

HV-10224 1st in line isolation ball valve on the water supply to the mix valve CLOSED

HV-10223 2nd in line isolation ball valve on the water supply to the mix valve CLOSED

HV-10218 3in Isolation ball valve upstream of 10-LCV-0401 on the produced water OPEN
outlet from the electrostatic coalescer

HV-10219 3in Isolation ball valve downstream of 10-LCV-0401 OPEN

HV-10222 2in Isolation globe valve on 10-LCV-0401 bypass line CLOSED

HV-10188 8in Isolation Valve for the electrostatic coalescer oil outlet line OPEN

HV-10185 4in Isolation valve for the inlet to Pressure Safety Relief Valve 10-PSV- INTERLOCKED
0403A OPEN

HV-10187 6in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10-PSV-0403A to the LP Flare OPEN

HV-10182 4in Isolation valve for the inlet to Pressure Safety Relief Valve 10-PSV- INTERLOCKED
0403B CLOSED

HV-10184 6in Isolation valve for the outlet from Pressure Safety Relief Valve INTERLOCKED
10-PSV-0403B to the LP Flare OPEN

HV-10188 1st in line isolation valve on bypass line for 10-PSV-0403A and B OPEN

HV-10189 2nd in line isolation valve on bypass line for 10-PSV-0403A and B CLOSED

HV-10208 Trycock valve from Nozzle N6A to cooler CLOSED

HV-10213 Outlet valve from trycock cooler - Nozzle N6A CLOSED

HV-10209 Trycock valve from Nozzle N6B to cooler CLOSED

HV-10214 Outlet valve from trycock cooler - Nozzle N6B CLOSED

HV-10210 Trycock valve from Nozzle N6C to cooler CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 32 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Valve Tag Valve Description Setting


HV-10215 Outlet valve from trycock cooler - Nozzle N6C CLOSED

Electrostatic Coalescer - Valve Checklist (Continued)

Valve Tag Valve Description Setting

HV-10211 Trycock valve from Nozzle N6D to cooler CLOSED

HV-10216 Outlet valve from trycock cooler - Nozzle N6D CLOSED

HV-10212 Trycock valve from Nozzle N6E to cooler CLOSED

HV-10217 Outlet valve from trycock cooler - Nozzle N6E CLOSED

HV-10198 Drain valve for coalescer bushings at Nozzle N5A CLOSED

HV-10195 Vent valve for coalescer bushings at Nozzle N5A OPEN

HV-10196 Isolation valve for coalescer bushings vent (Nozzle N5A) to oil outlet line OPEN
from the coalescer

HV-10197 Isolation valve for coalescer bushings vent (Nozzle N5A) to drainage CLOSED

HV-10202 Drain valve for coalescer bushings at Nozzle N5B CLOSED

HV-10199 Vent valve for coalescer bushings at Nozzle N5B OPEN

HV-10200 Isolation valve for coalescer bushings vent (Nozzle N5B) to oil outlet line OPEN
from the coalescer

HV-10201 Isolation valve for coalescer bushings vent (Nozzle N5B) to drainage CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 33 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Export Crude Oil Cooler - Valve Checklist

Ref P&ID No (CUR-MAS-PM-20047-501)

Valve Tag Valve Description Setting

HV-10225 8in Isolation ball valve on the crude inlet to the export crude oil cooler OPEN

HV-10229 8in Isolation ball valve on the crude outlet from the export crude oil cooler OPEN

10-XV-0458 PSD isolation valve for the crude outlet from the export crude oil cooler CLOSED

HV-10230 8in Isolation ball valve upstream of 10-LCV-0314 on the crude outlet from OPEN
the export crude oil cooler

HV-10231 8in Isolation valve downstream of 10-LCV-0314 OPEN

HV-10234 6in Isolation globe valve on 10-LCV-0314 bypass line CLOSED

HV-45103 6in Manual isolation valve for the Cooling Medium Supply to the export crude OPEN
oil cooler

HV-45096 6in Isolation ball valve upstream of 10-TCV-0455 on the cooling medium OPEN
outlet line from the export crude oil cooler

HV-45097 6in Isolation valve downstream of 10-TCV-0455 OPEN

HV-45100 4in Isolation globe valve on 10-TCV-0455 bypass line CLOSED

HV-45101 6in Manual isolation valve on the Heating Medium Return from the export OPEN
crude oil cooler

ID: M-CPH-1171-01417_EN_Section_5.doc Page 34 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.5 During the cold start-up of the Oil Processing Facilities the
Start-up Overrides following shutdown inputs to the Shutdown System require to be
overridden at the shutdown panel until steady operating
conditions have been achieved.

Switch Equipment Description Shutdown


Tag No Level

03-PALL-0016, 0116, - Wellheads PSD


0316, 1116

07-PALL-101, 201 - Production Risers PSD


and 301

10-LALL-0510 V-1005 Test separator Oil/Water Interface Level PSD

10-LALL-0512 V-1005 Test separator Gas/Oil Interface Level PSD

10-PALL-0508 V-1005 Test separator Pressure PSD

10-LALL-0110 V-1001 HP Separator Oil/Water Interface Level PSD

10-LALL-0112 V-1001 HP Separator Gas/Oil Interface Level PSD

10-PALL-0108 V-1001 HP Separator Pressure PSD

10-LALL-0210 V-1002 MP Separator Oil/Water Interface Level PSD

10-LALL-0212 V-1002 MP Separator Gas/Oil Interface Level PSD

10-PALL-0208 V-1002 MP Separator Pressure PSD

10-LALL-0310 V-1003 LP Separator Oil/Water Interface Level PSD

10-LALL-0312 V-1003 LP Separator Gas/Oil Interface Level PSD

10-PALL-0308 V-1003 LP Separator Pressure PSD

ID: M-CPH-1171-01417_EN_Section_5.doc Page 35 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure

STEP DESCRIPTION LOCAL PCS

Refer to Figures 3.01 to 3.03 in Section 3 of this Book while reading the
following procedure.

1 INFORM the Marine Supervisor that crude oil will shortly be available for
loading. The Marine Supervisor will select the appropriate tank loading
sequence and OPEN the appropriate valves to the cargo tank.

2 SET the controllers for the HP Separator as follows:

Vessel Pressure Controller 10-PIC-0107 to AUTO with a setpoint *


of 10 barg. This setpoint will provide flowline hydrate mitigation.

Field production routing keyswitch positioned at 76-XS-1000A in CCR


order to confirm Curlew production is routed to the HP Separator.

Produced water routing keyswitch positioned at 40-HS-4000A in CCR


order to align the HP Separator Hydrocyclone to the HP
Separator.

Note: Depending on the field water production rate anticipated, it is


important that the correct hydrocyclone unit is lined up. The HP
Hydrocyclone and the Test Hydrocyclone are rated to 18,000
BWPD and 5,000 BWPD respectively.

Oil/water Interface Level Controller 10-LIC-0111 to MANUAL *


with the Level Control Valve 10-LCV-0111 positioned on the clean
water outlet from the HP Separator hydrocyclone CLOSED.

Oil/gas Interface Level Controller 10-LIC-0114 to MANUAL with *


the Level Control Valve 10-LCV-0114 CLOSED.

3 SET the controllers for the MP Separator as follows:

Vessel Pressure Controller 10-PIC-0207 to AUTO with a setpoint *


of 7.7 barg.

Oil/water Interface Level Controller 10-LIC-0211 to MANUAL *


with the Level Control Valve 10-LCV-0211 positioned on the water
outlet to the MP Separator hydrocyclone CLOSED.

Oil/gas Interface Level Controller 10-LIC-0214 to MANUAL with *


the Level Control Valve 10-LCV-0214 CLOSED.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 36 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

4 SET the controllers for the LP Separator as follows:

Vessel Pressure Controller 10-PIC-0307 to AUTO with a setpoint *


of 0.7 barg.

Once an operable level has been established, set the oil/water *


Interface Level Controller 10-LIC-0311 to AUTO and Produced
Water Transfer Pumps P-1002A/B to AUTO. Any produced water
separated in the LP separator is pumped back to the MP
separator for further processing by the duty selected produced
water transfer pump on demand.

Oil/gas Interface Level Controller 10-LIC-0314 to MANUAL with *


the Level Control Valve 10-LCV-0314 CLOSED. The crude oil
recovered in the LP separator is pumped to the downstream
Electrostatic Coalescer for further processing under flow control
by the duty Crude Oil Transfer Pump on start-up.

5 SET the controllers on the Electrostatic Coalescer as follows:

Oil/Water Interface Level Controller 10-LIC-0401 to MANUAL *


with the Level Control Valve 10-LCV-0401 on the produced water
outlet line from the vessel CLOSED

The power supply to the transformers for the Electrostatic


Coalescer is SWITCHED OFF at the Local Control Panel
*

6 OPEN the 6in isolation ball valve for the cooling medium supply to the *
Crude Oil Cooler to REINSTATE the flow of cooling medium to the
cooler. SET Temperature Controller 20-TIC-0455 to AUTO with a
setpoint of 30C to ESTABLISH the flow of cooling medium through the
cooler.

7 OPEN the PSD Isolation Valve 44-XV-2017 for the heating medium outlet * *
from the HP Crude Oil Heater to REINSTATE the flow of heating medium
to the heater. SET Temperature Controller 10-TIC-0155 for the heater to
MANUAL with the Temperature Control Valve 10-TCV-0155 CLOSED.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 37 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

8 OPEN the isolation valve 07-XV-110 to line up the Riser D2 to the HP *


Separator.

9 ENSURE there is no significant Differential Pressure (DP) across the LOCAL *


Riser D2 ESD Valve 07-XXV-100, if necessary equalise using RESET
methanol, then OPEN this valve by RESETTING the solenoids at the
Local Field Panel. The operating pressure of the subsea flowline from
the Curlew Subsea Well(s) to the Riser D2 is indicated on 07-PI-102.

10 ENSURE there is no significant Differential Pressure (DP) across the LOCAL *


Riser D2 ESD Valve 07-XV-105, if necessary equalise using RESET
methanol, then OPEN this valve by RESETTING the solenoids at the
Local Field Panel.

11 SLOWLY OPEN the Topsides Choke 07-PCV-109 to not more than *


10% initially to blow through any gas and allow pressure equalisation
then FULLY OPEN the Topsides Choke 07-PCV-109.

Note: The topsides choke is NOT used to control the production rate
from the well during the cold start-up.

Well DP1 Start-up

12 CONFIRM Curlew Well DP1 Subsea Choke Valve 03-PCV-0008 is *


CLOSED.

13 OPEN Methanol Injection Valve 03-MIV-0007 to Curlew Well DP1 *


xmas tree upstream of Production Wing Valve 03-PWV-0006.
ENSURE manifold valves 03-XV-1001/2/3 are positioned to provide
an open flowpath of methanol.

14 START Methanol Injection Pump P-7301A, B, or C as required for * *


injection to Curlew Well DP1 and OBSERVE the output pressures and
operation to verify methanol is being injected.

Note: Operators must be in the field to observe the start of the pump.

15 ADJUST stroke length in stages slowly pressuring up the methanol *


piping and umbilical to the desired output.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 38 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

16 EQUALISE the pressure using methanol across 03-PUMV-0005 as *


compared from 03-PT-0015 with the last noted well CITHP.

17 Provide OPEN signal to 03-PUMV-0005 when the pressures are *


equalised.

Note: PWV must be shut prior to opening PUMV.

18 EQUALISE the pressure using methanol to enable 03-SSSV-0011 to * *


OPEN. Compare pressure at 03-PT-0015 with Downhole Pressure
Transmitter 03-PT-0013.

19 Provide OPEN signal to 03-SSSV-0011 when the pressures are *


equalised.

20 OPEN Curlew Well DP1 Production Wing Valve 03-PWV-0006. *

21 OPEN the Subsea Choke Valve 03-PCV-0008 for Curlew Well DP1 to *
18% initially (minimal flow) to avoid exceeding the jumper design
temperature (-20C). Cold temperatures may occur initially from
blowing a cold gas cap through the subsea choke. CHECK the
temperature at 03-TI-0009 on the DP1 well to ensure that the well is
flowing.

22 SLOWLY BEAN-UP the choke 03-PCV-0008 to the setting required to *


achieve topsides arrival temperatures above 20C. OBSERVE the
operating temperature of the well fluids arriving topsides via 07-TI-111
downstream of the topsides choke valve and continue to monitor this
temperature until the flowline warms up.

23 Adjust Methanol Pump stroke length to set rate to 0.5 m/h. Continue *
to inject Methanol at 0.5 m/h for at least 1 hour after DP1 well start-
up. Ensure the topsides arrival temperature from Riser D2 is above
20C before ceasing methanol injection to well DP1.

24 START chemical injection as required (referring to current Chemical *


Dosing Philosophy). Scale Inhibitor injection to well DP1. Corrosion
inhibitor injection downstream of Riser D2 topsides choke. Demulsifier
and Anti-foam injection to the inlet header for the HP separator.

25 MONITOR the rising operating level in the HP Separator and raise the *
controller setpoint gradually to an operating pressure of 38 barg.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 39 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

26 When the oil and produced water levels are established above the trip CCR
setpoints RESET PSD Isolation Valve 10-XV-0118 for the oil outlet
line.

27 SET the HP Separator Oil/Gas Interface Level Controller 10-LIC-0114 * *


to AUTO with a setpoint of 50% and ENSURE that the partially
stabilised crude oil is passed forward to the HP crude oil heater for
further processing.

28 SET the HP Separator Oil/Water Interface Level Controller * *


10-LIC-0111 to AUTO with a setpoint of 50% and ENSURE that any
produced water separated in the vessel is passed forward to the HP
Separator Hydrocyclone vessel for clean-up.

29 SET the HP Crude Oil Heater Temperature Controller 10-TIC-0155 to *


AUTO with a setpoint initially below 70C in order to prevent tripping
on high temperatures. Gradually increase the setpoint to 70C as
conditions allow to provide further stabilisation in the downstream MP
separator.

30 START Demulsifier and Anti-foam, chemical injection to inlet header *


for the MP separator, as required. As the crude oil has already been
chemically dosed at the inlet to the HP Separator, the addition of
demulsifier and anti-foam may not be necessary.

31 MONITOR the rising operating levels, temperature and pressure in *


the MP Separator and ensure that the pressure in the vessel is
controlled at 7.7 barg, with excess gas passing to the HP Flare.

32 OPEN the 6 isolation ball valve for the heating medium supply to the * *
MP Crude Oil Heater to REINSTATE the flow of heating medium to
the heater. After establishing an initial production flow rate, SET
Temperature Controller 10-TIC-0255 for the heater to MANUAL with
the Temperature Control Valve 10-TCV-0255 CRACKED OPEN to
establish a flow through the heater.

Note: The operating temperature of the MP Crude Oil Heater must be


closely monitored until well fluids are passing through the
heater. If the operating temperature increased above 70C the
flowrate of heating medium must be stopped to avoid tripping
the heater on high high temperature.

33 RESET the Pressurisation Bypass Valve 20-XV-1202/PSD Isolation CCR


Valve 20-XV-1201 on the gas outlet line from the MP separator.
These valves will OPEN in sequence to PRESSURISE the MP
Compressor Suction Cooler E-2002 with gas.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 40 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

34 When the oil and produced water levels are established above the trip CCR
setpoints RESET PSD Isolation Valve 10-XV-0218 for the oil outlet
line.

35 SET the MP Separator Oil/Gas Interface Level Controller 10-LIC-0214 * *


to AUTO with a setpoint of 50% and ENSURE that the crude oil is
passed forward to the MP Crude Oil Heater for further processing.

36 When required, SET the MP Separator Oil/Water Interface Level * *


Controller 10-LIC-0211 to AUTO with a setpoint of 50% and ENSURE
that any produced water separated in the vessel is passed forward to
the MP separator hydrocyclone vessel for further treatment.

37 SET the MP crude oil heater Temperature Controller 10-TIC-0255 to *


AUTO with a setpoint of 67oC. This setpoint ensures that the crude oil
from the MP Separator passes through the MP crude oil heater at a
satisfactory temperature to the downstream LP separator for full
stabilisation.

38 MONITOR the rising operating levels and temperature in the LP *


Separator and ENSURE that the pressure in the vessel is controlled
at 0.7 barg.

39 RESET the PSD Isolation Valve 20-XV-1221 on the gas outlet line CCR
from the LP Separator. This valve will OPEN to PRESSURISE the LP
Compressor Cooler E-2003 with gas.

40 When the oil level in the LP Separator is established above the trip set CCR
point, RESET PSD Isolation Valve 10-XV-335 for the oil outlet line.

41 SET the LP Separator Oil/Gas Interface Level Controller 10-LIC-0314 *


to AUTO with a setpoint of 50%. The Process Value (PV) from this
instrument will be used as the setpoint for the Level Control Valve 10-
LCV-0314 on the crude supply line from the outlet of the Export Crude
Oil Cooler to the Cargo Storage Tanks.

42 SELECT the Crude Oil Transfer Pump P-1001A for DUTY (Remote CCR
Operation in the MAERSK FPSOS HEADQUARTERS).

43 PRIME Crude Oil Transfer Pump P-1001A selected for duty by * *


OPENING the casing vent. CLOSE the vent valve when oil is evident
at the vent. SET the Minimum Flow Controller 10-FIC-0328 to AUTO
with a setpoint of 180 m3/hr (minimum flow for a single pump).

ID: M-CPH-1171-01417_EN_Section_5.doc Page 41 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS


44 ENSURE that the Electrostatic Coalescer is lined up to receive fully *
stabilised crude oil from the common discharge of the crude oil
transfer pumps and START P-1001A. MONITOR the crude oil transfer
pump for correct operation and ENSURE the crude oil is passed
forward from the pump to the Electrostatic Coalescer for further
processing at 6.5 barg. Any crude oil passed through the minimum
flowline is directed back to the LP Separator.

Note: the pump may have to be operated in batch mode until steady
operations have been achieved.

45 When the produced water level in the LP Separator is established CCR


above the trip setpoint, RESET PSD Isolation Valve 10-XV-0334 for
the produced water outlet line.

46 SELECT the Produced Water Transfer Pump P-1002A for DUTY *


(Remote Operation in the MAERSK FPSOS HEADQUARTERS).
This pump will AUTO-START to direct the produced water recovered
in the LP Separator back to the MP Separator for further processing
once the oil/water interface level achieves the setpoint of 50%.

47 MONITOR the rising operating level and pressure in the Electrostatic * CCR
Coalescer. When the oil level is established above the trip setpoint
Shutdown Condition 10-LALL-0406 should be observed to RESET at
the Local Control Panel.

Note: The dehydrated crude oil passes out of the Electrostatic


Coalescer to the export crude oil cooler for further cooling prior
to storage.
48 Once a suitable working level of 50% has been established in the *
Electrostatic Coalescer SET the Oil/Water Interface Level Controller
10-LIC-0401 for the vessel to AUTO with a setpoint of 50%.
Any produced water recovered in the Electrostatic Coalescer is
directed to the upstream MP Crude Oil Heater for further processing.

49 Switch on the power supply to the transformers for the Electrostatic *


Coalescer at the Local Control Panel.

Caution: Under no circumstances should the power supply be


switched on to the transformers of the Electrostatic
Coalescer until the vessel is liquid filled.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 42 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

50 ENSURE that the crude oil is now being directed forward from the *
Electrostatic Coalescer to the Export Crude Oil Cooler for further
cooling prior to storage. Once the temperature of the crude oil has
been reduced to 30C by heat exchange with cooling medium passing
through the export crude oil cooler, the crude is passed forward from
the Oil Processing Facilities under level control to the Crude Storage
Tanks.

Note: If the PSD Isolation Valve 10-XV-0458 or downstream Level


Control Valve 10-LCV-0314 on the crude oil supply line to the
Crude Storage Tanks fail closed, the operating level in the LP
separator will start to rise. If 10-XV-0458 is not reopened and
the flowrate of crude to the storage tanks re-established the
High High Level Trip 10-LTHH-0313 for the LP separator will be
activated which in turn initiates a PSD shutdown.

Note: The Curlew production is now on stream with the oil being
produced but all the produced gas flared. The Gas
COMPRESSION System should now be brought on line (refer
to POPM Volume N41C3).

51 OPEN the Pressurisation Bypass Valve 20-XV-1052 and PSD CCR


Isolation Valve 20-XV-1051 on the gas outlet line from the HP
Separator. These valves will pressurise the downstream system and
divert gas from the HP Separator to the Inlet Cooler E-2001.

52 Additional Curlew well(s) can now be started to the HP separator as *


required.

Well DP2 Start-up

53 CONFIRM Curlew Well DP2 Subsea Choke Valve 03-PCV-0108 is *


CLOSED.

54 OPEN Methanol Injection Valve 03-MIV-0107 to Curlew Well DP2 *


xmas tree upstream of Production Wing Valve 03-PWV-0106.
ENSURE manifold routing valves 03-XV-1001/2/3 provide an open
flowpath.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 43 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Production - Continued

STEP DESCRIPTION LOCAL PCS

55 START Subsea Methanol Injection Pump P-7301A, B, or C as * *


required for injection to Curlew Well DP2 and OBSERVE the output
pressures and operation and flow to verify methanol is being injected.

Note: Operators must be in the field to observe the start of the pump.

56 ADJUST stroke length in stages slowly pressuring up the methanol *


piping and umbilical to the desired output.

57 EQUALISE the pressure across 03-PUMV-0105 as compared at 03- *


PT-0115 with the last noted well CITHP.

58 Provide OPEN signal to 03-PUMV-0105 when the pressures are *


equalised.

Note: PWV must be shut prior to opening PUMV.

59 EQUALISE the pressure using methanol to enable 03-SSSV-0111 to * *


OPEN. Compare pressure at 03-PT-0115 with Downhole Pressure
Transmitter 03-PT-0113.

60 Provide OPEN signal to 03-SSSV-0111 when the pressures are *


equalised.

61 OPEN Curlew Well DP2 Production Wing Valve 03-PWV-0106. *

62 OPEN the Subsea Choke Valve 03-PCV-0108 for Curlew Well DP2 to *
18% initially (minimal flow) to avoid exceeding the jumper design
temperature (-20C). Cold temperatures may occur initially from
blowing a cold gas cap through the subsea choke. CHECK the
temperature at 03-TI-0109 on the DP2 well to ensure that the well is
flowing.

63 Adjust Methanol Pump stroke length to set rate to 0.5m/h. Continue *


to inject Methanol at a rate of 0.5m/h for 1 hour after DP2 well start-
up. After 1 hour and provided the topsides arrival temperature is still
above 20C methanol injection to Curlew Well DP2 can be ceased.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 44 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

64 CLOSE Methanol Injection Valve 03-MIV-0107 to Curlew Well DP2 *


xmas tree upstream of Production Wing Valve 03-PWV-0106.

65 ENSURE there is no significant Differential Pressure (DP) across the LOCAL *


Riser D1 ESD Valve 07-XXV-200, if necessary equalise using RESET
methanol, then OPEN this valve by RESETTING the solenoids at the
Local Field Panel. The operating pressure of the subsea flowline from
the Curlew Subsea Well(s) to the Riser D1 is indicated on 07-PI-202.

66 ENSURE there is no significant DP across the Riser D1 ESD Valve LOCAL *


07-XV-205 then OPEN this valve by RESETTING the solenoids at the RESET
Local Field Panel.

67 OPEN the Production Manifold Diverter Valve 07-XV-210 for Riser D1 *


to line-up to the HP Separator.

68 SLOWLY OPEN the Riser D1 Topsides Choke 07-PCV-209 to *


commence flow up Riser D1 and cutback on Riser D2 Choke 07-
PCV-109 in order to flow up both risers. Continue to FULLY OPEN
both chokes once flows are even.

Well DP4 Start-up

69 CONFIRM Curlew Well DP4 Subsea Choke Valve 03-PCV-1108 is *


CLOSED.

70 OPEN Methanol Injection Valve 03-MIV-1107 to Curlew Well DP4 *


xmas tree upstream of Production Wing Valve 03-PWV-1106.
ENSURE manifold valves 03-XV-1001/2/3 are positioned to provide
an open flowpath of methanol.

71 START Methanol Injection Pump P-7301A, B, or C as required for * *


injection to Curlew Well DP4 and OBSERVE the output pressures
and operation to verify methanol is being injected.

Note: Operators must be in the field to observe the start of the pump.

72 ADJUST stroke length in stages slowly pressuring up the methanol *


piping and umbilical to the desired output.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 45 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure Continued

STEP DESCRIPTION LOCAL PCS


73 EQUALISE the pressure using methanol across 03-PUMV-1105 as *
compared at 03-PT-1115 with the last noted well CITHP.

74 OPEN 03-PUMV-1105 when the pressures are equalised. *

Note: PWV must be shut prior to opening PUMV.

75 OPEN 03-SSSV-1111 (valve is self-equalising on well DP4). If it *


doesnt open then inject methanol to equalise pressure across the
valve.

76 OPEN Curlew Well DP4 Production Wing Valve 03-PWV-1106. *

77 SLOWLY OPEN the DP4 subsea choke valve 03-PCV-1108 to a choke *


setting of 12% to establish a very low flowrate of well fluids from Well
DP4. Once the FTHP falls below 85 barg then the choke can be
opened to 15%.

78 OBSERVE the temperature of the DP4 well fluids downstream of the *


choke on 03-TT-1122 and monitor until the well warms up.

79 Adjust Methanol Pump stroke length to set rate to 0.5m/h. Continue to *


inject Methanol at a rate of 0.5m/h for 1 hour after DP4 well start-up.
Ensure the topsides arrival temperature from both Risers is above 20C
and the temperature downstream of the DP4 choke is above 22C
before ceasing methanol injection to Well DP4.

Well DP3 Start-up

81 CONFIRM Curlew Well DP3 Subsea Choke Valve 03-PCV-0308 is *


CLOSED.

82 OPEN Methanol Injection Valve 03-MIV-0307 to Curlew Well DP3 *


xmas tree upstream of Production Wing Valve 03-PWV-0306.
ENSURE manifold routing valves 03-XV-1001/2/3 provide an open
flowpath.

83 START Methanol Injection Pump P-7301A, B, or C as required for * *


injection to Curlew Well DP3 and OBSERVE the output pressures
and operation to verify methanol is being injected.

Note: Operators must be in the field to observe the start of the pump.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 46 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued
STEP DESCRIPTION LOCAL PCS
84 ADJUST stroke length in stages slowly pressuring up the methanol *
piping and umbilical to the desired output.

85 EQUALISE the pressure using methanol across 03-PUMV-0305 as *


compared at 03-PT-0315 with the last noted well CITHP.

86 Provide OPEN signal to 03-PUMV-0305 when the pressures are *


equalised.

Note: PWV must be shut prior to opening PUMV.

87 EQUALISE pressure to enable 03-SSSV-1111 to OPEN. Compare *


pressure at 03-PT-0315 with Downhole Pressure Transmitter 03-
PT-0313.

88 Provide OPEN signal to 03-SSSV-1111 when the pressures are *


equalised.

89 OPEN Curlew Well DP3 Production Wing Valve 03-PWV-0306. *

90 OPEN the Subsea Choke Valve 03-PCV-0308 for Curlew Well DP3 *
to 18% initially (minimal flow) to avoid exceeding the jumper design
temperature (-20C). Cold temperatures may occur initially from
blowing a cold gas cap through the subsea choke. CHECK the
temperature at 03-TI-0009 on the DP3 well to ensure that the well
is flowing.

91 OBSERVE the operating temperature of the well fluids via tree *


sensor 03-TT-0309 and Riser D1 sensor 07-TT-211 and continue
to monitor these temperatures until the well warms up.

92 Adjust Methanol Pump stroke length to set rate to 0.5m/h. *


Continue to inject Methanol at a rate of 0.5m/h for at least 1hour
after DP3 well start-up. Provided topsides arrival temperature from
both Risers is above 20C then cease methanol injection to Well
DP3.

93 BEAN-UP Curlew D wells to desired rates by following Production *


Technologists latest Bean-up Procedure.

94 The chemical injection rates for all chemicals directed to the Oil *
Processing Facilities can now be SET to their optimum rate to
conserve chemicals.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 47 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued
STEP DESCRIPTION LOCAL PCS

Well BP1 Start-up

95 RESET the PSD Isolation Valve 20-XV-1191 on the gas outlet line CCR
from the Test separator.

96 SLOWLY OPEN the 10in isolation ball valve on the gas outlet line *
from the Test separator to the Inlet Cooler E-2201.

97 When the oil and produced water levels are established above the trip CCR
setpoints RESET PSD Isolation Valve 10-XV-0518 for the oil outlet
line.

Note: All PSD isolation valves must be correctly identified in the


Valve Checklists included in the Tables in Part 5 of this book
BEFORE the valves are reset to the open position.

98 SET the Test separator Oil/Gas Interface Level Controller * *


10-LIC-0514 to AUTO with a setpoint of 50% and ENSURE that the
crude oil is passed forward to the MP separator for further processing.

99 SET the Test separator Oil/Water Interface Level Controller * *


10-LIC-0511 to AUTO with a setpoint of 50% and ENSURE that any
produced water separated in the vessel is passed forward to the Test
separator hydrocyclone vessel for further treatment.

100 Ensure the Test separator is depressurised to minimum pressure for *


starting well BP1 to facilitate flowing of the well

101 The field production routing keyswitch is positioned at 76-XS-1000A *


in order to confirm that Curlew B is produced to the Test separator.

102 ENSURE there is no significant DP across the Curlew BP1 Flowline LOCAL *
ESD Valve 07-XV-305 then OPEN this valve by RESETTING the RESET
solenoids at the Local Field Panel.

103 OPEN the Test Manifold Diverter Valve 07-XV-404 for Curlew BP1 *
riser to line-up this well to the Test manifold.

Note: The Curlew BP-1 Riser is now isolated from the Test
separator by the Topsides Choke Valve 07-PCV-309.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 48 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure Continued
STEP DESCRIPTION LOCAL PCS
104 SET the controllers for the Test separator as follows:

Vessel Pressure Controller 10-PIC-0507B to AUTO with a *


setpoint of 10 barg.

The produced water routing keyswitch is positioned at 40-HS-4000A CCR


in order to align the Test separator Hydrocyclone to the Test
separator

Oil/water Interface Level Controller 10-LIC-0511 to MANUAL


with the Level Control Valve 10-LCV-0511 positioned on the *
clean water outlet from the Test separator hydrocyclone
CLOSED. Any produced water separated in the Test
separator is routed to the Test separator hydrocyclone for
further processing on start-up

Oil/gas Interface Level Controller 10-LIC-0514 to MANUAL *


with the Level Control Valve 10-LCV-0514 CLOSED.

105 ADJUST stroke length in stages slowly pressuring up the methanol *


piping and umbilical to the desired output.

106 EQUALISE the pressure across 03-PUMV-0205 as compared from *


03-PT-0215 with the last noted well CITHP.

107 Provide OPEN signal to 03-PUMV-0205 when the pressures are *


equalised.

Note: PWV must be shut prior to opening PUMV.

108 EQUALISE pressure to enable 03-SSSV-0211 to OPEN. Compare * *


pressure at 03-PT-0215 with Downhole Pressure Transmitter 03-PT-
0213.

109 Provide OPEN signal to 03-SSSV-0211 when the pressures are *


equalised.

110 FULLY OPEN the Subsea Choke Valve 03-PCV-0208 for Curlew Well *
BP1.

111 OPEN Curlew Well BP1 Production Wing Valve 03-PWV-0206. *


MONITOR BP1 wellhead temperature at 03-TT-0209 to ensure the
well is flowing.

112 RETURN the Subsea Choke Valve 03-PCV-0208 for Curlew Well BP1 *
to 50% once the FWT has reached 40 50C.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 49 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.01.6
Cold Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

113 Adjust Methanol Pump stroke length to set rate to 0.5m/h. Continue * *
to inject Methanol at a rate of 0.5m/h for at least 1 hour after BP1 well
start-up. Ensure the topsides arrival temperature from Riser B1 is
above 20C before ceasing methanol injection to well BP1.

114 OBSERVE the operating temperature of the well fluids arriving *


topsides via 07-TI-311 downstream of the topsides choke valve and
continue to monitor this temperature until the flowline warms up.

115 Once the topsides arrival temperature has reached 20C the Test *
Separator pressure can be steadily increased to desired pressure on
10-PIC-507B.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 50 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02
Hot Start-up of the Oil
Processing Facilities

5.02.1 This procedure assumes that the oil processing facilities have been
Preamble operating normally but have shutdown either manually for a short period
of time or as a result of a Production Stop or Process Trip.

The procedure assumes that the reason for the shutdown has been
rectified and it is considered safe to re-start the facilities and resume the
transfer of fully stabilised crude to the cargo storage tanks.

Is assumed for the purposes of this procedure that the subsea flowlines
to the FPSO are pressurised and have not cooled down below the
hydrate temperature.

All the production separators are still pressurised but there is no forward
flow of crude oil, produced water or process gas.

The levels, temperatures and pressures of all the vessels within the oil
processing facilities are at or near their normal operating levels.

The crude oil transfer pump and produced water transfer pump in service
have shut down.

The hot start-up procedure of the oil processing facilities can be


summarised in the following major steps:

Verify set points/operational modes of process controllers

Reset the shutdown valves on the outlets from the vessels and
suction lines for any pumps

Restart the duty crude oil transfer pump

Restart Produced Water Pumps P-1002A/B

ID: M-CPH-1171-01417_EN_Section_5.doc Page 51 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.1 Re-establish flow from the Curlew Subsea Wells DP1, DP2, DP3
Preamble - Continued and DP4 to the HP separator to re-introduce gas to the Fuel Gas
System and resume the forward flow of crude oil through Oil
Processing Facilities

Re-establish flow from the Curlew Subsea Well BP1 to the Test
separator, if required.

Restart chemical injection to the oil processing facilities

This hot start-up procedure must be read in conjunction with the hot
start-up procedures of the following systems:

Volume 1 Book A - Subsea Facilities

Volume 1 Book C - Gas Processing Facilities

Volume 1 Book D - Produced Water Facilities

Volume 1 Book K - Fuel Gas System

Volume 1 Book M - Chemical Injection

The hot start-up procedure of the oil processing facilities assumes that
the gas compression facilities are prepared to receive process gas from
the separation vessels and the produced water treatment package is
available to process the produced water from the system.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 52 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.2 WARNING: ALL SYSTEM PRESSURE SAFETY RELIEF VALVES


Preconditions MUST BE LINED UP FOR NORMAL OPERATION.

(1) No Permits to Work or electrical isolations are in force which may


prohibit system start-up.

(2) The Fire and Gas Detection/Protection, Process Control System


(PCS) and Safety Related Systems (PSDs) are operational along
with the alarms, trips and controllers.

(3) It is assumed that in a short duration shutdown, it is unlikely that


spades or blinds would be moved, or drain and vent valves
opened, unless to take corrective action on the cause of shutdown.
It is therefore unnecessary to recheck these items other than if
they have been disturbed.

(4) All instrument and level bridle drain valves are closed.

(5) All instrument isolation valves are open.

(6) Ensure the Inlet Cooler E-2201, MP Compressor Suction Cooler


E-2002 and LP Compressor Cooler E-2003 in the Gas Processing
Facilities are prepared to receive the process gas from the HP, MP
and LP separators.

(7) Ensure Glycol Circulation has been initiated and the glycol is up
to temperature in the Gas Dehydration System.

(8) The following utility systems are available:

Electrical Power Distribution (including trace heating)

Instrument Air

Heating Medium

Cooling Medium

Cooling Seawater

Chemical Injection Package including the availability of the


following chemicals as required:

- Methanol

- Demulsifier

- Anti-foam

- Scale Inhibitor

ID: M-CPH-1171-01417_EN_Section_5.doc Page 53 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

- Corrosion Inhibitor

- Wax Inhibitor

- HP Flare System

- LP Flare System
5.02.2
Preconditions- Continued - Hazardous Open Drains

(9) Communications have been established with all the personnel


involved.

(10) All HVAC and Turret Annulus Fans have been restarted.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 54 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.3 Refer to Figures 3.01 to 3.03 in Section 3 of this Volume and the P&IDs
Hot Start-up PSD identified below.
Valve Checklist
(1) The System Operator should CHECK the following valves to
confirm the valve settings are as given below.

(2) Where the valves are found to be out of position, the operator
should satisfy himself that it is safe to move the valves before
doing so.

Hot Start-up PSD Valve Checklist

Valve Tag Valve Description Setting

Subsea Production Wells


(P&ID Drawing Nos CUR-MAS-PB-20021-001 to 004)

03-AWV- Annulus Master Valve (Curlew Wells DP1/DP2/DP3/DP4/BP1) OPEN


0004/0104/0304/
1104/0204

03-AXOV- Annulus Crossover Valve (Curlew Wells DP1/DP2/DP3/DP4/BP1) CLOSED


0001/0101/0301/
1101/0201

03-SSSV- Subsurface Safety Valve (Curlew Wells DP1/DP2/DP3/DP4/BP1) OPEN


0011/0111/0311/
1111/0211

03-PUMV- Production Upper Master Valve (Curlew Wells DP1/DP2/DP3/DP4/BP1) OPEN


0005/0105/0305/
1105/0205

03-PWV- Production Wing Valve (Curlew Wells DP1/DP2/DP4/BP1) CLOSED


0006/0106/0306/
1106/0206

03-PCV- Production Choke Valve (Curlew Wells DP1/DP2/DP3/DP4/BP1) CLOSED


0008/0108/0308/
1108/0208

03-MIV- Methanol Injection Valve (Curlew Wells DP1/DP2/DP3/DP4/BP1) OPEN


0007/0107/0307/
1107/0207

ID: M-CPH-1171-01417_EN_Section_5.doc Page 55 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Valve Tag Valve Description Setting


03-PTIV- Production Test Isolation Valve (Curlew Wells DP1/DP2/DP3/DP4/BP1) CLOSED
0010/0110/0310/
1110/0210

Curlew D Production Manifold & SDU


(P&ID Drawing No MAERSK DRILLING AUSTRALIA-CP692-U-
0002-001 Rev C1)

03-XV-1001 Riser D2 Manifold Isolation Valve OPEN

03-XV-1002 Riser D1 Manifold Isolation Valve OPEN

03-XV-1003 Crossover Isolation Valve OPEN

Spare Production Flowline


(P&ID Drawing No CUR-MAS-TP-42035-001))

07-XXV-0500 Spare Flowline Riser ESD Valve CLOSED

07-XV-0505 Spare Flowline ESD Valve CLOSED

07-XV-0510 12in Spare Flowline Integrated DB&B Isolation Valve CLOSED

07-PCV-0509 Spare Flowline Topsides Choke Valve CLOSED

Curlew Production Flowlines


(P&ID Drawing No CUR-MAS-TP-42002-001)

07-XXV-100 Curlew Well D2 Riser PSD Valve CLOSED

07-XV-105 D2 Flowline ESD Valve CLOSED

07-PCV-109 Choke Valve D2 CLOSED

07-XV-110 D2 Diverter Valve to the HP Separator CLOSED

07-XV-402 D2 Diverter Valve to the Test Manifold OPEN

07-XXV-200 Curlew D1 Riser PSD Valve CLOSED

07-XV-205 D1 Flowline ESD Valve CLOSED

07-PCV-209 Choke Valve D1 CLOSED

ID: M-CPH-1171-01417_EN_Section_5.doc Page 56 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Valve Tag Valve Description Setting

07-XV-210 D1 Diverter Valve to the HP Separator OPEN

07-XV-403 D1 Diverter Valve to the Test Manifold CLOSED

07-XXV-300 Curlew B1 Riser PSD Valve CLOSED

07-XV-305 B1 Riser ESD Valve CLOSED

07-PCV-309 Topsides Choke Valve Riser B1 CLOSED

07-XV-310 Riser B1 Diverter Valve to the MP Separator CLOSED

07-XV-404 Riser B1 Diverter Valve to the Test Manifold OPEN

Test Separator
(P&ID Drawing Nos CUR- MAS-PM-20048-501
and CUR-MAS-PB-20048-002)

10-XV-0501 Blowdown Valve to HP Flare CLOSED

20-XV-1191 PSD Isolation Valve for gas outlet from Test separator CLOSED

10-XV-0518 PSD Isolation Valve for crude outlet from Test separator CLOSED

HP Separator
(P&ID Drawing Nos CUR-MAS-PM-20041-501
and CUR-MAS-PB-20041-002)

10-XV-0101 Blowdown Valve to HP Flare CLOSED

22-XV-1051 PSD Isolation Valve for gas outlet from HP separator CLOSED

22-XV-1052 Pressurisation Bypass Valve for gas outlet from HP separator CLOSED

10-XV-0118 PSD Isolation Valve on the crude outlet from HP separator CLOSED

HP Crude Oil Heater


(P&ID Drawing No CUR-MAS-PM-20042-501)

44-XV-2017 PSD Isolation Valve on heating medium return from the HP crude oil CLOSED
heater

ID: M-CPH-1171-01417_EN_Section_5.doc Page 57 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

Valve Tag Valve Description Setting


MP Separator
(P&ID Drawing Nos CUR-MAS-PM-20043-501
and CUR-MAS-PB-20043-002)

10-XV-0201 Blowdown Valve to LP Flare CLOSED

20-XV-1201 PSD Isolation Valve for gas outlet from MP separator CLOSED

20-XV-1202 Pressurisation Bypass Valve for gas outlet from MP separator CLOSED

10-XV-0218 PSD Isolation Valve on the crude outlet from MP separator CLOSED

LP Separator
(P&ID Drawing Nos CUR-MAS-PM-20045-501
and CUR-MAS-PB-20045-002)

10-XV-0301 Blowdown Valve to LP Flare CLOSED

20-XV-1221 PSD Isolation Valve for gas outlet from LP separator CLOSED

10-XV-0335 PSD Isolation Valve for crude outlet from LP separator CLOSED

10-XV-0334 PSD Isolation Valve for produced water outlet from LP separator CLOSED

Crude Transfer and Cooling


(P&ID Drawing No CUR-MAS-PM-20047-501)

10-XV-0458 PSD Isolation Valve for the crude outlet from the export crude oil CLOSED
cooler to storage

ID: M-CPH-1171-01417_EN_Section_5.doc Page 58 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.4 During the hot start-up of the Oil Processing Facilities there are no
Hot Start-up Overrides inputs to the Shutdown System which require to be overridden at the
shutdown panel until steady operating conditions have been
achieved.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 59 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.5
Hot Start-up Procedure

STEP DESCRIPTION LOCAL PCS

Refer to Figures 3.01 to 3.03 in Section 3 of this Volume while reading


the following procedure.

1 ENSURE that all inputs to the Shutdown System are healthy when CCR
RESETTING the PSD isolation valves identified in Steps 2 to 6.

2 On the HP separator RESET the Gas Outlet PSD Isolation Valve 22- CCR
XV-1051, Oil Outlet PSD Isolation Valve 10-XV-0118 and ENSURE
that the controllers are SET as follows:

Vessel Pressure Controller 10-PIC-0107 to AUTO with a *


setpoint of 38barg

Oil/Water Interface Level Controller 10-LIC-0111 to AUTO with *


a setpoint of 50%

Oil/Gas Interface Level Controller 10-LIC-0114 to AUTO with a


setpoint of 50% *

Note: If the operating levels in the HP separator are high, the level
controllers may initially require to be SET in MANUAL with zero
output (ie level control valves fully closed). This is to allow the
operating levels in the vessel to be slowly reduced by opening
the controllers in Manual.

3 On the HP crude oil heater RESET the Heating Medium Outlet PSD * CCR
Isolation Valve 44-XV-2017, RE-ESTABLISH a flowrate of heating
medium through the heater and ENSURE that the Temperature
Controller 10-TIC-0155 is SET to AUTO with a setpoint of 70C.

Note: Depending on the production throughput and fluid arrival


temperature, the set point should be set as high as possible
within the limit of the Heater rating. The outlet temperature
anticipated at the production profile, at full heater design duty
is expected to vary in the range of 54 to 71C. The alarm trip
points can be reset based on operating experience.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 60 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.5
Hot Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

4 On the MP separator RESET the Gas Outlet PSD Isolation Valve 20- CCR
XV-1201 and Oil Outlet PSD Isolation Valve 10-XV-0218 and
ENSURE that the controllers are SET as follows:

Vessel Pressure Controller 10-PIC-0207 to AUTO with a *


setpoint of 7 barg

Oil/Water Interface Level Controller 10-LIC-0211 to AUTO *


with a setpoint of 50%

Oil/Gas Interface Level Controller 10-LIC-0214 to AUTO with


a setpoint of 50% *

Note: If the operating levels in the MP separator are high, the level
controllers may initially require to be SET in MANUAL with zero
output (ie level control valves fully closed). This is to allow the
operating levels in the vessel to be slowly reduced by opening
the controllers in Manual.

5 On the MP crude oil heater ENSURE that the Temperature Controller * CCR
10-TIC-0255 is SET to AUTO with a setpoint of 67oC. A flowrate of
heating medium will RE-ESTABLISH itself through the MP crude oil
heater once the partially stabilised crude oil from the upstream MP
Separator is directed through the heater.

6 On the LP separator RESET the Gas Outlet PSD Isolation Valve 20- CCR
XV-1221, Oil Outlet PSD Isolation Valve 10-XV-0335 and Produced
Water Outlet Valve 10-XV-0334 and ENSURE that the controllers are
SET as follows:

Vessel Pressure Controller 10-PIC-0307 to AUTO with a *


setpoint of 1.1 barg

Oil/Water Interface Level Controller 10-LIC-0311 to AUTO with


a setpoint of 50% *

Oil/Gas Interface Level Controller 10-LIC-0314 to AUTO with a


setpoint of 50% *

Note: If the oil/water interface level in the LP separator is high, set


the pumps to manual and stop from the CCR. This is to prevent
the duty produced water transfer pump from AUTO-STARTING
before forward flow through the Oil Processing Facilities has
recommenced.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 61 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.5
Hot Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

7 On the Electrostatic Coalescer ENSURE that the Oil/Water Interface * CCR*


Level Controller 10-LIC-0401 is SET to AUTO with a setpoint of 50%.

CAUTION: ENSURE THAT VAPOUR BREAKOUT DOES NOT


OCCUR IN THE ELECTROSTATIC COALESCER AND
THE VESSEL REMAINS FULL OF LIQUID. THE VENT
VALVES FROM THE COALESCER BUSHINGS TO
THE OIL OUTLET LINE FROM THE VESSEL MUST
REMAIN IN THE OPEN POSITION.

8 ENSURE the flowrate of cooling medium to the export crude oil cooler * *
is uninterrupted and the Temperature Controller 20-TIC-0455 for the
cooler is SET to AUTO with a setpoint of 30oC.

9 ENSURE that the appropriate cargo oil tanks are lined up to receive *
fully stabilised crude oil from the oil processing facilities once
production re-commences.

10 ENSURE that the Minimum Flow Controller 10-FIC-032B for the *


Crude Oil Transfer Pumps P-1001A/B is SET to AUTO with a setpoint
of 180 m3/hr. (single pump setting)

11 RE-START the duty Crude Oil Transfer Pump P-1001A to *


RE-ESTABLISH the flow of fully stabilised crude oil from the LP
separator to the electrostatic coalescer.

Note: Until the forward flow of crude oil is re-established through the
oil processing facilities it is probable the duty crude oil transfer
pump will operate on full recycle. However, the pump may have
to be operated in manual batch dumping until continuous flow
has been established.

12 RESTART the power supply to the electrodes of the electrostatic *


coalescer by operating the reset button on the local control panel.

13 Ensure that the Curlew Riser D2 topside choke valve 07-PCV-0109 is *


in the closed position.

Caution: To avoid the risk of overpressurising the production


separator with a large gas blowby under the well CITHP
condition, the riser valve should not be opened without first
ensuring that the choke valve is in the closed position first.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 62 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.5
Hot Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

14 ENSURE there is no significant DP across Curlew D2 Riser ESD LOCAL


Valve 07-XXV-100, if necessary equalise using methanol, then RE- RESET
OPEN this valve by RESETTING the solenoids at the Local Field
Panel.

15 ENSURE there is no significant DP across the Curlew D2 Flowline *


ESD Valve 07-XV-105 then OPEN this valve by RESETTING the
solenoids at the Local Field Panel.

Note: The well fluids from the Curlew Riser D2 subsea flowline are
now isolated from the HP separator by the Topsides Choke
Valve 07-PCV-0109.

16 RE-OPEN Topsides Choke Valve 07-PCV-0109 choke. This action *


will RE-INTRODUCE well fluids from the flowline to the HP separator.

Note: The 8in choke valve should be stepped up carefully in small


increments of 5% in order to avoid the risk of overpressuring
the HP Separator. It should only be opened above 30% when
the pipeline pressure drops below 100barg.

17 If the DP1 wellhead temperature has fallen below 20C then OPEN *
Methanol Injection Valve 03-MIV-0007 to Curlew Well DP1 xmas tree
upstream of 03-PWV-0006. ENSURE manifold valves 03-XV-1001/2/3
are positioned to provide an open flowpath of methanol.

18 START Methanol injection to Well DP1 and OBSERVE the output * *


pressures and operation.

19 REOPEN 03-PWV-0006 for Curlew well DP1 at the xmas tree. *

20 SLOWLY OPEN Subsea Choke Valve 03-PCV-0008 for Curlew Well *


DP1 to its original setting to RE-ESTABLISH flow from the well.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 63 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.5
Hot Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

21 If the DP2 wellhead temperature has fallen below 20C then OPEN
Methanol Injection Valve 03-MIV-0107 and CLOSE DP1 Methanol
Injection Valve 03-MIV-0007.

22 REOPEN 03-PWV-0106 for Curlew well DP2 at the xmas tree, then *
slowly open Subsea Choke Valve 03-PCV-0108 for Curlew Well
DP2 to its original setting to RE-ESTABLISH flow from the well.

23 OBSERVE arrival temperature topsides at 07-TT-104 and cease * *


Methanol injection if temperature is above 20C.

24 As the well fluids arrive at the FPSO the forward flow of crude oil *
from the HP separator will recommence. Once the operating levels,
temperatures and pressures of the equipment in the downstream
processing facilities returns to normal set the pumps to AUTO from
the CCR. This is to allow the duty produced water transfer pump to
AUTO-START to control the oil/water interface level in the LP
separator.

Note: As the forward flow of fully stabilised crude oil from the plant
increases the Level Control Valve 10-LCV-0314 for the LP
separator will progressively OPEN to INCREASE the flowrate
of dead crude to the Cargo Storage Tanks.

25 RESTART the following chemical injection facilities, as required:

Scale Inhibitor at wellheads and Corrosion Inhibitor topsides


*
Demulsifier and Anti-foam to the crude inlet of the HP, Test
and MP separators
*

26 ENSURE there is no significant DP across the Curlew D1 riser LOCAL *


ESD Valve 07-XV-205 and 07-XXV-200 then OPEN these valves RESET
by RESETTING the solenoids at the Local Field Panel.

27 SLOWLY OPEN the Topsides Choke 07-PCV-209 for Curlew D1 *


Riser until fully open.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 64 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.5
Hot Start-up Procedure - Continued

STEP DESCRIPTION LOCAL PCS

28 REOPEN 03-PWV-1106 for Curlew well DP4 at the xmas tree. *

29 If the temperature downstream of the DP4 choke, as measured on


03-TT-1122, has fallen below 22C then START Methanol injection
to Well DP4 and OBSERVE the output pressures and operation.

30 SLOWLY OPEN Subsea Choke Valve 03-PCV-1108 for Curlew *


Well DP4 to its original setting to RE-ESTABLISH flow from the
well.

31 STOP the methanol injection to well DP4 when temperature * *


downstream of the DP4 choke is above 22C.

32 REOPEN 03-PWV-0306 for Curlew well DP3 at the xmas tree. *

33 If the DP3 wellhead temperature has fallen below 20C then START
Methanol injection to Well DP3 and OBSERVE the output pressures
and operation.

34 SLOWLY OPEN Subsea Choke Valve 03-PCV-0308 for Curlew *


Well DP3 to its original setting to RE-ESTABLISH flow from the
well.

35 STOP the methanol pump when arrival temperatures from D1 and * *


D2 flowlines are above 20C.

36 In order to route Curlew B1 to the Test Separator, RESET the Gas *


Outlet PSD Isolation Valve 20-XV-1191, Oil Outlet PSD Isolation
Valve 10-XV-0518 and Produced Water Outlet PSD Isolation Valve
10-XV-0520 and ENSURE that the controllers are SET as follows:

Vessel Pressure Controller 10-PIC-0507 to AUTO with a


minimal setpoint below 2bar in order to facilitate flowing the
Curlew B well *
Oil/Water Interface Level Controller 10-LIC-0511 to AUTO
with a setpoint of 50%

Oil/Gas Interface Level Controller 10-LIC-0514 to AUTO *


with a setpoint of 50%

ID: M-CPH-1171-01417_EN_Section_5.doc Page 65 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.02.5
Hot Start-up Procedure - Continued

37 ENSURE there is no significant DP across Curlew B1 Riser ESD LOCAL *


Valve 07-XV-300 then OPEN this valve by RESETTING the RESET
solenoids at the Local Field Panel

38 ENSURE there is no significant DP across the Curlew B1 Flowline *


ESD Valve 07-XV-305 then OPEN this valve by RESETTING the
solenoids at the Local Field Panel.

Note: The Curlew B1 Riser is now isolated from the Test separator
by the Topsides Choke Valve 07-PCV-309.

39 SLOWLY OPEN the Topsides Choke 07-PCV-309 for Curlew *


BP-1 Riser until fully open.

40 If the BP1 wellhead temperature has fallen below 20C then START
Methanol injection to Well BP1 and OBSERVE the output pressures
and operation.

41 FULLY OPEN the Subsea Choke Valve 03-PCV-0208 for Curlew *


Well BP1.

42 REOPEN 03-PWV-0206 for Curlew well BP1 at the xmas tree to *


re-establish flow from the well.

43 STOP the methanol pump to Curlew well BP1 when Curlew B1 * *


Flowline arrival temperatures are above 20C as measured on 07-
TT-304.

44 RETURN the Subsea Choke Valve 03-PCV-0208 for Curlew Well *


BP1 to 50% once the FWT has reached 40 50C.

Note: If the well fails to flow immediately, leave the well open to the
Test separator until advised to shut in by Production
engineering.

45 RESTART the following chemical injection facilities, as required:

Scale Inhibitor at BP1 wellhead and Corrosion Inhibitor


*
topsides

Demulsifier and Anti-foam to the crude inlet of the Test


separator *

ID: M-CPH-1171-01417_EN_Section_5.doc Page 66 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.03 Under normal operating conditions the oil processing facilities are
Normal Running automatically controlled via the PCS with minimal field operator
intervention. However, the following checks should be carried out
periodically to ensure that all system equipment is operated within the
desired parameters.

Operational Checks Check all levels, pressures and temperatures throughout the system.

The Field Operator should regularly line walk the system to visually
inspect for leaks, damage, and any system abnormality. Report any
leaks, malfunctions or irregular operating occurrences to the Shift
Supervisor immediately.

The Field Operator should regularly liaise with the control room operator
to cross check the accuracy of the instrumentation, ie the comparison
between the local level gauge and the transmitted level at the PCS.
Where necessary, blowdown the instruments via their impulse lines.

Note: The blowdown of instruments must be a controlled operation


when hydrocarbon gases are concerned.

Visually inspect the condition of the equipment and pipework for


corrosion. Excessive corrosion must be reported to supervision.

Visually inspect the condition of the key operated interlocks for the
pressure safety relief valves included in the system. Protect against the
weather with grease or other weather proofing materials.

Check the chemical injection rates are correctly set for the flowrates
through the oil processing facilities and the rates as necessary.

If production rates up both Curlew D risers does not achieve arrival


temperatures that exceed the wax appearance temperature of 35C then
Curlew D should be changed to single riser production, However,
commingling flow via both flowlines hydraulically unconstrains Curlew D
production as FTHPs decline.

Monitor well arrival temperatures to check if wax inhibitor injection


becomes a requirement. Routinely monitor for wax deposits through
recording pipeline pressure drop at various rates.

Check the inventory of the following chemical stocks:


Methanol
Demulsifier
Anti-foam
Scale Inhibitor
Corrosion Inhibitor
Wax Inhibitor

ID: M-CPH-1171-01417_EN_Section_5.doc Page 67 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.03 Shift operator log books are to contain sufficient detail of the plant status
Normal Running - including any deviation from the norm such as well alignment or vessel
Continued isolations, in particular isolations to any protective equipment.

Off-going shift operators are to ensure that the oncoming shift operators
are full briefed on the status of the plant as detailed in the log book.

Both the off-going and oncoming shift operators must sign the Area Log
Book before shift responsibility is handed over.

Test/HP/MP Separators (1) Monitor the operation of the separators, ensuring that the
automatic pressure and level control systems are maintaining the
operating conditions of the vessels at the desired values.

(2) Check the water in oil concentration of the crude outlet from the
test, HP and MP separators. If the three-phase separation process
in these vessels is working efficiently the water in oil concentration
should not exceed 5.0% (volume).

(3) Check the oil in water concentration of the produced water from
the test, HP and LP separators. If the three phase separation
process in these vessels is working efficiently the oil in water
concentration should not exceed 200 to 300PPM.

HP/MP Crude Oil Heaters (1) Monitor the operation of the heaters, ensuring that the automatic
temperature control systems are maintaining the temperature of
the incoming crude at the desired temperature of 75oC for the HP
crude oil heater and 67oC for the MP crude oil heater.

(2) Check the pressure of the heating medium supply to and return
from the heaters. Low pressures for the heating medium supply
and return are indicative of a heating medium distribution fault and
not a problem with the crude oil heaters.

LP Separator (1) Monitor the operation of the LP separator, ensuring that the
automatic pressure and level control systems are maintaining the
operating conditions of the vessels at the desired values.

(2) Ensure that the duty produced water transfer pump auto-starts on
demand to control the oil/water interface level in the LP separator.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 68 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.03
Normal Running -
Continued

Produced Water/Crude Oil (1) Check the pump suction and discharge pressure readings are
Transfer Pumps normal by observing the local pressure gauges on the suction and
discharge lines.

(2) Check all joints, valve glands and mechanical seals for leaks.

(3) Check the pumpset for unusual/excessive noise or vibration.

Electrostatic Coalescer (1) Check the local control panel and investigate alarm or trip
conditions.

Export Crude Oil Cooler (1) Monitor the operation of the export crude oil cooler, ensuring that
the automatic temperature control system is maintaining the
stabilised crude exiting the cooler at the desired temperature of
30oC.

(2) Check the pressure of the cooling medium supply to and return
from the cooler.
Low operating pressures for the cooling medium supply and
return are indicative of a cooling seawater distribution fault and not
a problem with the crude oil cooler internals.

Curlew D Single Flowline (1) Check single riser production is sufficient for the target production
Capacity rate by referring to the chart below. The chart provides capacity
liquid and gas rate for a particular flowing tubing head pressure.
Optimise oil rate up single riser from Curlew D wells by using
selected well choke settings as advised by Production Dept.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 69 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.04
Planned Shutdown of the
Oil Processing Facilities

5.04.1 The following planned shutdown procedure describes the shutdown of


Preamble the oil processing facilities as part of an overall shutdown of the FPSO
processing facilities in preparation for major inspection/maintenance
activities that are described in Section 6 of this Volume.

The planned shutdown procedure for the Oil Processing Facilities can be
summarised in the following major steps:

Commence Methanol injection to the subsea production facilities.


This is to protect the entire length of the flowlines from hydrate
formation once production has stopped

Reduce the flowrate of well fluids from the Curlew D and B


reservoirs by progressively shutting in the wells

Direct the decreasing flowrate of crude oil to the selected Crude


Oil Storage Tanks

Depressurise all flowlines to the separation vessels in the oil


processing facilities

Flush the crude inventories of the separation vessels to the crude


storage tanks using the jetting facilities and deaerated seawater

Shutdown the Electrostatic Coalescer

Shutdown the duty Crude Oil Transfer Pump and Produced


Water Return Pump

Reduce the liquid levels in the separation vessels to LALL.

Depressurise the separation vessels in the oil processing


facilities

Shut in and drain the heating and cooling medium from the
heaters and crude oil cooler

ID: M-CPH-1171-01417_EN_Section_5.doc Page 70 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.04.2 (1) No Permits to Work or electrical isolations are in force which may
Preconditions prohibit the shutdown of the Oil Processing Facilities.

(2) The Fire and Gas Detection/Protection, Distributed Control


System (DCS), Safety Related Systems (PSDs) are operational
along with the alarms, trips, and controllers.

(3) Safety meetings have been held with all directly and indirectly
concerned parties, outlining the workscope and procedures.

Note: All drainings from the oil processing facilities must be directed to
the Hazardous Area Open Drains which are suitable for disposing
of liquid hydrocarbons.

(4) Communications have been established between the personnel


involved in this procedure.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 71 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.04.3
Planned Shutdown Procedure

STEP DESCRIPTION LOCAL PCS

1 COMMENCE methanol injection to the xmas trees for the Curlew D * *


production wells. In order to ensure the flowlines are inhibited
methanol injection must continue for at least a 2-hour period and at a
rate of approximately 1.2m/h prior to shutting in the wells. Each well
that has been in operation should have methanol injected to it for at
least half an hour in turn.

Note: Time to dose the flowlines will depend on production rates and
must ensure the whole flowline and riser is inhibited.

2 COMMENCE methanol injection to the BP1 xmas tree to inhibit the


Curlew B flowline. Methanol injection must continue for at least 1-hour
and at a rate of approximately 1.2m/h prior to shutting the well.

Note: Time to dose the flowlines will depend on production rates and
must ensure the whole flowline and riser is inhibited.

3 SHUT DOWN all chemical injection pumps lined up to the Oil *


Processing Facilities.

4 PROGRESSIVELY CLOSE the Subsea Choke Valves for the Curlew


production wells.

5 CLOSE the Tree Valves for the Curlew production wells: PWV, *
PUMV, SSSV and then MIV, CIVs.

The following shutdown steps may also be implemented at the


discretion of the Production Supervisor. These relate to
shutdown of the rest of the oil processing facilities.

6 Once all forward flow of well fluids through the swivel stack has *
ceased, the Leak Recuperation System must be SHUT DOWN.
Details on how to operate these facilities are provided in Sections 4
and 5 of Operating Procedures Manual Volume 1 Book A - Subsea
Facilities.

7 ENSURE that the Crude Oil Transfer Pump in service is operating on * *


FULL RECYCLE once all forward flow through the Oil Processing
Facilities ceases.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 72 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.04.3
Planned Shutdown Procedure - Continued

STEP DESCRIPTION LOCAL PCS

8 ENSURE that the Produced Water Transfer Pump selected for service *
has shut down on demand from the LP Separator oil/water interface
controller. SET the pumps to manual and STOP from the CCR for
both produced water transfer pumps. This is to prevent the pumps
AUTO-STARTING on demand when the LP Separator is water
flushed later in the procedure.

9 At this point in the procedure it will be necessary to WATER FLUSH


the separation vessels in preparation for boundary isolation using the
sand jetting facilities and utility seawater. The Marine Supervisor must
SELECT the appropriate tank loading sequence to LINE UP the Oil
Processing Facilities to the Crude Oil Storage Tanks.

10 CONNECT a hose suitable for jetwashing operations to the hose * *


connection for the HP separator jetting water manifold and
INTRODUCE seawater into the vessel by OPENING the individual
Jetting Water Valve(s).

11 Slowly RAISE the setpoint of Oil/Water Interface Level Controller 10- *


LIC-0111 for the HP separator to increase the produced water level in
the separator to just above the weir (@ +1.11m above the vessel
bottom elevation).

Note: This action will eventually introduce seawater into the oilside
of the HP Separator, which in time will displace all the oil from
the vessel through the HP Crude Oil Heater to the MP
Separator. Once flushing operations on the HP separator have
been completed, the Test separator can be FLUSHED to the
MP Separator in an identical manner.

12 JETWASH the HP Separator until all crude has been displaced from * *
the vessel. The belly drains for the vessel can be periodically opened
to the Skid Drip Pan to confirm when all oil is displaced from the
vessel.

Note: To ensure that there is adequate pressure differential (about


2bar) to drive the crude to downstream oil processing system, it
may be necessary to recharge the HP Separator pressure with
nitrogen and/or lowering the pressure of the MP separator.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 73 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.04.3
Planned Shutdown Procedure - Continued

STEP DESCRIPTION LOCAL PCS

13 SLOWLY LOWER the produced water level in the HP Separator to a * *


minimum without gas blowby by DECREASING the setpoint of 10-
LIC-0111 to just below the trip setting (@ +0.2m above the vessel
bottom elevation). MONITOR the decreasing level in the HP separator
via the Local Gauge 10-LG-0116.

14 SLOWLY LOWER the oil level in the HP separator to a minimum * *


without gas blowby by DECREASING the setpoint of Level Controller
10-LIC-0114 to just below the trip setting (@ +0.95m above vessel
bottom elevation). MONITOR the decreasing level in the separator via
Local Gauge 10-LG-0117.

Note: The field operator must ENSURE that the PSD Isolation Valve
10-XV-0118 on the oil outlet from the vessel and also 40-XV-
0103 and 40-XV-0104 at the HP Hydrocyclone move to the
CLOSED position as a result of procedural steps 15 and 16
above. This is to test the effectiveness of the shutdown system.

15 The Test Separator can be isolated in a similar manner to the


HP Separator.

16 CONNECT a hose suitable for jet-washing operations to the hose * *


connection for the MP Separator jetting water manifold and
INTRODUCE seawater into the vessel by OPENING the individual
Jetting Water Valve(s).

17 Slowly RAISE the setpoint of Oil/Water Interface Level Controller 10- *


LIC-0211 for the MP Separator to increase the produced water level in
the separator to just above the weir (@ +1.28m above vessel bottom
elevation).

Note: This action will eventually introduce seawater into the oil side
of the MP separator which in time will displace all the oil from
the vessel through the MP crude oil heater to the LP separator.

18 JETWASH the MP Separator until all crude has been displaced from * *
the vessel. The belly drains for the vessel can be periodically opened
to the Skid Drip Pan to confirm when all oil is displaced from the
vessel.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 74 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.04.3
Planned Shutdown Procedure - Continued

STEP DESCRIPTION LOCAL PCS

19 SLOWLY LOWER the produced water level in the MP Separator to a * *


minimum without gas blowby by DECREASING the setpoint of 10-
LIC-0211 to just below the trip setting (@ +0.2m above the vessel
bottom elevation). MONITOR the decreasing level in the MP
separator via the Local Gauge 10-LG-0216.

20 SLOWLY LOWER the oil level in the MP separator to a minimum * *


without gas blowby by DECREASING the setpoint of Level Controller
10-LIC-0214 to just below the trip setting (@ +1.14m above the vessel
bottom elevation). MONITOR the decreasing level in the separator via
the Local Gauge 10-LG-0217.

Note: The field operator must ENSURE that the PSD Isolation Valve
10-XV-0218 on the oil outlet from the vessel and also 40-XV-
0203 and 40-XV-0204 at the MP Hydrocyclone move to the
CLOSED position as a result of actions 21 and 22 above. This
is to test the effectiveness of the shutdown system.

21 CONNECT a hose suitable for jet-washing operations to the hose * *


connection for the LP Separator jetting water manifold, and
INTRODUCE seawater into the vessel by OPENING the individual
Jetting Water Valve(s).

22 Slowly RAISE the setpoint of Oil/Water Interface Level Controller 10- *


LIC-0311 for the LP Separator to increase the produced water level in
the separator to just above the weir (@ +1.28m above the vessel
bottom elevation).

Note: This action will eventually introduce seawater into the oil side
of the LP separator which in time will displace all the oil from
the vessel.

23 As the crude inventory in the LP separator is replaced by seawater *


ENSURE that the duty crude oil transfer continues to operate
normally. The crude oil transfer pumps are designed to pump crude oil
from the separator to the electrostatic coalescer with a maximum
water content of 0.05% (volume), so it is bad operating practice to
pump water for a prolonged period of time.

24 JETWASH the LP Separator until all crude has been displaced from * *
the vessel. The belly drains for the vessel can be periodically opened
to the Skid Drip Pan to confirm when all oil is displaced from the
vessel.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.04.3
Planned Shutdown Procedure - Continued

STEP DESCRIPTION LOCAL PCS

25 SLOWLY LOWER the water level in the LP separator to just below the * *
trip setting (@ +0.2m above the vessel bottom elevation) by opening
the belly drains for the vessel. MONITOR the decreasing level in the
LP separator via the Local Gauge 20-LG-0317.

Note: The Field Operator must ENSURE that the PSD Isolation
Valve 10-XV-0334 on the produced water outlet from the vessel
moves to the CLOSED position as a result of this action. This is
to test the effectiveness of the shutdown system.

26 INSTALL the override for the Low low Oil Level Trip 10-LSLL-0406 for */CCR
the Electrostatic Coalescer. As the flowrate of crude oil to this vessel
from the duty crude oil transfer pump DECREASES the operating
level in the coalescer will fall.

27 RAISE the setpoint of oil/water Interface Level Controller */CCR


10-LIC-0401 to 100%. This will ensure that all crude is removed from
the vessel.

28 SWITCH OFF the power to the electrodes for the Electrostatic *


Coalescer at the Local Control Panel prior to commencement of drain
down operations from the coalescer.

29 SLOWLY LOWER the oil level in the LP separator to a minimum * *


without gas blowby by DECREASING the setpoint of Level Controller
10-LIC-0314 to just below the trip setting (@+1.15m above the vessel
bottom elevation). MONITOR the decreasing level in the separator via
the Local Gauge 10-LG-0317.

Note: The Field Operator must ENSURE that the PSD Isolation
Valve 10-XV-0335 on the oil outlet from the vessel moves to the
CLOSED position and the duty crude oil transfer pump trips as
a result of this action. This will stop all forward flow of seawater
and any remaining crude and test the effectiveness of the
shutdown system.

30 DEPRESSURISE the Test separator to the HP Flare System by *


OPENING the Pressure Controller 10-PIC-0507 for the vessel in
MANUAL mode. This will TRIP the Test separator on low low
pressure.

Note: The Field Operator must ENSURE that the PSD Isolation
Valve 21-XV-1191 on the gas outlet line from the Test
separator moves to the CLOSED position. This is to test the
effectiveness of the shutdown system.

ID: M-CPH-1171-01417_EN_Section_5.doc Page 76 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.04.3
Planned Shutdown Procedure - Continued

STEP DESCRIPTION LOCAL PCS

31 DEPRESSURISE the HP separator to the HP Flare System by *


OPENING the Pressure Controller 10-PIC-0107 for the vessel in
MANUAL mode. This will TRIP the HP separator on low low pressure.

Note: The Field Operator must ENSURE that the PSD Isolation
Valve 22-XV-1051 and Bypass Valve 22-XV-1052 on the gas
outlet line from the HP separator moves to the CLOSED
position. This is to test the effectiveness of the shutdown
system.

32 DEPRESSURISE the MP separator to the HP Flare System by FULLY *


OPENING the Pressure Controller 10-PIC-0207 for the vessel in
MANUAL mode. This will TRIP the MP separator on low low pressure.

Note: The Field Operator must ENSURE that the PSD Isolation
Valve 22-XV-1201 and Bypass Valve 22-XV-1202 on the gas
outlet line from the MP separator move to the CLOSED position
as a result of this action. This is to test the effectiveness of the
shutdown system.

33 DEPRESSURISE the LP separator to the LP Flare System by FULLY *


OPENING the Pressure Controller 10-PIC-0307 for the vessel in
MANUAL mode This will TRIP the LP separator on low low pressure.

Note: The Field Operator must ENSURE that the PSD Isolation
Valve 22-XV-1221 on the gas outlet line from the LP separator
moves to the CLOSED position as a result of this action. This is
to test the effectiveness of the shutdown system.

34 CLOSE the 4in isolation ball valve on the heating medium supply line *
to the HP crude oil heater and ENSURE the PSD Isolation Valve 44-
XV-2017 on the heating medium return line from the heater is
CLOSED.

35 CLOSE the 6in isolation ball valves on the heating medium supply *
and return lines for the MP Crude Oil heater.

36 CLOSE the 6in isolation ball valves on the cooling medium supply *
and return lines to and from the crude oil cooler.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.05
Unplanned Shutdown of
the Oil Processing
Facilities

5.05.1 The following unplanned shutdown procedure describes the shutdown of


Preamble the oil processing facilities as part of a Process Trip or Production Stop.

The unplanned shutdown procedure for the Oil Processing Facilities can
be summarised in the following major steps:

Methanol injection into the wellhead

Depressurise all flowlines to the separation vessels in the oil


processing facilities

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MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.05.2
Unplanned Shutdown Procedure

STEP DESCRIPTION LOCAL PCS

There are several unplanned shutdown scenarios with each case


requiring different actions.

Short shutdowns where an immediate restart is expected and the


temperature downstream of the subsea chokes does not drop below
22 C will not require shutdown actions.

Short shutdown where restart is expected to be within the flowline no


touch time (likely no less than 4 hours). Inject methanol upstream and
downstream of all producing wells subsea chokes.

Shutdowns expected to exceed 4 hours where the flowline


temperature falls below the hydrate formation temperature of 20C.
Inject methanol upstream and downstream of all producing wells
subsea chokes and depressurise the flowlines if possible.
Note: if wells remain open under a process trip then a restart is required or
all tree valves should be closed before the pipeline pressure rises
above circa. 50barg.

Methanol Injection

1 Inject 0.5m of methanol upstream and downstream of the subsea choke * *


for each producing well in turn to protect the immediate area that is subject
to rapid cooldown.

Flowline Depressurisation

2 All flowlines must be DEPRESSURISED to 10barg for flowline hydrate *


suppression if the shutdown time is to exceed 4 hours. It will be necessary
to temporarily install the overrides for the Low Low Pressure Trips 07-
PALL-301, 07-PALL-201 and 07-PALL-101 on the risers prior to the start
of depressurisation. Depressurisation should be carefully controlled and
the rate should not exceed 100 bar/hour for the Curlew D Risers and 10
bar/hour for Riser B1.

3 SLOWLY REDUCE the setpoint of the Pressure Controller *


for the HP separator and Test separator from operating pressure to about
10barg. This allows the Curlew flowlines to settle out to separator
pressure.

4 CLOSE the Tree Valves AMV, PUMV and PWV in addition to the subsea *
choke valves for all Curlew wells.

5 Once the Curlew flowlines are depressurised to 10barg CLOSE the *


Topsides Choke Valves (07-PCV-0109, 07-PCV-0209 and 07-PCV-0309).

ID: M-CPH-1171-01417_EN_Section_5.doc Page 79 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

5.06
Process and Emergency Refer to Drawing Nos CUR-MAS-PB-20655.
Cause and Effect Charts

5.07 Figure 5.01 on the following page shows a typical PSV arrangement with
Pressure Safety Valve PSV A in service and PSV B isolated in the maintenance position. The
Five Key Interlock purpose of the 5 key Interlock System is to ensure that one PSV is
Operations always on line. Each isolating valve has two (2) locks. One lock has a
key locked in, the second has the key removed. The fifth key is held by
the Production Supervisor. The valves are changed out as follows:

Obtain the A key for the PSV set from the Production Supervisor

Insert the A key in the empty lock on the closed flare side valve
on PSV B and open the valve to release the trapped B key. The
supervisors A key remains in the lock

Insert the retrieved B key in the locked closed valve below


PSV B and open the valve to release the trapped C key. The B
key originally from the flare side of PSV B remained trapped

Insert the retrieved C key in the locked open valve below


PSV A and close the valve to release the trapped D key. The C
key originally from the process side valve of PSV B remains
trapped

Insert the D key in the locked open flare side valve on PSV A
and close the valve to release the trapped E key. The final E key
is now released and returned to the supervisor

This sequence is for switching B into service and isolating A.


The procedures is reversed to switch from A to B.

For a full maintenance isolation of both PSVs, typically when the process
vessel is to be removed from service for a vessel entry, then a sixth key
(the maintenance key) is required to enable all four isolation valves to be
closed.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Operating Procedures 002 / MAY 2010

INTERLOCKED VALVES

TO FLARE HEADER

PSV PSV
A B

FLARE SIDE FLARE SIDE


VALVE VALVE

VESSEL VESSEL
SIDE VALVE SIDE VALVE

VESSEL

NOTE:
Relief valve PSV shown isolated for maintenance. In normal operation
both flare side isolation valves are open. The on-line relief valve vessel
side isolation valve in open and the off-line valve vessel side isolation
valve in closed.

N41B3.005

Fig 5.01 Interlocked Pressure Safety Valves

ID: M-CPH-1171-01417_EN_Section_5.doc Page 81 / 81


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

Isolation/Reinstatement Procedures

6.01 Oil Processing Facilities, Boundary Isolation, Flushing, Draining and


Nitrogen Purging Operations
6.01.1 Introduction
6.01.2 Preconditions
6.01.3 Boundary Isolation
6.01.4 Oil Processing Facilities, Flushing Operation - Part 1
Oil Processing Facilities, Flushing Operation - Part 2
6.01.5 Oil Processing Facilities, Nitrogen Purging Operation
6.01.6 Oil Processing Facilities Boundary Isolation Valve Checklist

6.02 Test Separator V-1005


6.02.1 Preconditions
6.02.2 Preparation for Vessel Entry Procedure
6.02.3 Reinstatement Procedure
6.02.4 Spading Checklist V-1005

6.03 HP Separator V-1001


6.03.1 Preconditions
6.03.2 Preparation for Vessel Entry Procedure
6.03.3 Reinstatement Procedure
6.03.4 Spading Checklist V-1001

6.04 HP Crude Oil Heater E-1001


6.04.1 Preconditions
6.04.2 Isolation Procedure
6.04.3 Reinstatement Procedure
6.04.4 Spading Checklist E-1001

6.05 MP Separator V-1002


6.05.1 Preconditions
6.05.2 Preparation for Vessel Entry Procedure
6.05.3 Reinstatement Procedure
6.05.4 Spading Checklist V-1002

6.06 MP Crude Oil Heater E-1002


6.06.1 Preconditions
6.06.2 Isolation Procedure
6.06.3 Reinstatement Procedure
6.06.4 Spading Checklist E-1002

6.07 LP Separator V-1003


6.07.1 Preconditions
6.07.2 Preparation for Vessel Entry Procedure
6.07.3 Reinstatement Procedure
6.07.4 Spading Checklist V-1003

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

Isolation/Reinstatement Procedures (Continued)

6.08 Produced Water Transfer Pumps P-1002A/B


6.08.1 Preconditions
6.08.2 Isolation Procedure
6.08.3 Reinstatement Procedure
6.08.4 Valve Isolation Checklist P-1002A (Stand-alone)
6.08.5 Valve Isolation Checklist P-1002B (Stand-alone)
6.08.6 Spading Checklist P-1002A
6.08.7 Spading Checklist P-1002B

6.09 Crude Oil Transfer Pumps P-1001A/B


6.09.1 Preconditions
6.09.2 Isolation Procedure
6.09.3 Reinstatement Procedure
6.09.4 Valve Isolation Checklist P-1001A (Stand-alone)
6.09.5 Valve Isolation Checklist P-1001B (Stand-alone)
6.09.6 Spading Checklist P-1001A
6.09.7 Spading Checklist P-1001B

6.10 Electrostatic Coalescer V-1004


6.10.1 Preconditions
6.10.2 Preparation for Vessel Entry Procedure
6.10.3 Reinstatement Procedure
6.10.4 Spading Checklist V-1004

6.11 Export Crude Oil Cooler E-1004


6.11.1 Preconditions
6.11.2 Isolation Procedure
6.11.3 Reinstatement Procedure
6.11.4 Spading Checklist E-1004

6.12 Oil Processing Facilities Boundary Reinstatement


6.12.1 Introduction
6.12.2 Boundary Reinstatement

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01 WARNING: THIS PROCEDURE MUST BE READ


Oil Processing Facilities, AND FULLY UNDERSTOOD BEFORE
Boundary Isolation, ATTEMPTING TO CARRY OUT ANY ACTION.
Flushing, Draining and
Nitrogen Purging
Operations

6.01.1 The oil processing facilities have been shut down, and jetwashed with
Introduction utility seawater in preparation for major maintenance activities. Details of
this operation are described in the planned shutdown procedure included
in Section 5.05 of this book.

The Boundary Isolation provides a safe haven for work to be conducted


within the whole system, specifically during an annual shutdown for
maintenance activities.

Each Work Permit issued thereafter shall have a copy of the Boundary
Isolation issued with it, together with any Mechanical (spading), Electrical
or Instrument isolations and any Vessel Entry Permits required for the
specific task in hand.

The Boundary Isolation shall remain in place until all work within its
confines has been completed.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.2 (1) All the necessary Work Permits have been raised and authorised
Preconditions prior to commencing this procedure and controls have been
established in accordance with Maersk Work Permit Procedures.

(2) No operations or Work Permits are in force which may prohibit


this procedure.

(3) The following equipment is electrically isolated and an Electrical


Isolation Certificate issued for each facility:

Heat Tracing Circuits for all Pipework and Instrumentation


Produced Water Transfer Pumps, P-1002A/B
Crude Oil Transfer Pumps, P-1001A/B
Electrostatic Coalescer, V-1004
All Chemical Injection Pumps for the Oil Processing Facilities

(4) The Subsea Control System for the oil production wells is no
longer required for service. Therefore the Topsides HPU, EPU and
MCS have been shut down for an extended period. Details on the
shutdown of the subsea control system are provided in Section 5
of Operating Procedures Manual Volume 1 Book A - Subsea
Facilities.

6.01.2 (5) There is sufficient capacity in the Hazardous Drains Collection


Preconditions (Continued) Tank T-6001 to accept the flushed contents of vessels, pumps and
equipment in the Oil Processing Facilities. Excess liquids from the
hazardous drains collection tank are routinely pumped to the Port
Slops Tank for safe disposal.

(6) All pipework rendered open-ended during the isolation of plant for
the maintenance/inspection must be spaded/blanked off to the
potentially live section of line with correctly rated flanges.

This procedure should be used in conjunction with the Boundary Isolation


Checklist, and with the following marked up P&IDs included at the end of
the procedure.

WARNING: THE EXEMPLARY PROCEDURES INCLUDED IN THIS


SECTION WERE RAISED IN 1996 AND ARE INCLUDED
NOW AS AN AID TO OPERATORS. ACTUAL
ISOLATIONS MUST BE MADE AGAINST LATEST
CONTROLLED COPIES OF THE P&IDS AND IN
ACCORDANCE WITH THE CURRENT OPERATIONAL
MANAGEMENT SYSTEM, SPECIFICALLY THE
ISOLATIONS STANDARDS AND PROCEDURES.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.3 The closing and securing of all isolation valves and isolation of electrical
Boundary Isolation equipment must be in accordance with Maersk Isolation Philosophy
Document Number CUR-MAS-PB-20656.

Refer to P&ID (1) ENSURE that the Spare Riser ESD Valve 07-XXV-0500 is
CUR-MAS-TP-42035-001 CLOSED, then DISABLE and TAG the hydraulically operated
actuator.

(2) ENSURE that the Double Block and Bleed Valve for the Spare
Riser low point drain line (downstream of the ESD valve) is
CLOSED, then LOCK and TAG the valve.

(3) ENSURE that the Double Block and Bleed Valve for the Spare
Flowline methanol injection point is CLOSED, then LOCK and
TAG the valve.

(4) ENSURE that the Spare Flowline ESD Valve 07-XV-0505 is


CLOSED, then DISABLE and TAG the hydraulically operated
actuator.

(5) ENSURE that the Double Block and Bleed Valve for the Spare
Flowline corrosion inhibitor injection point is CLOSED, then LOCK
and TAG the valve.

(6) ENSURE that the Double Block and Bleed Valve for the Spare
Flowline low point drain line (downstream of the topsides choke
valve) is CLOSED.

Refer to P&ID (7) ENSURE that the BP1 Riser ESD Valve 07-XXV-300 is CLOSED,
CUR-MAS-TP-42002-001 then DISABLE and TAG the hydraulically operated actuator.

(8) ENSURE that the Double Block and Bleed Valve for BP1 Riser
low point drain line (downstream of the ESD valve) is CLOSED,
then LOCK and TAG the valve.

(9) ENSURE that the Double Block and Bleed Valve for BP1 Flowline
methanol injection point is CLOSED, then LOCK and TAG the
valve.

(10) ENSURE that the BP1 Flowline ESD Valve 07-XV-305 is


CLOSED, then DISABLE and TAG the hydraulically operated
actuator.

(11) ENSURE that the Double Block and Bleed Valve for BP1 Flowline
corrosion inhibitor injection point is CLOSED, then LOCK and TAG
the valve.

(12) ENSURE that the Double Block and Bleed Valve for BP1 Flowline
low point drain line (downstream of the topsides choke valve) is
CLOSED.

Note: DO NOT LOCK this valve closed until after the flushing operation.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.3 (13) ENSURE that the DP1 Riser ESD Valve 07-XXV-200 is
Boundary Isolation CLOSED, then DISABLE and TAG the hydraulically operated
actuator.
(Continued)

(14) ENSURE that the Double Block and Bleed Valve for DP1 Riser
low point drain line (downstream of the ESD valve) is CLOSED,
then LOCK and TAG the valve.

(15) ENSURE that the Double Block and Bleed Valve for DP1
Flowline methanol injection point is CLOSED, then LOCK and
TAG the valve.

(16) ENSURE that the DP1 Flowline ESD Valve 07-XV-205 is


CLOSED, then DISABLE and TAG the hydraulically operated
actuator.

(17) ENSURE that the Double Block and Bleed Valve for DP1
Flowline corrosion inhibitor injection point is CLOSED, then LOCK
and TAG the valve.

(18) ENSURE that the Double Block and Bleed Valve for DP1
Flowline low point drain line (downstream of the topsides choke
valve) is CLOSED.

Note: DO NOT LOCK this valve closed until after the flushing operation.

(19) ENSURE that the DP2 Riser ESD Valve 07-XXV-100 is


CLOSED, then DISABLE and TAG the hydraulically operated
actuator.

(20) ENSURE that the Double Block and Bleed Valve for DP2 Riser
low point drain line (downstream of the ESD valve) is CLOSED,
then LOCK and TAG the valve.

(21) ENSURE that the Double Block and Bleed Valve for DP2
Flowline methanol injection point is CLOSED, then LOCK and
TAG the valve.

(22) ENSURE that the DP2 Flowline ESD Valve 07-XV-105 is


CLOSED, then DISABLE and TAG the hydraulically operated
actuator.

(23) ENSURE that the Double Block and Bleed Valve for DP2 Flowline
corrosion inhibitor injection point is CLOSED, then LOCK and TAG
the valve.

(24) ENSURE that the Double Block and Bleed Valve for DP2 Flowline
low point drain line (downstream of the topsides choke valve) is
CLOSED.

Note: DO NOT LOCK this valve closed until after the flushing operation.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

Refer to P&ID (25) CLOSE, LOCK and TAG the in Isolation Block Valve
CUR-MAS-PM-20048-501 HV-73007 at the demulsifier injection point on the inlet header to
the Test separator.

(26) CLOSE, LOCK and TAG the in Isolation Block Valve


HV-73009 at the defoamer injection point on the inlet header to the
Test separator.

(27) ENSURE that the ESD Valve 10-XV-0501 on the Blowdown Line
from the Test separator to the HP Flare Header is CLOSED, then
CLOSE, LOCK and TAG the downstream isolation ball valve.

(28) ENSURE that the three 1in Isolation Ball Valves on the manual
depressurisation line to LP Flare for the Test separator are
CLOSED.

Note: DO NOT LOCK these valves closed until after the nitrogen purge
operation.

(29) CLOSE, LOCK and TAG the 6in isolation ball valves
downstream of Pressure Safety Relief Valves 10-PSV-0503A
and 10-PSV-0503B.

Note: This will require the use of the sixth key (maintenance key) and
will result in all four isolation valves for the interlocked pressure
safety relief valves being closed.

(30) ENSURE that the isolation valves to HP Flare for the bypass
line around the pressure safety relief valves are CLOSED,
then LOCK and TAG the valves.

(31) ENSURE that the isolation valves for the gas outlet sample line
are CLOSED, then LOCK and TAG the valves.

(32) CLOSE, LOCK and TAG the Double Block and Bleed Valve
HV-10253/4 downstream of 10-PCV-0507B on the gas outlet
line from the Test separator to the HP Flare Header.

(33) CLOSE, LOCK and TAG the Double Block and Bleed Valve
HV-10258/9 downstream of 10-PCV-0507A on the gas outlet
line from the Test separator to the Gas Compression Facilities.

(34) ENSURE that the isolation valves HV-10283 and HV-10284 for
the crude outlet sample line are CLOSED.

Note: DO NOT LOCK these valves closed until after the flushing
operation.
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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

(35) CLOSE, LOCK and TAG the 4in Isolation Ball Valve
HV-10281 on the produced water outlet line from the Test
separator to the Test Hydrocyclone/HP Hydrocyclone.

(36) ENSURE that the Jetting Water Valve HV-10273 is CLOSED.

(37) ENSURE that the Jetting Water Valve HV-10275 is CLOSED.

(38) ENSURE that the Jetting Water Valve HV-10277 is CLOSED.

Note: DO NOT LOCK these valves closed until after the flushing
operation.

Refer to P&ID (39) ENSURE that the PSD Valve 20-XV-1191 for the gas outlet
CUR-MAS-PB-20048-002 from the Test separator is CLOSED, then DISABLE and TAG
the pneumatically operated actuator.

6.01.3
Boundary Isolation
(Continued)
Refer to P&ID (40) CLOSE, LOCK and TAG the in Isolation Block Valve HV-73001
CUR-MAS-PM-20041-501 at the demulsifier injection point on the inlet header to the HP
Separator

(41) CLOSE, LOCK and TAG the in Isolation Block Valve HV-73002
at the defoamer injection point on the inlet header to the HP
Separator.

(42) ENSURE that the ESD Valve 10-XV-0101 on the Blowdown Line
from the HP separator to the HP Flare Header is CLOSED, then
CLOSE, LOCK and TAG the downstream isolation ball valve.

(43) ENSURE the 1in Isolation Ball Valves on the manual


depressurisation line for the HP separator are CLOSED.

Note: DO NOT LOCK these valves closed until after the nitrogen purge
operation.

(44) CLOSE, LOCK and TAG the 8in isolation ball valves downstream
of Pressure Safety Relief Valves 10-PSV-0103A and 10-PSV-
0103B.

Note: This will require the use of the sixth key (maintenance key) and
will result in all four isolation valves for the interlocked pressure
ID: M-CPH-1171-01417_EN_Section_6.doc Page 8 / 105
MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

safety relief valves being closed.

(45) ENSURE that the isolation valves for the bypass line around the
pressure safety relief valves are CLOSED, then LOCK and TAG
the valves.

(46) ENSURE that the isolation valve HV-10021 for the gas outlet
sample line are CLOSED, then LOCK and TAG the valves.

(47) ENSURE that the isolation valves HV-10049 and HV-10050 for
the crude outlet sample line are CLOSED.

Note: DO NOT LOCK these valves closed until after the flushing
operation.

(48) CLOSE, LOCK and TAG the 6in Isolation Ball Valve HV-10046 on
the produced water outlet line from the HP separator to the HP
Hydrocyclone/Test Hydrocyclone.

(49) ENSURE that the Jetting Water Valve HV-10037 is CLOSED.

(50) ENSURE that the Jetting Water Valve HV-10039 is CLOSED.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.3 (51) ENSURE that the Jetting Water Valve HV-10041 is CLOSED.
Boundary Isolation
(Continued)
(52) ENSURE that the Jetting Water Valve HV-10043 is CLOSED.

(53) ENSURE that the Jetting Water Valve HV-10060 is CLOSED.

Note: DO NOT LOCK these valves closed until after the flushing
operation.

Refer to P&ID (54) CLOSE, LOCK and TAG the 14in Isolation Ball Valve HV-22001
CUR-MAS-PB-20041-002 downstream of 10-PCV-0107 on the gas outlet line from the HP
separator to the HP Flare Header.

(55) CLOSE, LOCK and TAG the 4in Isolation Ball Valve HV-52002 on
the gas outlet line from the HP separator to the Fuel Gas Cooler E-
5202.

(56) ENSURE that the PSD Valve 22-XV-1051 for the gas outlet from
the HP separator is CLOSED, then DISABLE and TAG the
pneumatically operated actuator.

(57) ENSURE that the Bypass Valve 22-XV-1052 for the gas outlet
from the HP separator is CLOSED, then DISABLE and TAG the
pneumatically operated actuator.

(58) CLOSE, LOCK and TAG the 10in Isolation Ball Valve
HV-22002 on the gas outlet line from the HP separator to the Inlet
Cooler E-2201.

Refer to P&ID (59) ENSURE that the PSD Isolation Valve 44-XV-2017 on the heating
CUR-MAS-PM-20042-501 medium return from the HP crude oil heater is CLOSED, then
DISABLE and TAG the pneumatically operated actuator.

(60) ENSURE that the 4in Isolation Ball Valve HV-44054 on the
heating medium supply to the HP crude oil heater is CLOSED,
then LOCK and TAG the valve.

(61) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-10067
downstream of 10-PSV-0153 for the crude oil outlet from the HP
crude oil heater.

Refer to P&ID (62) CLOSE, LOCK and TAG the in Isolation Block Valve HV-73004
CUR-MAS-PM-20043-501 at the demulsifier injection point on the inlet header to the MP
Separator

(63) CLOSE, LOCK and TAG the in Isolation Block Valve HV-73006
at the defoamer injection point on the inlet header to the MP
Separator

ID: M-CPH-1171-01417_EN_Section_6.doc Page 10 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.3 (64) ENSURE that the ESD Valve 10-XV-0201 on the Blowdown Line
Boundary Isolation from the MP separator to the LP Flare Header is CLOSED, then
(Continued) CLOSE, LOCK and TAG the downstream 12in isolation ball valve
HV-10079.

(65) CLOSE, LOCK and TAG the 8in isolation ball valves downstream
of Pressure Safety Relief Valves 10-PSV-0203A and 10-PSV-
0203B.

Note: This will require the use of the sixth key (maintenance key) and
will result in all four isolation valves for the interlocked pressure
safety relief valves being closed.

(66) ENSURE that the isolation valves for the 1in bypass line around
the pressure safety relief valves are CLOSED.

Note: DO NOT LOCK these valves closed until after the purging
operation.

(67) ENSURE that the isolation valves HV-10091/2 for the gas outlet
sample line are CLOSED, then LOCK and TAG the valves.

(68) CLOSE, LOCK and TAG the Isolation Ball Valve HV-10090
downstream of 10-PCV-0207B on the gas outlet line from the MP
separator to the HP Flare Header.

(69) ENSURE that the isolation valves HV-10116/7 for the crude outlet
sample line are CLOSED.

Note: DO NOT LOCK these valves closed until after the flushing
operation.

(70) CLOSE, LOCK and TAG the 6in Isolation Ball Valve HV-10112 on
the produced water outlet line from the MP separator to the MP
Hydrocyclone.

(71) ENSURE that the Jetting Water Valve HV-10102 is CLOSED.

(72) ENSURE that the Jetting Water Valve HV-10104 is CLOSED.

(73) ENSURE that the Jetting Water Valve HV-10106 is CLOSED.

(74) ENSURE that the Jetting Water Valve HV-10108 is CLOSED.

(75) ENSURE that the Jetting Water Valve HV-10110 is CLOSED.

Note: DO NOT LOCK these valves closed until after the flushing
operation.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 11 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.3
Boundary Isolation
(Continued)
Refer to P&ID (76) ENSURE that the PSD Valve 20-XV-1201 for the gas outlet from
CUR-MAS-PB-20043-002 the MP separator is CLOSED, then DISABLE and TAG the
pneumatically operated actuator.

(77) ENSURE that the Bypass Valve 20-XV-1202 for the gas outlet
from the MP separator is CLOSED, then DISABLE and TAG the
pneumatically operated actuator.

Refer to P&ID (78) CLOSE, LOCK and TAG the 4in Isolation Ball Valve HV-22039
CUR-MAS-PB-20122-001 downstream of 22-LCV-0009 to the MP Separator.

(79) CLOSE, LOCK and TAG 22-LCV-0009 3in bypass valve


HV-22038.

Refer to P&ID (80) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-10007
CUR-MAS-PB-20131-001 downstream of 20-LCV-1135 to the MP Separator.

(81) CLOSE, LOCK and TAG 20-LCV-1135 1in bypass valve


HV-10008
.
Refer to P&ID (82) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-40037 on
CUR-MAS-PM-20053-501 the reject oil line from the Test separator hydrocyclone
downstream of 40-PCV-0301.

(83) CLOSE, LOCK and TAG the 1in Isolation globe Valve HV-40040
on the bypass line for 40-PCV-0301.

Refer to P&ID (84) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-40021 on
CUR-MAS-PM-20052-501 the reject oil line from the MP separator hydrocyclone downstream
of 40-PCV-0201.

(85) CLOSE, LOCK and TAG the 1in Isolation globe Valve HV-40024
on the bypass line for 40-PCV-0201.

Refer to P&ID (86) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-40003 on
CUR-MAS-PM-20051-501 the reject oil line from the HP separator hydrocyclone downstream
of 40-PCV-0101.

(87) CLOSE, LOCK and TAG the 1in Isolation globe Valve HV-40006
on the bypass line for 40-PCV-0101.

Refer to P&ID (88) ENSURE that the PSD Valve 10-XV-1081 for the dump line from
CUR-MAS-PB-20044-002 the fuel gas scrubber is CLOSED, then DISABLE and TAG the
pneumatically operated actuator.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 12 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.3
Boundary Isolation
(Continued)

Refer to P&ID (89) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-20012
CUR-MAS-PB-20112-001 for the LP Suction Scrubber Pump P-2002A discharge line to the
MP crude oil heater.

(90) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-20015
for the LP Suction Scrubber Pump P-2002B discharge line to the
MP crude oil heater.

Refer to P&ID (91) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-10008
CUR-MAS-PB-20182-001 for the HP Flare KO Drum Pump P-5001A discharge line to the MP
crude oil heater.

(92) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-10009
for the HP Flare KO Drum Pump P-5001B discharge line to the MP
crude oil heater.

Refer to P&ID (93) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-10010
CUR-MAS-PB-20192-001 for the LP Flare KO Drum Pump P-5101A discharge line to the MP
crude oil heater.

(94) CLOSE, LOCK and TAG the 2in Isolation Ball Valve HV-10011
for the LP Flare KO Drum Pump P-5101B discharge line to the MP
crude oil heater.

Refer to P&ID (95) CLOSE, LOCK and TAG the Isolation Ball Valve HV-20031
CUR-MAS-PB-20115-001 downstream of 20-LCV-1098 on the liquid outlet line from the MP
suction scrubber to the MP crude oil Heater.

(96) CLOSE, LOCK and TAG the isolation globe valve HV-20074 on
20-LCV-1098 bypass line.
Refer to P&ID (97) ENSURE that the 6in Isolation Ball Valve HV-44072 on the
CUR-MAS-PM-20044-501 heating medium return from the MP crude oil heater is CLOSED,
then LOCK and TAG the valve.

(98) ENSURE that the 6in Isolation Ball Valve HV-44064 on the
heating medium supply to the MP crude oil heater is CLOSED,
then LOCK and TAG the valve.

(99) CLOSE, LOCK and TAG the Isolation Ball Valve HV-10126
downstream of 10-PSV-0253 on the crude oil inlet to the MP crude
oil heater.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 13 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.3
Boundary Isolation
(Continued)
Refer to P&ID (100) ENSURE that the ESD Valve 10-XV-0301 on the Blowdown Line
CUR-MAS-PM-20045-501 from the LP separator to the LP Flare Header is CLOSED, then
CLOSE, LOCK and TAG the downstream 10in isolation ball valve
HV-10135.
(101) CLOSE, LOCK and TAG the 6in isolation ball valves downstream
of Pressure Safety Relief Valves 10-PSV-0303A and 10-PSV-
0303B.

Note: This will require the use of the sixth key (maintenance key) and
will result in all four isolation valves for the interlocked pressure
safety relief valves being closed.

(102) ENSURE that the isolation valves for the 1in bypass line around
the pressure safety relief valves are CLOSED.

Note: DO NOT LOCK these valves closed until after the purging
operation.

(103) ENSURE that the isolation valves for the gas outlet sample line
are CLOSED, then LOCK and TAG the valves.

(104) CLOSE, LOCK and TAG the Isolation Ball Valve HV-10136
downstream of 10-PCV-0307B on the gas outlet line from the LP
separator to the LP Flare Header.

(105) ENSURE that the isolation valves HV-10160/1 for the crude outlet
sample line are CLOSED.

Note: DO NOT LOCK these valves closed until after the flushing
operation.

(106) ENSURE that the Jetting Water Valve HV-10140 is CLOSED.

(107) ENSURE that the Jetting Water Valve HV-10142 is CLOSED.

(108) ENSURE that the Jetting Water Valve HV-10144 is CLOSED.

(109) ENSURE that the Jetting Water Valve HV-10146 is CLOSED.

(110) ENSURE that the Jetting Water Valve HV-10148 is CLOSED.

Note: DO NOT LOCK these valves closed until after the flushing
operation.

Refer to P&ID (111) ENSURE that the PSD Valve 20-XV-1221 for the gas outlet from
CUR-MAS-PB-20045-002 the LP separator is CLOSED, then DISABLE and TAG the
pneumatically operated actuator.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 14 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.3
Boundary Isolation
(Continued)

Refer to P&ID (112) CLOSE, LOCK and TAG the isolation ball valves downstream of
CUR-MAS-PM-20046-501 Pressure Safety Relief Valves 10-PSV-0403A/B.

(113) ENSURE that the Drain Valve No 1 for the coalescer bushings at
Nozzle N5A is CLOSED, then LOCK and TAG the valve.

(114) ENSURE that the Drain Valve No 2 for the coalescer bushings at
Nozzle N5A is CLOSED, then LOCK and TAG the valve.

(115) ENSURE that the Drain Valve No 1 for the coalescer bushings at
Nozzle N5B is CLOSED, then LOCK and TAG the valve.

(116) ENSURE that the Drain Valve No 2 for the coalescer bushings at
Nozzle N5B is CLOSED, then LOCK and TAG the valve.

(117) ENSURE that the Isolation Valves for Sample Line No 1 at


Nozzle N6A are CLOSED.

(118) ENSURE that the Isolation Valves for Sample Line No 2 at


Nozzle N6B are CLOSED.

(119) ENSURE that the Isolation Valves for Sample Line No 3 at


Nozzle N6C are CLOSED.

(120) ENSURE that the Isolation Valves for Sample Line No 4 at


Nozzle N6D are CLOSED.

(121) ENSURE that the Isolation Valves for Sample Line No 5 at


Nozzle N6E are CLOSED.

Refer to P&ID (122) ENSURE that the 6in Isolation Ball Valve HV-45101 on the
CUR-MAS-PM-20047-501 cooling medium return from the export crude oil cooler is
CLOSED, then LOCK and TAG the valve.

(123) ENSURE that the 6in Isolation Ball Valve HV-45103 on the
cooling medium supply to the export crude oil heater is CLOSED,
then LOCK and TAG the valve.

(124) ENSURE that the PSD Valve 10-XV-0458 for the crude outlet
from the export crude oil cooler is CLOSED, then DISABLE and
TAG the pneumatically operated actuator.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 15 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.4 CAUTION: THE WATER FLUSHING OPERATION DESCRIBED IN


Oil Processing Facilities, STEPS 1 TO 23 DETAILS THE FLUSHING OF THE
Flushing Operation - FLOWLINES, MANIFOLDS AND HEADERS TO THE
TEST, HP AND MP SEPARATORS. THE FLUSHINGS
Part 1
FROM THE SEPARATORS ARE THEN DISPOSED OF TO
THE HAZARDOUS AREA OPEN DRAINS.

Note: The following procedure assumes normal operation where


Curlew fluids are produced to the HP Separator via the production
swivel and to the Test separator via the test swivel.

(1) ENSURE that the low point drain lines for the Curlew Risers and
flowlines are CONNECTED to the Port or Starboard hazardous
drains collection tanks with correctly rated flexible hoses.

(2) ENSURE that the Port or Starboard hazardous drains collection


tanks have sufficient capacity to accept the crude drainings from
the risers and flowlines by OBSERVING local gauge glasses fitted
to the vessels. If this is not the case, the Port or Starboard
hazardous drains tank pumps will AUTO-START on demand to
control the rising level in the tanks. The discharges from the
hazardous drains tank pumps are lined up to the Port Slops Tank,
which is suitable for the storage of liquid hydrocarbons.

(3) DRAIN the contents of the Risers and flowlines located below
the turret to the Port or Starboard hazardous drains collection
tanks by OPENING the double block and bleed valves for the low
drain points. OPEN the valves for the Curlew flowlines to the test
separation train and the production separation trains to facilitate
full draindown. CLOSE the isolation valves for the low drain point
on completion.

Note: Due to the mechanical interlocks fitted on the test and production
diverter valves it is necessary to open these valves one at a time.

(4) CLOSE the test and production diverter valves for all flowlines
then CONNECT a utility seawater supply hose to the flushing
point for each flowline.

(5) FLUSH all Curlew flowlines through the test manifold and test
swivel to the Test separator.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 16 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.4 (6) ENSURE that there is no pressure remaining in the Test


Oil Processing Facilities, separator by REMOVING the blank then carefully OPENING the
Flushing Operation - vent valves fitted to the level gauge glasses for the vessel. OPEN
the four 2in Isolation valves for the belly drains to drain the
Part 1 (Continued) contents of the Test separator to the hazardous area open drain
via the Skid Drip Pan. The hazardous area open drain header
directs all flushings to the Port Hazardous Drains Collection Tank
T-6001 for subsequent disposal. CLOSE the belly drains on
completion.

(7) CONNECT a suitable seawater hose to the purge/utility


connection of the Test separator. OPEN the isolation valve on the
seawater supply and the purge/utility connection valve to flood the
vessel. OPEN the four 2in Isolation valves for the belly drains to
drain the contents of the separator to the hazardous area open
drain header. This will remove all liquid hydrocarbons from the
vessel.

(8) REMOVE the blank then connect a suitable seawater hose to the
vent valve for oil/water Interface Level Gauge 10-LG-0516. OPEN
the isolation valve for the seawater supply and the drain valve to
flush the level gauge to the hazardous area open drains.

(9) FLUSH the following instrumentation for the Test separator to


the hazardous area open drains:

Interface Level Gauge 10-LG-0517

(10) FLUSH the flowlines for the Curlew wells through the 8in
Production Swivel X-0703 in the turret on to the HP separator.

(11) ENSURE that there is no pressure remaining in the HP separator


by REMOVING the blank then carefully OPENING the vent valves
fitted to the level gauge glasses for the vessel. OPEN the six 2in
Isolation valves for the belly drains to drain the contents of the HP
separator to the hazardous area open drain via the Skid Drip Pan.
The hazardous area open drain header directs all flushings to the
Port Hazardous Drains Collection Tank T-6001 for subsequent
disposal. CLOSE the belly drains on completion.

(12) CONNECT a suitable seawater hose to the purge/utility


connection of the HP separator. OPEN the isolation valve on the
seawater supply and the purge/utility connection valve to flood the
vessel. OPEN the six 2in Isolation valves for the belly drains to
drain the contents of the separator to the hazardous area open
drain header. This will remove all liquid hydrocarbons from the
vessel.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 17 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.4 (13) REMOVE the blank then connect a suitable seawater hose to the
Oil Processing Facilities, vent valve for oil/water Interface Level Gauge 10-LG-0116. OPEN
Flushing Operation - the isolation valve for the seawater supply and the drain valve to
Part 1 (Continued) flush the level gauge to the hazardous area open drains.

(14) FLUSH the following instrumentation for the HP separator to the


hazardous area open drains:

Interface Level Gauge 10-LG-0117

(15) CLOSE the Double Block and Bleed Valve downstream of


10-LCV-0114 on the crude oil outlet from the HP crude oil heater.
Also ENSURE the 3in isolation ball valve HV-10073 for the
bypass valve is CLOSED. CONNECT a utility seawater supply
hose to the drain point on the upstream side of 10-LCV-0114.

(16) OPEN the isolation valve for the seawater supply and the drain
valve. Periodically OPEN the 1in isolation ball valve from the
process inlet of the HP crude oil heater to the Skid Drip Pan to
BACKFLUSH the heater to the hazardous open drains.

Note: If heating medium is available, it will be beneficial to


recommission the HP crude oil heater in order to heat the utility
seawater during flushing.

(17) SHUT OFF the seawater supply to the HP crude oil heater and
DISCONNECT the supply hose. DRAIN the tubeside of the HP
crude oil heater to the Skid Drip Pan. CLOSE the 1in isolation ball
valve from the process inlet of the HP crude oil heater to the Skid
Drip Pan on completion.

(18) FLUSH the flowline for the Curlew BP1 well through the 8in
Production Swivel X-0704 in the turret on to the MP separator.

(19) ENSURE that there is no pressure remaining in the MP


separator by REMOVING the blank then carefully OPENING the
vent valves fitted to the level gauge glasses for the vessel. OPEN
the six 2in Isolation valves for the belly drains to drain the
contents of the MP separator to the hazardous area open drain
via the Skid Drip Pan. The hazardous area open drain header
directs all flushings to the Port Hazardous Drains Collection Tank
T-6001 for subsequent disposal. CLOSE the belly drains on
completion.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 18 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.4 (20) CONNECT a suitable seawater hose to the purge/utility


Oil Processing Facilities, connection of the MP separator. OPEN the isolation valve on the
Flushing Operation - seawater supply and the purge/utility connection valve to flood the
Part 1 (Continued) vessel. OPEN the six 2in Isolation valves for the belly drains to
drain the contents of the separator to the hazardous area open
drain header. This will remove all liquid hydrocarbons from the
vessel.

(21) REMOVE the blank then connect a suitable seawater hose to the
vent valve for oil/water Interface Level Gauge 10-LG-0216. OPEN
the isolation valve for the seawater supply and the drain valve to
flush the level gauge to the hazardous area open drains.

(22) FLUSH the following instrumentation for the MP separator to the


hazardous area open drains:

Interface Level Gauge 10-LG-0217

(23) Once the flowlines, manifolds and headers are completely


flushed and the test, HP and MP Separators are drained of all
liquids, ENSURE that the following drain valves are CLOSED,
LOCKED and TAGGED:

Double Block and Bleed Valves at the low drainage points for
the Risers and flowlines

Double Block and Bleed Valve at the flush points for the
flowlines

Note: The valves listed above are part of the Oil Processing Facilities
Boundary Isolation Valve Checklist 6.01.6.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 19 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.4 CAUTION: THE WATER FLUSHING OPERATION DESCRIBED IN


Oil Processing Facilities, STEPS 24 TO 42 DETAILS THE FLUSHING OF THE
Flushing Operation - REMAINING EQUIPMENT IN THE OIL STABILISATION
FACILITIES.
Part 2

(24) CLOSE the Isolation Ball Valve HV-10118 upstream of


10-LCV-0214 on the crude oil outlet from the MP separator. Also
ENSURE that the 4in isolation ball valve HV-10080 for the bypass
line is CLOSED. CONNECT a utility seawater supply hose to the
drain point HV-10121 on the downstream side of 10-LCV-0214.

(25) OPEN the isolation valve for the seawater supply and the drain
valve to flush all linework from the oil outlet of the MP separator
through the MP crude oil heater and on to the LP separator.
Periodically OPEN the 1in isolation ball valve from the process
inlet of the MP crude oil heater to the Skid Drip Pan to FLUSH the
heater to the hazardous open drains.

Note: If heating medium is available, it will be beneficial to


recommission the MP crude oil heater in order to heat the utility
seawater during flushing.

(26) SHUT OFF the seawater supply to the crude outlet from the MP
separator and DISCONNECT the supply hose. DRAIN the
internals of the MP crude oil heater to the Skid Drip Pan. CLOSE
the 1in isolation ball valve from the process inlet of the MP crude
oil heater to the Skid Drip Pan on completion.

(27) CLOSE the Isolation Ball Valve HV-10285 upstream of


10-LCV-0514 on the crude oil outlet from the Test separator. Also
ENSURE that the 3in isolation ball valve HV-10289 for the bypass
line is CLOSED. CONNECT a utility seawater supply hose to the
drain point HV-10288 on the downstream side of 10-LCV-0514.

(28) OPEN the isolation valve for the seawater supply and the drain
valve to flush all linework from the outlet of the Test separator
through the MP crude oil heater to the LP separator. It may be
necessary to OPEN the 6in Isolation Ball Valve HV-10122 on the
crude oil outlet from the Test separator to the MP crude oil heater
and CLOSE the 6in Isolation Ball Valve HV-10077 on the crude oil
outlet from the Test separator to the MP separator to divert the
flushing water through the heater.

(29) SHUT OFF the seawater supply to the crude outlet from the Test
separator and DISCONNECT the supply hose once flushing is
complete.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 20 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.4 (30) ENSURE that there is no pressure remaining in the LP separator


Oil Processing Facilities, by REMOVING the blank then carefully OPENING the vent valves
Flushing Operation - fitted to the level gauge glasses for the vessel. OPEN the six 2in
Isolation valves for the belly drains to drain the contents of the LP
Part 2 (Continued) separator to the hazardous area open drain via the Skid Drip Pan.
The hazardous area open drain header directs all flushings to the
Port Hazardous Drains Collection Tank T-6001 for subsequent
disposal. CLOSE the belly drains on completion.

(31) CONNECT a suitable seawater hose to the purge/utility


connection of the LP separator. OPEN the isolation valve on the
seawater supply and the purge/utility connection valve to flood the
vessel. OPEN the six 2in Isolation valves for the belly drains to
drain the contents of the separator to the hazardous area open
drain header. This will remove all liquid hydrocarbons from the
vessel.

(32) REMOVE the blank then connect a suitable seawater hose to the
vent valve for oil/water Interface Level Gauge 10-LG-0316. OPEN
the isolation valve for the seawater supply and the drain valve to
flush the gauge to the hazardous area open drains.

(33) FLUSH the following instrumentation for the LP separator to the


hazardous area open drains:

Interface Level Gauge 10-LG-0317

(34) CONNECT a suitable seawater hose to the drain point on each


produced water transfer pump suction line in turn:

ENSURE that the manual isolation valve HV-10173/6 on the


pump discharge line is OPEN to FLUSH back to the MP
separator

CLOSE the drain valve HV-10172/5 on each produced water


transfer pump suction line and DISCONNECT the flushing
hose on completion

(35) CONNECT a suitable seawater hose to the drain point on each


crude oil transfer pump suction line in turn:

FLUSH the pump suction line and minimum flowline back to


the LP separator

ENSURE that the manual isolation valves HV-10168/9 on the


pump discharge line are OPEN to flush through to the
electrostatic coalescer

CLOSE the drain valve HV-10163/6 on each oil transfer pump


suction line and DISCONNECT the flushing hose on
completion

ID: M-CPH-1171-01417_EN_Section_6.doc Page 21 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.4 (36) REMOVE the blank then connect a suitable seawater hose to the
Oil Processing Facilities, vent valve for electrostatic coalescer Oil/Water Interface Level
Flushing Operation - Gauge 13-LG-0414. OPEN the isolation valve for the seawater
supply and the vent valve to flush the level gauge to the
Part 2 (Continued) hazardous area open drains.

(37) FLUSH the following instrumentation for the electrostatic


coalescer to the Hazardous Area Open Drain Header:

Tricock 1 at Nozzle N6A

Tricock 2 at Nozzle N6B

Tricock 3 at Nozzle N6C

Tricock 4 at Nozzle N6D

Tricock 5 at Nozzle N6E

(38) ENSURE that there is no pressure remaining in the electrostatic


coalescer then OPEN the 2in Isolation valve for the belly drain to
drain the contents of the vessel to the hazardous area open drain
header. CLOSE the belly drain valve on completion.

Note: All hydrocarbons have been previously removed from the


coalescer by the jetting operations performed during the planned
shutdown procedure.

(39) REMOVE the blank then CONNECT a suitable seawater hose to


the high vent point HV-10226 for the crude inlet to the export
crude oil cooler.

(40) ENSURE that the 8in Isolation Ball Valve HV-10225 for the inlet
to the export crude oil cooler is CLOSED and commence flushing
the plate internals of the cooler.

(41) Periodically OPEN the 1in Isolation Ball Valve HV-10228 from
the crude outlet of the export crude oil cooler to the Skid Drip Pan
to FLUSH the oil outlet from the electrostatic coalescer.

(42) Once flushing is complete, SHUT OFF the seawater supply to


the process inlet of the export crude oil cooler and DISCONNECT
the supply hose.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 22 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.5 WARNING: ANY VENTING OF NITROGEN TO ATMOSPHERE


Oil Processing Facilities, SHOULD BE TREATED WITH EXTREME CARE, AS IN
Nitrogen Purging HIGH CONCENTRATIONS, INHALATION WILL CAUSE
Operation UNCONSCIOUSNESS ALMOST IMMEDIATELY.
THEREFORE, NO CONTINUOUS VENTING OF
EQUIPMENT SHOULD TAKE PLACE UNLESS IT IS
TEMPORARILY PIPED TO A SUITABLE LOCATION
WHERE PERSONNEL ARE NOT EXPOSED.

With flushing operations complete, nitrogen purging operations of the oil


processing facilities can commence. This is accomplished by purging
each vessel and associated lines to flare, as described below.

(1) CHECK all local drain valves from the Oil Processing Facilities to
the hazardous area open drains are CLOSED.

(2) CLOSE the 10in Isolation Ball Valve on the inlet header from the
Test Manifold to the Test separator.

(3) CONNECT the nitrogen hose to the Purge Connection Point for
the Test separator.

(4) OPEN the 1in Isolation Ball Valves on the depressurisation line
to the LP Flare.

(5) OPEN the Isolation Valve for the Purge Connection Point and
PURGE the Test separator to the LP Flare by displacement.

(6) PERIODICALLY SAMPLE the purge gas in the Test separator


from the vent valves provided for the level gauges.
DISCONTINUE the Test separator purge when the hydrocarbon
content is less than 0.25% (volume).

(8) CLOSE, LOCK and TAG the 1in Isolation Ball Valves on the
depressurisation line for the Test separator to the LP Flare.

Note: These valves form part of the Oil Processing Facilities Boundary
Isolation Valve Checklist 6.01.6.

(9) CLOSE the 14in Isolation Ball Valve on the inlet header from the
turret to the HP Separator.

(10) CONNECT the nitrogen hose to the Purge Connection Point for
the HP separator.

(11) OPEN the 1in Isolation Ball Valves on the depressurisation line
to the LP Flare.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 23 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.5 (12) OPEN the Isolation Valve for the Purge Connection Point and
Oil Processing Facilities, PURGE the HP separator to the LP Flare by displacement.
Nitrogen Purging
Operation (Continued) (13) PERIODICALLY SAMPLE the purge gas in the HP separator
from the vent valves provided for the level gauges.
DISCONTINUE the HP separator purge when the hydrocarbon
content is less than 0.25% (volume).

(14) CLOSE, LOCK and TAG the 1in Isolation Ball Valves on the
depressurisation line for the vessel to the LP Flare.

Note: These valves form part of the Oil Processing Facilities Boundary
Isolation Valve Checklist 6.01.6.

(15) CLOSE the 8in Isolation Ball Valve on the inlet header from the
Turret to the MP Separator.

(16) CLOSE the 10in Isolation Ball Valve on the oil outlet line from the
HP crude oil heater to the MP Separator.

(17) CONNECT the nitrogen hose to the Purge Connection Point for
the MP separator.

(18) OPEN the 1in Isolation Valves on the bypass line for the
interlocked Pressure Safety Relief Valves 10-PSV-0203A and B to
the LP Flare.

(19) OPEN the Isolation Valve for the Purge Connection Point and
PURGE the MP separator to the LP Flare by displacement.

(19) PERIODICALLY SAMPLE the purge gas in the MP separator


from the vent valves provided for the level gauges.
DISCONTINUE the MP separator purge when the hydrocarbon
content is less than 0.25% (volume).

(20) CLOSE, LOCK and TAG the 1in Isolation Ball Valves on the
bypass line for the vessel pressure safety relief valves to the LP
Flare.

Note: These valves form part of the Oil Processing Facilities Boundary
Isolation Valve Checklist 6.01.6.

(21) CLOSE the 16in Isolation Ball Valve on the inlet line to the MP
crude oil heater.

(22) CONNECT the nitrogen hose to the Purge Connection Point for
the LP separator.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 24 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.5 (23) OPEN the 1in Isolation Valves on the bypass line for the
Oil Processing Facilities, interlocked Pressure Safety Relief Valves 10-PSV-0303A and B to
the LP Flare.
Nitrogen Purging
Operation (Continued)
(24) OPEN the Isolation Valve for the Purge Connection Point and
PURGE the LP separator to the LP Flare by displacement.

(25) PERIODICALLY SAMPLE the purge gas in the LP separator


from the vent valves provided for the level gauges.
DISCONTINUE the LP separator purge when the hydrocarbon
content is less than 0.25% (volume).

(26) CLOSE, LOCK and TAG the 1in Isolation Ball Valves on the
bypass line for the vessel pressure safety relief valves to the LP
Flare.

Note: These valves form part of the Oil Processing Facilities Boundary
Isolation Valve Checklist 6.01.6.

(27) CLOSE the 8in Mix Valve on the inlet line to the electrostatic
coalescer.

(28) CONNECT the nitrogen hose to the Purge Connection Point for
the electrostatic coalescer.

(29) REMOVE the blank and CONNECT a hose suitable for purging
operations to the vent point for the Level Gauge 10-LG-0414.
ENSURE that the hose is routed to a safe area.

(30) OPEN the Isolation Valve for the Purge Connection Point and
PURGE the electrostatic coalescer to atmosphere by
displacement.

(31) PERIODICALLY SAMPLE the purge gas in the electrostatic


coalescer from the vent valves provided for the level gauge.
DISCONTINUE the purge when the hydrocarbon content is less
than 0.25% (volume).

6.01.6
ID: M-CPH-1171-01417_EN_Section_6.doc Page 25 / 105
MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

Oil Processing Facilities Boundary Isolation Valve Checklist


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE
Refer to P&ID Nos
CUR-MAS-TP-42002-001 and
CUR-MAS-TP-42005-001

07-XXV-100 Well DP2 Riser ESD Valve 8in-F-07102-25SDB2-PG CLOSED

- Well DP1 Riser Low Point Drain N/A CLOSED


Valve

- Methanol Injection Double Block 1in-ME-73205-25DA CLOSED


and Bleed Valve for Well DP2
Riser

07-XV-105 Well DP2 Flowline ESD Valve 8in-F-07102-25SDB2-PG CLOSED

- Corrosion Inhibitor Injection 1/4in-C-73228-25SSA3 CLOSED


Double Block and Bleed Valve
for Well DP2 Flowline

- Well DP2 Flowline Low Point N/A CLOSED


Drain Valve

- Flush point from Well DP2 N/A CLOSED


Flowline to Test Separation
Train

- Flush point from Well DP2 N/A CLOSED


Flowline to Production
Separation Train
COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 26 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE
07-XXV-200 Well DP1 Riser ESD Valve 8in-F-07202-25SDB2-PG CLOSED

- Well DP1 Riser Low Point Drain N/A CLOSED


Valve

- Methanol Injection Double Block 1in-ME-73204-25DA CLOSED


and Bleed Valve for Well DP1
Riser

07-XV-205 Well DP1 Flowline ESD Valve 8in-F-07202-25SDB2-PG CLOSED

- Corrosion Inhibitor Injection in-C-73229-25SSA3 CLOSED


Double Block and Bleed Valve
for Well DP1 Flowline

- Well DP1 Flowline Low Point N/A CLOSED


Drain Valve

- Flush point from Well DP1 N/A CLOSED


Flowline to Test Separation
Train

- Flush point from Well DP1 N/A CLOSED


Flowline to Production
Separation Train

07-XXV-300 Well BP1 Riser ESD Valve 8in-F-07302-25DB2-PG CLOSED

- Well BP1 Riser Low Point Drain N/A CLOSED


Valve

- Methanol Injection Double Block 1in-ME-73206-25DA CLOSED


and Bleed Valve for Well BP1
Riser
COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 27 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE
07-XV-305 Well BP1 Flowline ESD Valve 8in-F-07302-25DB3-PG CLOSED

- Corrosion Inhibitor Injection in-C-73227-25SSA3 CLOSED


Double Block and Bleed Valve
for Well BP1 Flowline

- Well BP1 Flowline Low Point N/A CLOSED


Drain Valve

- Flush point from Well BP1 N/A CLOSED


Flowline to Test Separation
Train

- Flush point from Well BP1 N/A CLOSED


Flowline to Production
Separation Train

Refer to P&ID No
CUR-MAS-TP-42035-001

07-XXV-0500 Spare Well Riser ESD Valve 12in-F-07552-K15CSC1T- CLOSED


PFP

Spare Well Riser Low Point N/A CLOSED


Drain Valve

07-XV-0505 Spare Well Flowline ESD Valve 12in-F-07553-K15CSC2- CLOSED


HC

Spare Well Flowline Low Point N/A CLOSED


Drain Valve

Spectacle blind on Spare Well N/A CLOSED


Flowline to Test Separation
Train

Spectacle blind on Spare Well N/A CLOSED


Flowline to Production
Separation Train

Spectacle blind on Spare Well N/A CLOSED


Flowline to Water Injection
Swivel

ID: M-CPH-1171-01417_EN_Section_6.doc Page 28 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE
Refer to P&ID Nos CUR-MAS-
PM-20048-501 and CUR-MAS-
PB-20048-002

HV-73007 Isolation valve for demulsifier to 1in-C-73514-D6A CLOSED


the Test separator inlet manifold

HV-73009 Isolation valve for defoamer to 1in-C-73522-D6A CLOSED


the Test separator inlet manifold

10-XV-0501 Blowdown valve for the Test 3in-V-10003-HB7A CLOSED


separator

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 29 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE
HV-10239 Downstream isolation valve for 8in-V-10-003-HB7A CLOSED
10-XV-0501

HV-10237 1st in-line isolation valve for Test 1in-V-10005-HB7A CLOSED


separator depressurisation line

HV-10236 2nd in-line isolation valve for Test 1in-V-10005-HB7A CLOSED


separator depressurisation line

HV-10235 3rd in-line isolation valve for Test 1in-V-10005-HB7A CLOSED


separator depressurisation line

HV-10238 Vent valve for Test separator 1in-V-10005-HB76A CLOSED


depressurisation line

HV-10243/4 Downstream isolation valve for 10in-V-10002-HA6A CLOSED


10-PSV-0503A

HV-10248/9 Downstream isolation valve for 10in-V-10002-HA6A CLOSED


10-PSV-0503B

HV-10251 1st in-line isolation valve for PSV 1in-V-10-001-HB7A CLOSED


bypass line

HV-10250 2nd in-line isolation valve for PSV 1in-V-10-001-HB7A CLOSED


bypass line

HV-10255 1st in line isolation valve for gas N/A CLOSED


outlet sample point

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 30 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

HV-10256 2nd in-line isolation valve for N/A CLOSED


gas outlet sample point

HV-10253/4 Downstream isolation valve for 10in-V-10006-HA6A CLOSED


10-PCV-0507B for the gas
outlet from Test separator to
the HP Flare

HV-10258/9 Downstream isolation valve for 10in-G-10-001-HB7A-PG CLOSED


10-PCV-0507A for the gas
outlet from Test separator to
the inlet cooler

HV-10283 1st in-line isolation valve for N/A CLOSED


crude outlet sample point

HV-10284 2nd in-line isolation valve for N/A CLOSED


crude outlet sample point

HV-10281 Isolation ball valve on Test CLOSED


separator produced water 4in-WP-10001-B2D-
outlet to test/HP hydrocyclone HC25
package

HV-10273 Jetting Water Valve 1 1in-WW-10001-HB2D CLOSED

HV-10275 Jetting Water Valve 2 1in-WW-10001-HB2D CLOSED

HV-10277 Jetting Water Valve 3 1in-WW-10001-HB2D CLOSED

HV-10278 Jetting water outlet valve to 1in-D-10005-HA1C CLOSED


skid drip pan

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 31 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

20-XV-1191 Shutdown valve for the Test 10in-G-20506-B7A-PG CLOSED


separator Gas outlet

Refer to P&ID Nos CUR-MAS-


PM-20041-501 and CUR-MAS-
PB-20041-002

HV-73001 Isolation valve for demulsifier to 1in-C-73512-D6A CLOSED


the HP separator inlet manifold

HV-73002 Isolation valve for defoamer to 1in-C-73520-D6A CLOSED


the HP separator inlet manifold

10-XV-0101 Blowdown valve for the HP CLOSED


separator 4in-V-10009-HB7A

HV-10033 Downstream isolation valve for CLOSED


10-XV-0101 10in- V-10009-HB7A

HV-10015 1st in-line isolation valve for HP CLOSED


separator depressurisation line 1in-V-10011-HB7A

HV-10017 2nd in-line isolation valve for HP CLOSED


separator depressurisation line 1in-V-10011-HB7A

HV-10018 3rd in-line isolation valve for HP 1in-V-10011-HB7A CLOSED


separator depressurisation line

HV-10016 Vent isolation valve for HP 1in-V-10011-HB7A CLOSED


separator depressurisation line
COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 32 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

HV-10023/4 Downstream isolation valve for CLOSED


10-PSV-0103A 10in-V-10008-HA6A

HV-10029/30 Downstream isolation valve for CLOSED


10-PSV-0103B 10in-V-10008-HA6A

HV-10032 1st in-line isolation valve for CLOSED


PSV bypass line 1in-V-10007-HB7A

HV-10031 2nd in-line isolation valve for CLOSED


PSV bypass line 1in-V-10007-HB7A

HV-10021 1st in-line isolation valve for N/A CLOSED


gas outlet sample point

HV-10027 2nd in-line isolation valve for N/A CLOSED


gas outlet sample point

HV-10049 1st in-line isolation valve for N/A CLOSED


crude outlet sample point

HV-10050 2nd in-line isolation valve for N/A CLOSED


crude outlet sample point

HV-10046 Isolation ball valve on HP CLOSED


separator produced water 6in-WP-10002-B7A-HC25
outlet to HP/Test hydrocyclone
package

HV-10037 Jetting Water Valve 1 1in-WW-10002-HB2D CLOSED

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 33 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

HV-10039 Jetting Water Valve 2 1in-WW-10002-HB2D CLOSED

HV-10041 Jetting Water Valve 3 1in-WW-10002-HB2D CLOSED

HV-10043 Jetting Water Valve 4 1in-WW-10002-HB2D CLOSED

HV-10060 Jetting Water Valve 5 1in-WW-10002-HB2D CLOSED

HV-22001 Downstream isolation valve for 14in-G-50526-A6A-PG CLOSED


10-PCV-0107 on the gas outlet
line from the HP separator to
the HP Flare

HV-52001 Isolation valve for the gas outlet 4in-GF-52516-B7A-PG CLOSED


line from the HP separator to
the Fuel Gas Cooler

22-XV-1051 Shutdown valve for the HP 10in-G-10-22501-B7A-PG CLOSED


separator Gas outlet

22-XV-1052 Bypass valve for the HP 2in-G-10-22501-B7A-PG CLOSED


separator Gas outlet

HV-22002 Isolation valve for the gas outlet 10in-G-10-22501-B7A-PG CLOSED


from the HP separator Gas to
the inlet gas cooler

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


ID: M-CPH-1171-01417_EN_Section_6.doc Page 34 / 105
MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

VALVE LOCATION LINE No ISOLATED SIG/


TAG No POSITION DATE

Refer to P&ID No CUR-MAS-PM-


20042-501

HV-44054 Isolation valve for the Heating 4in-HM-44001-HA1C- CLOSED


Medium supply to the HP crude HC50
oil heater

HV-44063 Isolation valve for the Heating 4in-HM-44002-HA1C- CLOSED


Medium return from the HP crude HC50
oil heater

HV-10067 Downstream isolation valve for CLOSED


10-PSV-0153 2in-V-10012-HAGA

Refer to P&ID Nos CUR-MAS-


PM-20043-501 and CUR-MAS-
PB-20043-002

HV-73004 Isolation valve for demulsifier to 1in-C-73513-D6A CLOSED


the MP separator inlet manifold

HV-73006 Isolation valve for defoamer to 1in-C-73521-D6A CLOSED


the MP separator inlet manifold

10-XV-0201 Blowdown valve for the MP CLOSED


separator 4in-V-10015-HA2D

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 35 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE
HV-10079 Downstream isolation valve for 12in-V-10005-HA20 CLOSED
10-XV-0201

HV-10083 Downstream isolation valve for 8in-V-10004-HA1C CLOSED


10-PSV-0203A

HV-10086 Downstream isolation valve for 8in-V-10004-HA1C CLOSED


10-PSV-0203B

HV-10088 1st in-line isolation valve for PSV 1in-V-10013-HA2D CLOSED


bypass line

HV-10087 2nd in-line isolation valve for PSV 1in-V-10013-HA2D CLOSED


bypass line

HV-10091 1st in-line isolation valve for gas N/A CLOSED


outlet sample point

HV-10092 2nd in-line isolation valve for gas N/A CLOSED


outlet sample point

HV-10090 Downstream isolation valve for 8in-V-10017-HA1C CLOSED


10-PCV-0207B for the gas outlet
from MP separator to the LP Flare

HV-10116 1st in-line isolation valve for crude N/A CLOSED


outlet sample point

HV-10117 2nd in-line isolation valve for crude N/A CLOSED


outlet sample point

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 36 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

HV-10112 Isolation ball valve on MP CLOSED


separator produced water outlet 6in-WP-10003-HA1E-
to MP hydrocyclone package HC25

HV-10102 Jetting Water Valve 1 1in-WW-10003-HA2D CLOSED

HV-10104 Jetting Water Valve 2 1in-WW-10003-HA2D CLOSED

HV-10106 Jetting Water Valve 3 1in-WW-10003-HA2D CLOSED

HV-10108 Jetting Water Valve 4 1in-WW-10003-HA2D CLOSED

HV-10110 Jetting Water Valve 5 1in-WW-10003-HA2D CLOSED

HV-10115 Jetting water drain outlet to skid 1in-D-10024-HA1C CLOSED


drip pan

20-XV-1201 Shutdown valve for the MP 10in-G-20502-B2D-PG CLOSED


separator Gas outlet

20-XV-1202 Bypass valve for the MP 2in-G-22502-B2D-PG CLOSED


separator Gas outlet

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 37 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

Refer to P&ID Nos CUR-MAS-


PB-20122-001

HV-22039 22-LCV-0009 downstream block 4in-P-10551-A2D-HT CLOSED


valve on Condensate outlet line
from Glycol Contactor C-2201 to
the MP Separator

HV-22038 Bypass valve around 3in-P-10551-A2D-HT CLOSED


22-LCV-0009

Refer to P&ID Nos CUR-MAS-


PB-20131-001

HV-10007 20-LCV-1135 downstream block 2in-P-10552-A2D CLOSED


valve on Condensate outlet line
from Export Gas Scrubber
V-2001 to the MP Separator

HV-10006 Bypass valve around 1in-P-10552-A2D CLOSED


20-LCV-1135

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 38 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

Refer to P&ID No CUR-MAS-


PB-20112-001

HV-20012 Isolation Ball Valve for LP 2in-P-20601-A2D-HT CLOSED


Suction Scrubber Pump
P-2002A discharge to the MP
crude oil heater

HV-20015 Isolation Ball Valve for LP 2in-P-20601-A2D-HT CLOSED


Suction Scrubber Pump
P-2002B discharge to the MP
crude oil heater

Refer to P&ID No CUR-MAS-


PB-20115-001

HV-20031 Downstream isolation valve for 4in-P-10553-A2D-HT CLOSED


20-LCV-1096 on the liquid outlet
from the MP suction scrubber to
the MP crude oil heater

HV20074 Isolation valve for 20-LCV-1096 3in-P-10553-A2D-HT CLOSED


bypass line

Refer to P&ID No CUR-MAS-


PB-20182-001

HV-10008 Isolation Ball Valve for HP Flare 2in-P-10556-A2D-HT CLOSED


KO Drum Pump P-5001A
discharge to the MP crude oil
heater

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 39 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

HV-10009 Isolation Ball Valve for HP Flare 2in-P-10556-A2D-HT CLOSED


KO Drum Pump P-5001B
discharge to the MP crude oil
heater

Refer to P&ID No CUR-MAS-


PB-20192-001

HV-10010 Isolation Ball Valve for LP Flare 2in-P-10557-A2D-HT CLOSED


KO Drum Pump P-5101A
discharge to the MP crude oil
heater

HV-10011 Isolation Ball Valve for LP Flare 2in-P-10557-A2D-HT CLOSED


KO Drum Pump P-5101B
discharge to the MP crude oil
heater

Refer to P&ID Nos CUR-MAS-


PB-20044-002

10-XV-1081 Shutdown valve for the liquids 2in-P-10558-B2D CLOSED


outlet from the fuel gas scrubber
to the MP crude oil heater

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 40 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE
Refer to P&ID Nos CUR-MAS-
PM-20044-501

HV-44064 Isolation valve for the Heating 6in-HM-44003-HA1C- CLOSED


Medium supply to the MP crude HC50
oil heater

Refer to P&ID No CUR-MAS-


PM-20051-501

HV-40003 Isolation Valve downstream of 2in-WP-40102-HA1E-HT CLOSED


40-PCV-0101 on oil reject line
from the HP hydrocyclone to the
MP crude oil heater

HV-40006 Isolation Valve on 40-PCV-0101 1in-WP-40102-HA1E-HT CLOSED


bypass line

Refer to P&ID No CUR-MAS-


PM-20052-501

HV-40021 Isolation Valve downstream of 2in-WP-40110-HA1E-HT CLOSED


40-PCV-0201 on oil reject line
from the MP hydrocyclone to the
MP crude oil heater

HV-40024 Isolation Valve on 40-PCV-0201 1in-WP-40110-HA1E-HT CLOSED


bypass line

Refer to P&ID No CUR-MAS-


PM-20053-501

HV-40037 Isolation Valve downstream of 2in-WP-40121-HA1E-HT CLOSED


40-PCV-0301 on oil reject line
from the test hydrocyclone to the
MP crude oil heater

HV-40040 Isolation Valve on 40-PCV-0301 1in-WP-40121-HA1E-HT CLOSED


bypass line
COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 41 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

HV-44063 Isolation valve for the Heating 4in-HM-44002-HA1C- CLOSED


Medium return from the HP HC50
crude oil heater

HV-10126 Downstream isolation valve for 3in-V-10018-HA1C CLOSED


10-PSV-0253

Refer to P&ID Nos CUR-MAS-


PM-20045-501

10-XV-0301 Blowdown valve for the LP 4in-V-10021-HA2D CLOSED


separator

HV-10135 Downstream isolation valve for 10in-V-10022-HA1C CLOSED


10-XV-0301

HV-10129 Downstream isolation valve for 10in-V-10020-HA1C CLOSED


10-PSV-0303A

HV-10132 Downstream isolation valve for 10in-V-10020-HA1C CLOSED


10-PSV-0303B

HV-10134 1st in-line isolation valve for PSV 1in-V-10019-HA2D CLOSED


bypass line

HV-10133 2nd in-line isolation valve for 1in-V-10019-HA2D CLOSED


PSV bypass line

HV-10138 1st in-line isolation valve for gas N/A CLOSED


outlet sample point

HV-10139 2nd in-line isolation valve for gas N/A CLOSED


outlet sample point
COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 42 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

HV-10136 Downstream isolation valve for 14in-V-10023-HA1C CLOSED


10-PCV-0307B for the gas outlet
from LP separator to the LP Flare

HV-10160 1st in-line isolation valve for crude N/A CLOSED


outlet sample point

HV-10161 2nd in-line isolation valve for crude N/A CLOSED


outlet sample point

HV-10140 Jetting Water Valve 1 1in-WW-10004-HA2D CLOSED

HV-10142 Jetting Water Valve 2 1in-WW-10004-HA2D CLOSED

HV-10144 Jetting Water Valve 3 1in-WW-10004-HA2D CLOSED

HV-10146 Jetting Water Valve 4 1in-WW-10004-HA2D CLOSED

HV-10148 Jetting Water Valve 5 1in-WW-10004-HA2D CLOSED

HV-10170 Jetting water outlet drain valve to 1in-D-10034-HA1C CLOSED


skid drip pan

Refer to P&ID Nos CUR-MAS-PB-


20045-002

20-XV-1221 Shutdown valve for the LP 16in-G-20503-A2D-PG CLOSED


separator Gas outlet

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 43 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

Refer to P&ID Nos CUR-MAS-


PM-20046-501

HV-10187 Downstream isolation valve for CLOSED


10-PSV-0403A 8in-V-10024-HA1C

HV-10184 Downstream isolation valve for 8in-V-10024-HA1C CLOSED


10-PSV-0403B

HV-10208 Isolation valve to Tricock Cooler in-D-10048-HA2D- CLOSED


for sample line at Nozzle N6A HC25

HV-10213 Isolation valve from Tricock in-D-10048-HA2D- CLOSED


Cooler for sample line at Nozzle HC25
N6A

HV-10209 Isolation valve to Tricock Cooler in-D-10047-HA2D- CLOSED


for sample line at Nozzle N6B HC25

HV-10214 Isolation valve from Tricock in-D-10047-HA2D- CLOSED


Cooler for sample line at Nozzle HC25
N6B

HV-10210 Isolation valve to Tricock Cooler in-D-10046-HA2D- CLOSED


for sample line at Nozzle N6C HC25

HV-10215 Isolation valve from Tricock in-D-10046-HA2D- CLOSED


Cooler for sample line at Nozzle HC25
N6C

HV-10211 Isolation valve to Tricock Cooler in-D-10045-HA2D- CLOSED


for sample line at Nozzle N6D HC25

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 44 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6 Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)


VALVE LOCATION LINE No ISOLATED SIG/
TAG No POSITION DATE

HV-10216 Isolation valve from Tricock in-D-10045-HA2D- CLOSED


Cooler for sample line at Nozzle HC25
N6D

HV-10212 Isolation valve to Tricock Cooler in-D-10044-HA2D- CLOSED


for sample line at Nozzle N6E HC25

HV-10217 Isolation valve from Tricock in-D-10044-HA2D- CLOSED


Cooler for sample line at Nozzle HC25
N6E

HV-10197 Drain Valve No 1 for coalescer in -D-10042-HA1C CLOSED


bushings at Nozzle N5A

HV-10198 Drain Valve No 2 for coalescer in-D-10041-HA1C CLOSED


bushings at Nozzle N5A

HV-10201 Drain Valve No 1 for coalescer in -D-10040-HA1C CLOSED


bushings at Nozzle N5B

HV-10202 Drain Valve No 2 for coalescer in -D-10041-HA1C CLOSED


bushings at Nozzle N5B

Refer to P&ID Nos CUR-MAS-


PM-20047-501

HV-45103 Isolation valve for the Cooling 6in-CM-45001-HA1C CLOSED


Medium supply to the export
crude oil cooler

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 45 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.01.6
Oil Processing Facilities, Boundary Isolation Valve Checklist (Continued)

VALVE LOCATION LINE No ISOLATED SIG/


TAG No POSITION DATE

HV-45101 Isolation valve for the Cooling 6in-CM-45002-HA1C CLOSED


Medium return from the export
crude oil cooler

10-XV-0458 Shutdown valve for the crude oil 8in-F-10015-HA2D CLOSED


outlet from the export crude oil
cooler

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 46 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.02 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


Test Separator V-1005 UNDERSTOOD BEFORE ATTEMPTING TO CARRY
OUT ANY ACTION.

6.02.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the Test separator has been flushed, drained and nitrogen
purged, as described in Section 6.01 of this volume

This vessel entry procedure is undertaken within the oil facilities


boundary isolations as listed under the Boundary Isolation Valve
Checklist

Prior to vessel entry, the Test separator requires to be physically


disconnected from the associated pipework by either the rotation of
spectacle blinds or the removal of maintenance spools within the
process side blinded with correctly rated blind flanges

It is assumed that the pressure safety relief valves for the Test
separator will be removed for certification. The flare side flanges for
the relief valves must be isolated by suitably rated blind flanges

Prior to vessel entry, the hydrocarbon and nitrogen gases must be


displaced until the atmosphere within the vessel contains 21%
oxygen and less than 0.25% (volume) hydrocarbons

WARNING: ANY VENTING OF NITROGEN TO ATMOSPHERE


SHOULD BE TREATED WITH EXTREME CARE, AS IN
HIGH CONCENTRATIONS INHALATION WILL CAUSE
UNCONSCIOUSNESS ALMOST IMMEDIATELY. NO
LOCAL CONTINUOUS VENTING OF EQUIPMENT
SHOULD TAKE PLACE UNLESS IT IS PIPED TO A
SUITABLE LOCATION WHERE PERSONNEL ARE
NOT EXPOSED.

While a nitrogen atmosphere remains within the vessel, any work


entailing the splitting of pipe flanges (turning of spectacled blinds
etc) may require to be undertaken with personnel wearing positive
pressure Breathing Apparatus sets

This procedure should be used in conjunction with Spading


Checklist, V-1005 and marked up P&ID CUR-MAS-PM-20048-501,
included at the end of this procedure

ID: M-CPH-1171-01417_EN_Section_6.doc Page 47 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.02.2 (1) REMOVE the blanks then carefully OPEN the vent valves for the
Preparation for Vessel level gauges fitted to the vessel. This will ENSURE that there is
Entry Procedure no pressure trapped in the Test separator.

Note: Any remaining gases in the Test separator must be vented to a


safe area suitable for the disposal of hydrocarbon gases.

(2) SWING Spectacled Blind SB1 on the inlet header to the


CLOSED position.

(3) SWING Spectacled Blind SB2 on the gas outlet line to the
CLOSED position.

(4) SWING Spectacled Blind SB3 on the oil outlet line to the
CLOSED position.

(5) SWING Spectacled Blind SB4 on the produced water outlet line
to the CLOSED position.

(6) SWING Spectacled Blind SB6 on the Belly Drain line at Nozzle
N6 to the CLOSED position.

(7) DIVIDE the Sandwash line at Nozzle N10A and INSERT Spade
S10A to the flange faces.

(8) DIVIDE the Sandwash line at Nozzle N10B and INSERT Spade
S10B to the flange faces.

(9) DIVIDE the Sandwash line at Nozzle N10C and INSERT Spade
S10C to the flange faces.

(10) DIVIDE the Belly Drain line at Nozzle N11A and SWING
Spectacle Blind SB11A to the CLOSED position.

(11) DIVIDE the Belly Drain line at Nozzle N11B and SWING
Spectacle Blind SB11B to the CLOSED position.

(12) DIVIDE the Belly Drain line at Nozzle N11C and SWING
Spectacle Blind SB11C to the CLOSED position.

(13) SWING Spectacle Blind SB7A on the Blowdown line to the


CLOSED position.

(14) SWING Spectacle Blind SB7B on the Manual Depressurisation


line to the CLOSED position.

(15) DIVIDE the Relief line at Nozzle N8 and INSERT Spade S8 to


the flange faces.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 48 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.02.2 (16) OPEN the Vessel Access Hatches M1A and M1B installed at the
Preparation for Vessel ends of the separator.
Entry Procedure
(Continued) (17) POSITION an air mover within each vessel access hatch
ENSURING the exhaust ducting vents are led away to a safe
area.

(18) Use the air mover to displace the gases within the separator until
the atmosphere inside the vessel contains 21% oxygen and less
than 0.25% hydrocarbons.

(19) If the Pressure Relief Valves 10-PSV-0503A and B are to be


removed for recertification, the flare pipework must be blinded off
using Blind Flanges BF12 and BF13 and included on Spading
Checklist V-1005.

Note: Ensure the open-ended pipework on the relief line from the Test
separator are blanked off once the pressure safety relief valves
are removed.

(20) The Test separator is available for entry when the appropriate
Vessel Entry Permit has been issued.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 49 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.02.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) CONFIRM that all equipment has been removed from the vessel
and the internal trim is in place and secure.

(2) CLOSE the Access Hatch Doors M1A and M1B.

(3) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or turning spectacled
blinds.

(4) SWING Spectacled Blind SB1 on the inlet header to the OPEN
position.

(5) SWING Spectacled Blind SB2 on the gas outlet line to the OPEN
position.

(6) SWING Spectacled Blind SB3 on the oil outlet line to the OPEN
position.

(7) SWING Spectacled Blind SB4 on the produced water outlet line
to the OPEN position.

(8) SWING Spectacled Blind SB6 on the Belly Drain line at Nozzle
N6 to the OPEN position.

(9) DIVIDE the Sandwash line at Nozzle N10A and REMOVE Spade
S10A then MAKE UP the flange faces.

(10) DIVIDE the Sandwash line at Nozzle N10B and REMOVE Spade
S10B then MAKE UP the flange faces.

(11) DIVIDE the Sandwash line at Nozzle N10C and REMOVE Spade
S10C then MAKE UP the flange faces.

(12) DIVIDE the Belly Drain line at Nozzle N11A and SWING SB11A
to the OPEN position then MAKE UP the flange faces.

(13) DIVIDE the Belly Drain line at Nozzle N11B and SWING SB11B
to the OPEN position then MAKE UP the flange faces.

(14) DIVIDE the Belly Drain line at Nozzle N11C and SWING SB11C
to the OPEN position then MAKE UP the flange faces.

(15) SWING Spectacled Blind SB7A on the Blowdown line to the


OPEN position.

(16) SWING Spectacled Blind SB7B on the Manual Depressurisation


line to the OPEN position.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 50 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.02.3 (17) DIVIDE the Relief line at Nozzle N8 and REMOVE Spade S8
Reinstatement Procedure then MAKE UP the flange faces.
(Continued)
(18) If the Pressure Relief valves 10-PSV-0503A and B have been
removed for recertification, REMOVE Blind Flanges BF12 and
BF13 from the flare side pipe flanges and REFIT the relief valves.

The Test separator, V-1005 has now been reinstated. The oil processing
facilities boundary isolations are still in place and should not be removed
until all maintenance work is complete within the boundary.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 51 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.02.4
Spading Checklist V-1005

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

SB1 Nozzle N1 10in-F-10001-HB2D-PG

SB2 Nozzle N2 10in-G-10001-HB7A-PG

SB3 Nozzle N3 6in-F-10002-HB2D-PG

SB4 Nozzle N4 4in-WP-10001-B2D-HC25

SB6 Nozzle N6 2in-D-10004-HA1C

SB7A Blowdown Line 8in-V-10003-HB7A

SB7B Depressurisation Line 1in-V-10005-HB7A

S8 Nozzle N8 4in-V-10001-HB7A

S10A Nozzle N10A 1in-WW-10001-HB2D

S10B Nozzle N10B 1in-WW-10001-HB2D

S10C Nozzle N10C 1in-WW-10001-HB2D

SB11A Nozzle N11A 2in-D-10001-HA1C

SB11B Nozzle N11B 2in-D-10002-HA1C

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 52 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.02.4
Spading Checklist V-1005 (Continued)

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

SB11C Nozzle N11C 2in-D-10003-HA1C

BF12 13-PSV-0503A 6in-V-10002-HA6A

BF13 13-PSV-0503B 6in-V-10002-HA6A

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 53 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.03 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


HP Separator V-1001 UNDERSTOOD BEFORE ATTEMPTING TO CARRY
OUT ANY ACTION.

6.03.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the HP separator has been flushed, drained and nitrogen
purged, as described in Section 6.01 of this volume

This vessel entry procedure is undertaken within the oil facilities


boundary isolations as listed under the Boundary Isolation Valve
Checklist

Prior to vessel entry the HP separator requires to be physically


disconnected from the associated pipework by either the rotation of
spectacle blinds or the removal of maintenance spools within the
process side blinded with correctly rated blind flanges

It is assumed that the pressure safety relief valves for the HP


separator will be removed for certification. The flare side flanges for
the relief valves must be isolated by suitably rated blind flanges

Prior to vessel entry, the hydrocarbon and nitrogen gases must be


displaced until the atmosphere within the vessel contains 21%
oxygen and less than 0.25% (volume) hydrocarbons

WARNING: ANY VENTING OF NITROGEN TO ATMOSPHERE


SHOULD BE TREATED WITH EXTREME CARE, AS IN
HIGH CONCENTRATIONS INHALATION WILL CAUSE
UNCONSCIOUSNESS ALMOST IMMEDIATELY. NO
LOCAL CONTINUOUS VENTING OF EQUIPMENT
SHOULD TAKE PLACE UNLESS IT IS PIPED TO A
SUITABLE LOCATION WHERE PERSONNEL ARE NOT
EXPOSED.

While a nitrogen atmosphere remains within the vessel, any work


entailing the splitting of pipe flanges (turning of spectacled blinds
etc) may require to be undertaken with personnel wearing positive
pressure Breathing Apparatus sets

This procedure should be used in conjunction with Spading


Checklist, V-1001 and marked up P&ID CUR-MAS-PM-20041-501,
included at the end of this procedure

ID: M-CPH-1171-01417_EN_Section_6.doc Page 54 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.03.2 (1) REMOVE the blanks then carefully OPEN the vent valves for the
Preparation for Vessel level gauges fitted to the vessel. This will ENSURE that there is
Entry Procedure no pressure trapped in the HP separator.

Note: Any remaining gases in the HP separator must be vented to a


safe area suitable for the disposal of hydrocarbon gases.

(2) SWING Spectacled Blind SB1 on the inlet header to the


CLOSED position.

(3) SWING Spectacled Blind SB2 on the gas outlet line to the
CLOSED position.

(4) SWING Spectacled Blind SB3 on the oil outlet line to the
CLOSED position.

(5) SWING Spectacled Blind SB4 on the produced water outlet line
to the CLOSED position.

(6) DIVIDE the Belly Drain line at Nozzle N6 and SWING Spectacle
Blind SB6 to the CLOSED position.

(7) DIVIDE the Sandwash line at Nozzle N10A and INSERT Spade
S10A to the flange faces.

(8) DIVIDE the Sandwash line at Nozzle N10B and INSERT Spade
S10B to the flange faces.

(9) DIVIDE the Sandwash line at Nozzle N10C and INSERT Spade
S10C to the flange faces.

(10) DIVIDE the Sandwash line at Nozzle N10D and INSERT Spade
S10D to the flange faces.

(11) DIVIDE the Sandwash line at Nozzle N10E and INSERT Spade
S10E to the flange faces.

(12) DIVIDE the Belly Drain line at Nozzle N11A and SWING
Spectacle Blind SB11A to the CLOSED position.

(13) DIVIDE the Belly Drain line at Nozzle N11B and SWING
Spectacle Blind SB11B to the CLOSED position.

(14) DIVIDE the Belly Drain line at Nozzle N11C and SWING
Spectacle Blind SB11C to the CLOSED position.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 55 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.03.2 (15) DIVIDE the Belly Drain line at Nozzle N11D and SWING
Preparation for Vessel Spectacle Blind SB11D to the CLOSED position.
Entry Procedure
(Continued) (16) DIVIDE the Belly Drain line at Nozzle N11E and SWING
Spectacle Blind SB11E to the CLOSED position.

(17) SWING Spectacle Blind SB7A on the Blowdown line to the


CLOSED position.

(18) SWING Spectacle Blind SB7B on the Manual Depressurisation


line to the CLOSED position.

(19) DIVIDE the Relief line at Nozzle N8 and INSERT Spade S8 to


the flange faces.

(20) OPEN the Vessel Access Hatches M1A and M1B installed at the
ends of the separator.

(21) POSITION an air mover within each vessel access hatch


ENSURING the exhaust ducting vents are led away to a safe
area.

(22) Use the air mover to displace the gases within the separator until
the atmosphere inside the vessel contains 21% oxygen and less
than 0.25% hydrocarbons.

(23) If the Pressure Relief Valves 10-PSV-0103A and B are to be


removed for recertification, the flare pipework must be blinded off
using Blind Flanges BF12 and BF13 and included on Spading
Checklist V-1001.

Note: Ensure that the open-ended pipework on the relief line from the
HP separator are blanked off once the pressure safety relief valves
are removed.

(24) The HP separator is available for entry when the appropriate


Vessel Entry Permit has been issued.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 56 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.03.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) CONFIRM that all equipment has been removed from the vessel
and the internal trim is in place and secure.

(2) CLOSE the Access Hatch Doors M1A and M1B.

(3) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or turning spectacled
blinds.

(4) SWING Spectacled Blind SB1 on the inlet header to the OPEN
position.

(5) SWING Spectacled Blind SB2 on the gas outlet line to the OPEN
position.

(6) SWING Spectacled Blind SB3 on the oil outlet line to the OPEN
position.

(7) SWING Spectacled Blind SB4 on the produced water outlet line
to the OPEN position.

(8) DIVIDE the Belly Drain line at Nozzle N6 and SWING Spectacle
Blind SB6 to the OPEN position.

(9) DIVIDE the Sandwash line at Nozzle N10A and REMOVE Spade
S10A then MAKE UP the flange faces.

(10) DIVIDE the Sandwash line at Nozzle N10B and REMOVE Spade
S10B then MAKE UP the flange faces.

(11) DIVIDE the Sandwash line at Nozzle N10C and REMOVE Spade
S10C then MAKE UP the flange faces.

(12) DIVIDE the Sandwash line at Nozzle N10D and REMOVE Spade
S10D then MAKE UP the flange faces.

(13) DIVIDE the Sandwash line at Nozzle N10E and REMOVE Spade
S10E then MAKE UP the flange faces.

(14) DIVIDE the Belly Drain line at Nozzle N11A and SWING SB11A
to the OPEN position, then MAKE UP the flange faces.

(15) DIVIDE the Belly Drain line at Nozzle N11B and SWING SB11B
to the OPEN position then MAKE UP the flange faces.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 57 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

(16) DIVIDE the Belly Drain line at Nozzle N11C and SWING SB11C
to the OPEN position then MAKE UP the flange faces.

6.03.3 (17) DIVIDE the Belly Drain line at Nozzle N11D and SWING SB11D
Reinstatement Procedure to the OPEN position then MAKE UP the flange faces.
(Continued)
(18) DIVIDE the Belly Drain line at Nozzle N11E and SWING SB11E
to the OPEN position then MAKE UP the flange faces.

(19) SWING Spectacled Blind SB7A on the Blowdown line to the


OPEN position.

(20) SWING Spectacled Blind SB7B on the Manual Depressurisation


line to the OPEN position.

(21) DIVIDE the Relief line at Nozzle N8 and REMOVE Spade S8


then MAKE UP the flange faces.

(22) If the Pressure Relief valves 10-PSV-0103A and B have been


removed for recertification, REMOVE Blind Flanges BF12 and
BF13 from the flare side pipe flanges and REFIT the relief valves.

The HP separator, V-1001 has now been reinstated. The oil processing
facilities boundary isolations are still in place and should not be removed
until all maintenance work is complete within the boundary.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 58 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.03.4
Spading Checklist V-1001

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

SB1 Nozzle N1 14in-F-10004-HB2D-PG

SB2 Nozzle N2 12in-G-10003-HB7A-PG

SB3 Nozzle N3 6in-F-10005-HB2D-PG

SB4 Nozzle N4 6in-WP-10002-HB1E-


HC25

SB6 Nozzle N6 2in-D-10013-HA1C

SB7A Blowdown Line 10in-V-10008-HB7A

SB7B Depressurisation Line 1in-V-10011-HB7A

S8 Nozzle N8 6in-V-10007-HB7A

S10A Nozzle N10A 1in-WW-10002-HB2D

S10B Nozzle N10B 1in-WW-10002-HB2D

S10C Nozzle N10C 1in-WW-10002-HB2D

S10D Nozzle N11A 1in-WW-10002-HB2D

S10E Nozzle N11B 1in-WW-10002-HB2D

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 59 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.03.4 Spading Checklist V-1001 (Continued)


BLIND LOCATION LINE No DATE SIG DATE SIG
No FITTED PULLED

SB11A Nozzle N11A 2in-D-10008-HA1C

SB11B Nozzle N11B 2in-D-10009-HA1C

SB11C Nozzle N11C 2in-D-10010-HA1C

SB11D Nozzle N11D 2in-D-100011-HA1C

SB11E Nozzle N11E 2in-D-10012-HA1C

BF12 10-PSV-0103A 8in-V-10008-HA6A

BF13 10-PSV-0103B 8in-V-10008-HA6A

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 60 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.04 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


HP Crude Oil Heater UNDERSTOOD BEFORE ATTEMPTING TO CARRY
OUT ANY ACTION.
E-1001

6.04.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the HP crude oil heater has been flushed and drained, as
described in Section 6.01 of this volume

This procedure is undertaken within the oil facilities boundary


isolations as listed under the Boundary Isolation Valve Checklist

This procedure is written with the viewpoint that the HP crude oil
heater has been shut down as part of the overall oil processing
facilities shutdown. When the Curlew production wells are flowing
to the Oil Processing Facilities, the HP crude oil heater is normally
in constant use to heat the crude oil passing from the HP separator
to the MP separator

The following procedure describes the mechanical isolation


(spading) required for boundary situations

It is assumed that the Pressure Safety Relief Valve


10-PSV-0153 for the crude outlet from the HP crude oil heater will
be removed for certification. The flare side flange on the relief line
must be isolated by a suitably rated blind flange

If Pressure Safety Relief Valve 44-PSV-2013 for the heating


medium return from the heater is to be removed for certification the
inlet flange must be blanked off once the valve is removed

This procedure should be used in conjunction with the Boundary


Isolation Valve Checklist, Spading Checklist E-1001 and marked up
P&ID CUR-MAS-PM-20042-501, included at the end of this
procedure

ID: M-CPH-1171-01417_EN_Section_6.doc Page 61 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.04.2 (1) Carefully OPEN the drain valve for the crude inlet to the HP
Isolation Procedure crude oil heater. This will ENSURE that there is no pressure
trapped in the tubeside of the heater.

Note: Any remaining drainings from the tubeside of the heater must be
directed to the skid drip pan, which is suitable for the disposal of
liquid hydrocarbons.

(2) SWING Spectacled Blind SB1 on the crude inlet to the CLOSED
position.

(3) SWING Spectacled Blind SB2 on the crude outlet to the


CLOSED position.

(4) Carefully OPEN the drain valve for the heating medium outlet
from the HP crude oil heater. This will ENSURE that there is no
pressure trapped in the shellside of the heater.

Note: Any remaining drainings from the shellside of the heater must be
directed to the skid drip pan, which is suitable for the disposal of
heating medium.

(5) SWING Spectacled Blind SB3 on the heating medium inlet to the
CLOSED position.

(6) SWING Spectacled Blind SB4 on the heating medium outlet to


the CLOSED position.

(7) If the Pressure Safety Relief Valve 10-PSV-0153 for the crude
outlet is to be removed for recertification, the flare pipework must
be blinded off using Blind Flange BF5 and included on Spading
Checklist E-1001.

(6) If the Pressure Safety Relief Valve 44-PSV-2013 for the heating
medium return is to be removed for recertification, the flare
pipework must be blinded off using Blind Flange BF6 and included
on Spading Checklist E-1001.

Note: Ensure that the open-ended pipework on the crude and heating
medium outlets from the HP crude oil heater are blanked off once
the pressure safety relief valves are removed.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 62 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.04.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or turning spectacled
blinds.

(2) SWING Spectacled Blind SB1 on the crude inlet to the OPEN
position.

(3) SWING Spectacled Blind SB2 on the crude outlet to the OPEN
position.

(4) SWING Spectacled Blind SB3 on the heating medium inlet to the
OPEN position.

(5) SWING Spectacled Blind SB4 on the heating medium outlet to


the OPEN position.

(6) If the Pressure Safety Relief Valve, 10-PSV-0153 has been


removed for recertification, REMOVE Blind Flange BF5 on the
flare side pipe flange and REFIT the relief valve.

(7) If the Pressure Safety Relief Valve, 44-PSV-2013 has been


removed for recertification, REMOVE Blind Flange BF6 on the
flare side pipe flange and REFIT the relief valve.

(8) ENSURE that the drain valves for the crude inlet and heating
medium outlet lines are CLOSED.

The HP Crude Oil Heater, E-1001 has now been reinstated. The oil
processing facilities boundary isolations are still in place and should not
be removed until all maintenance work is complete within the boundary.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 63 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.04.4
Spading Checklist E-1001

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

SB1 Crude oil inlet 6in-F-10005-HB2D-PG

SB2 Crude oil outlet 6in-F-10006-HB2D-PG

SB3 Heating Medium inlet 4in-HM-44001-HA1C-


HC50

SB4 Heating Medium outlet 4in-HM-44002-HA1C-


HC50

BF5 10-PSV-0153 2in-V-10012-HA6A

BF6 44-PSV-2013 3in-V-44025-HA1C

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 64 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.05 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


MP Separator V-1002 UNDERSTOOD BEFORE ATTEMPTING TO CARRY
OUT ANY ACTION.

6.05.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the MP separator has been flushed, drained and nitrogen
purged, as described in Section 6.01 of this volume

This vessel entry procedure is undertaken within the oil facilities


boundary isolations as listed under the Boundary Isolation Valve
Checklist

Prior to vessel entry, the MP separator requires to be physically


disconnected from the associated pipework by either the rotation of
spectacle blinds or the removal of maintenance spools within the
process side blinded with correctly rated blind flanges

It is assumed that the pressure safety relief valves for the MP


separator will be removed for certification. The flare side flanges for
the relief valves must be isolated by suitably rated blind flanges

Prior to vessel entry, the hydrocarbon and nitrogen gases must be


displaced until the atmosphere within the vessel contains 21%
oxygen and less than 0.25% (volume) hydrocarbons

WARNING: ANY VENTING OF NITROGEN TO ATMOSPHERE


SHOULD BE TREATED WITH EXTREME CARE, AS IN
HIGH CONCENTRATIONS INHALATION WILL CAUSE
UNCONSCIOUSNESS ALMOST IMMEDIATELY. NO
LOCAL CONTINUOUS VENTING OF EQUIPMENT
SHOULD TAKE PLACE UNLESS IT IS PIPED TO A
SUITABLE LOCATION WHERE PERSONNEL ARE NOT
EXPOSED.

While a nitrogen atmosphere remains within the vessel, any work


entailing the splitting of pipe flanges (turning of spectacled blinds
etc) may require to be undertaken with personnel wearing positive
pressure Breathing Apparatus sets

This procedure should be used in conjunction with Spading


Checklist, V-1002 and marked up P&ID CUR-MAS-PM-20043-501,
included at the end of this procedure

ID: M-CPH-1171-01417_EN_Section_6.doc Page 65 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.05.2 (1) REMOVE the blanks then carefully OPEN the vent valves for the
Preparation for Vessel level gauges fitted to the vessel. This will ENSURE that there is
Entry Procedure no pressure trapped in the MP separator.

Note: Any remaining gases in the MP separator must be vented to a


safe area suitable for the disposal of hydrocarbon gases.

(2) SWING Spectacled Blind SB1 on the inlet header to the


CLOSED position.

(3) SWING Spectacled Blind SB2 on the gas outlet line to the
CLOSED position.

(4) SWING Spectacled Blind SB3 on the oil outlet line to the
CLOSED position.

(5) SWING Spectacled Blind SB4 on the produced water outlet line
to the CLOSED position.

(6) DIVIDE the Belly Drain line at Nozzle N6 and SWING Spectacled
Blind SB6 to the CLOSED position.

(7) DIVIDE the Sandwash line at Nozzle N10A and INSERT Spade
S10A to the flange faces.

(8) DIVIDE the Sandwash line at Nozzle N10B and INSERT Spade
S10B to the flange faces.

(9) DIVIDE the Sandwash line at Nozzle N10C and INSERT Spade
S10C to the flange faces.

(10) DIVIDE the Sandwash line at Nozzle N10D and INSERT Spade
S10D to the flange faces.

(11) DIVIDE the Sandwash line at Nozzle N10E and INSERT Spade
S10E to the flange faces.

(12) DIVIDE the Belly Drain line at Nozzle N11A and SWING
Spectacled Blind SB11A to the CLOSED position.

(13) DIVIDE the Belly Drain line at Nozzle N11B and SWING
Spectacled Blind SB11B to the CLOSED position.

(14) DIVIDE the Belly Drain line at Nozzle N11C and SWING
Spectacled Blind SB11C to the CLOSED position.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 66 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.05.2 (15) DIVIDE the Belly Drain line at Nozzle N11D and SWING
Preparation for Vessel Spectacled Blind SB11D to the CLOSED position.
Entry Procedure
(Continued) (16) DIVIDE the Belly Drain line at Nozzle N11E and SWING
Spectacled Blind SB11E to the CLOSED position.

(17) DIVIDE the Blowdown line at Nozzle N7 and INSERT Spade S7


to the flange faces.

(18) DIVIDE the Relief line at Nozzle N8 and INSERT Spade S8 to


the flange faces.

(19) OPEN the Vessel Access Hatches M1A and M1B installed at the
ends of the separator.

(20) POSITION an air mover within each vessel access hatch


ENSURING the exhaust ducting vents are led away to a safe
area.

(21) Use the air mover to displace the gases within the separator until
the atmosphere inside the vessel contains 21% oxygen and less
than 0.25% hydrocarbons.

(22) If the Pressure Relief Valves 10-PSV-0203A and B are to be


removed for recertification, the flare pipework must be blinded off
using Blind Flanges BF12 and BF13 and included on Spading
Checklist V-1002.

Note: Ensure that the open-ended pipework on the relief line from the
MP separator are blanked off once the pressure safety relief
valves are removed.

(23) The MP separator is available for entry when the appropriate


Vessel Entry Permit has been issued.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 67 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.05.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) CONFIRM that all equipment has been removed from the vessel
and the internal trim is in place and secure.

(2) CLOSE the Access Hatch Doors M1A and M1B.

(3) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or turning spectacled
blinds.

(4) SWING Spectacled Blind SB1 on the inlet header to the OPEN
position.

(5) SWING Spectacled Blind SB2 on the gas outlet line to the OPEN
position.

(6) SWING Spectacled Blind SB3 on the oil outlet line to the OPEN
position.

(7) SWING Spectacled Blind SB4 on the produced water outlet line
to the OPEN position.

(8) DIVIDE the Belly Drain line at Nozzle N6 and SWING Spectacled
Blind SB6 to the OPEN position then MAKE UP the flange faces.

(9) DIVIDE the Sandwash line at Nozzle N10A and REMOVE Spade
S10A then MAKE UP the flange faces.

(10) DIVIDE the Sandwash line at Nozzle N10B and REMOVE Spade
S10B then MAKE UP the flange faces.

(11) DIVIDE the Sandwash line at Nozzle N10C and REMOVE Spade
S10C then MAKE UP the flange faces.

(12) DIVIDE the Sandwash line at Nozzle N10D and REMOVE Spade
S10D then MAKE UP the flange faces.

(13) DIVIDE the Sandwash line at Nozzle N10E and REMOVE Spade
S10E then MAKE UP the flange faces.

(14) DIVIDE the Belly Drain line at Nozzle N11A and SWING
Spectacled Blind SB11A to the OPEN position then MAKE UP the
flange faces.

(15) DIVIDE the Belly Drain line at Nozzle N11B and SWING
Spectacled Blind SB11B to the OPEN position then MAKE UP the
flange faces.
ID: M-CPH-1171-01417_EN_Section_6.doc Page 68 / 105
MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.05.3 (16) DIVIDE the Belly Drain line at Nozzle N11C and SWING
Reinstatement Procedure Spectacled Blind SB11C to the OPEN position then MAKE UP the
(Continued) flange faces.

(17) DIVIDE the Belly Drain line at Nozzle N11D and SWING
Spectacled Blind SB11D to the OPEN position then MAKE UP the
flange faces.

(18) DIVIDE the Belly Drain line at Nozzle N11E and SWING
Spectacled Blind SB11E to the OPEN position then MAKE UP the
flange faces.

(19) DIVIDE the Blowdown line at Nozzle N7 and REMOVE Spade


S7 then MAKE UP the flange faces.

(20) DIVIDE the Relief line at Nozzle N8 and REMOVE Spade S8


then MAKE UP the flange faces.

(21) If the Pressure Relief valves 10-PSV-0203A and B have been


removed for recertification, REMOVE Blind Flanges BF12 and
BF13 from the flare side pipe flanges and REFIT the relief valves.

The MP separator, V-1002 has now been reinstated. The oil processing
facilities boundary isolations are still in place and should not be removed
until all maintenance work is complete within the boundary.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 69 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.05.4 Spading Checklist V-1002


BLIND LOCATION LINE No DATE SIG DATE SIG
No FITTED PULLED

SB1 Nozzle N1 14in-F-10008-HA2D-PG

SB2 Nozzle N2 10in-G-10004-HA2D-PG

SB3 Nozzle N3 8in-F-10009-HA2D-PG

SB4 Nozzle N4 6in-WP-10003-HA1E-


HC25

SB6 Nozzle N6 2in-D-10023-HA1C

S7 Blowdown Line 4in-V-10015-HA2D

S8 Nozzle N8 6in-V-10013-HA2D

S10A Nozzle N10A 1in-WW-10003-HA2D

S10B Nozzle N10B 1in-WW-10003-HA2D

S10C Nozzle N10C 1in-WW-10003-HA2D

S10D Nozzle N10D 1in-WW-10003-HA2D

S10E Nozzle N10E 1in-WW-10003-HA2D

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 70 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.05.4 Spading Checklist V-1002 (Continued)


BLIND LOCATION LINE No DATE SIG DATE SIG
No FITTED PULLED

SB11A Nozzle N11A 2in-D-10018-HA1C

SB11B Nozzle N11B 2in-D-10019-HA1C

SB11C Nozzle N11C 2in-D-10020-HA1C

SB11D Nozzle N11D 2in-D-10021-HA1C

SB11E Nozzle N11E 2in-D-10022-HA1C

BF12 10-PSV-0203A 8in-V-10014-HA1C

BF13 10-PSV-0203B 8in-V-10014-HA1C

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 71 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.06 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


MP Crude Oil Heater UNDERSTOOD BEFORE ATTEMPTING TO CARRY
OUT ANY ACTION.
E-1002

6.06.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the MP crude oil heater has been flushed and drained, as
described in Section 6.01 of this volume

This procedure is undertaken within the oil facilities boundary


isolations as listed under the Boundary Isolation Valve Checklist

This procedure is written with the viewpoint that the MP crude oil
heater has been shut down as part of the overall oil processing
facilities shutdown. The MP crude oil heater is normally in constant
use to heat the partially stabilised crude oil from the MP separator
passing to the LP separator for full stabilisation

The following procedure describes the mechanical isolation


(spading) required for boundary situations

It is assumed that the Pressure Safety Relief Valve 10-PSV-0253


for the crude inlet to the MP crude oil heater will be removed for
certification. The flare side flange on the relief line must be isolated
by a suitably rated blind flange

This procedure should be used in conjunction with the Boundary


Isolation Valve Checklist, Spading Checklist E-1002 and marked up
P&ID CUR-MAS-PM-20044-501, included at the end of this
procedure

ID: M-CPH-1171-01417_EN_Section_6.doc Page 72 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.06.2 (1) Carefully OPEN the drain valve for the crude inlet to the MP
Isolation Procedure crude oil heater. This will ENSURE that there is no pressure
trapped in the cold side of the heater.

Note: Any remaining drainings from the cold side of the heater must be
directed to the skid drip pan which is suitable for the disposal of
liquid hydrocarbons.

(2) SWING Spectacled Blind SB1 on the crude inlet to the CLOSED
position.

(3) SWING Spectacled Blind SB2 on the crude outlet to the


CLOSED position.

(4) Carefully OPEN the drain valve for the heating medium outlet
from the MP crude oil heater. This will ENSURE that there is no
pressure trapped in the warm side of the heater.

Note: Any remaining drainings from the warm side of the heater must
be directed to the skid drip pan which is suitable for the disposal of
heating medium.

(5) SWING Spectacled Blind SB3 on the heating medium inlet to the
CLOSED position.

(6) SWING Spectacled Blind SB4 on the heating medium outlet to


the CLOSED position.

(7) If the Pressure Safety Relief Valve 10-PSV-0253 for the crude
inlet is to be removed for recertification, the flare pipework must
be blinded off using Blind Flange BF5 and included on Spading
Checklist E-1002.

Note: Ensure that the open-ended pipework on the crude inlet and
heating medium outlet from the MP crude oil heater are blanked
off once the pressure safety relief valves are removed.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 73 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.06.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or turning spectacled
blinds.

(2) SWING Spectacled Blind SB1 on the crude inlet to the OPEN
position.

(3) SWING Spectacled Blind SB2 on the crude outlet to the OPEN
position.

(4) SWING Spectacled Blind SB3 on the heating medium inlet to the
OPEN position.

(5) SWING Spectacled Blind SB4 on the heating medium outlet to


the OPEN position.

(6) If the Pressure Safety Relief Valve, 10-PSV-0253 has been


removed for recertification, REMOVE Blind Flange BF5 on the
flare side pipe flange and REFIT the relief valve.

(7) ENSURE that the drain valves for the crude inlet and heating
medium outlet lines are CLOSED.

The MP Crude Oil Heater, E-1002 has now been reinstated. The oil
processing facilities boundary isolations are still in place and should not
be removed until all maintenance work is complete within the boundary.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 74 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.06.4
Spading Checklist E-1002

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

SB1 Crude oil inlet 16in-F-10009-HA2D-PG

SB2 Crude oil outlet 20in-F-10010-HA2D

SB3 Heating Medium inlet 6in-HM-44003-HA1C-


HC50

SB4 Heating Medium outlet 6in-HM-44004-HA1C-


HC50

BF5 10-PSV-0253 3in-V-10018-HA1C

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 75 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.07 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


LP Separator V-1003 UNDERSTOOD BEFORE ATTEMPTING TO CARRY
OUT ANY ACTION.

6.07.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the LP separator has been flushed, drained and nitrogen
purged, as described in Section 6.01 of this volume

This vessel entry procedure is undertaken within the oil facilities


boundary isolations as listed under the Boundary Isolation Valve
Checklist

Prior to vessel entry, the LP separator requires to be physically


disconnected from the associated pipework by either the rotation of
spectacle blinds or the removal of maintenance spools within the
process side blinded with correctly rated blind flanges

It is assumed that the pressure safety relief valves for the LP


separator will be removed for certification. The flare side flanges for
the relief valves must be isolated by suitably rated blind flanges

Prior to vessel entry, the hydrocarbon and nitrogen gases must be


displaced until the atmosphere within the vessel contains 21%
oxygen and less than 0.25% (volume) hydrocarbons

WARNING: ANY VENTING OF NITROGEN TO ATMOSPHERE


SHOULD BE TREATED WITH EXTREME CARE, AS IN
HIGH CONCENTRATIONS INHALATION WILL CAUSE
UNCONSCIOUSNESS ALMOST IMMEDIATELY. NO
LOCAL CONTINUOUS VENTING OF EQUIPMENT
SHOULD TAKE PLACE UNLESS IT IS PIPED TO A
SUITABLE LOCATION WHERE PERSONNEL ARE NOT
EXPOSED.

While a nitrogen atmosphere remains within the vessel, any work


entailing the splitting of pipe flanges (turning of spectacled blinds
etc) may require to be undertaken with personnel wearing positive
pressure Breathing Apparatus sets

This procedure should be used in conjunction with Spading


Checklist, V-1003 and marked up P&ID CUR-MAS-PM-20045-501,
included at the end of this procedure

ID: M-CPH-1171-01417_EN_Section_6.doc Page 76 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.07.2 (1) REMOVE the blanks then carefully OPEN the vent valves for the
Preparation for Vessel level gauges fitted to the vessel. This will ENSURE that there is
Entry Procedure no pressure trapped in the LP separator.

Note: Any remaining gases in the LP separator must be vented to a


safe area suitable for the disposal of hydrocarbon gases.

(2) SWING Spectacled Blind SB1 on the inlet header to the


CLOSED position.

(3) SWING Spectacled Blind SB2 on the gas outlet line to the
CLOSED position.

(4) SWING Spectacled Blind SB3 on the oil outlet line to the
CLOSED position.

(5) SWING Spectacled Blind SB4 on the produced water outlet line
to the CLOSED position.

(6) DIVIDE the minimum flowline for the crude oil transfer pumps at
Nozzle N5 and INSERT Spade S5 to the flange faces.

(7) LEAVE Spectacle Blind SB6 on the crude oil outlet drain line in
the CLOSED position.

(8) DIVIDE the Sandwash line at Nozzle N10A and INSERT Spade
S10A to the flange faces.

(9) DIVIDE the Sandwash line at Nozzle N10B and INSERT Spade
S10B to the flange faces.

(10) DIVIDE the Sandwash line at Nozzle N10C and INSERT Spade
S10C to the flange faces.

(11) DIVIDE the Sandwash line at Nozzle N10D and INSERT Spade
S10D to the flange faces.

(12) DIVIDE the Sandwash line at Nozzle N10E and INSERT Spade
S10E to the flange faces.

(13) DIVIDE the Belly Drain line at Nozzle N11A and SWING
Spectacled Blind SB11A to the CLOSED position.

(14) DIVIDE the Belly Drain line at Nozzle N11B and SWING
Spectacled Blind SB11B to the CLOSED position.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 77 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.07.2 (15) DIVIDE the Belly Drain line at Nozzle N11C and SWING
Preparation for Vessel Spectacled Blind SB11C to the CLOSED position.
Entry Procedure
(Continued) (16) DIVIDE the Belly Drain line at Nozzle N11D and SWING
Spectacled Blind SB11D to the CLOSED position.

(17) DIVIDE the Belly Drain line at Nozzle N11E and SWING
Spectacled Blind SB11E to the CLOSED position.

(18) DIVIDE the Blowdown line at Nozzle N7 and INSERT Spade S7


to the flange faces.

(19) DIVIDE the Relief line at Nozzle N8 and INSERT Spade S8 to


the flange faces.

(20) OPEN the Vessel Access Hatches M1A and M1B installed at the
ends of the separator.

(21) POSITION an air mover within each vessel access hatch


ENSURING that the exhaust ducting vents are led away to a safe
area.

(22) Use the air mover to displace the gases within the separator until
the atmosphere inside the vessel contains 21% oxygen and less
than 0.25% hydrocarbons.

(23) If the Pressure Relief Valves 10-PSV-0303A and B are to be


removed for recertification, the flare pipework must be blinded off
using Blind Flanges BF12 and BF13 and included on Spading
Checklist V-1003.

Note: Ensure that the open-ended pipework on the relief line from the
LP separator are blanked off once the pressure safety relief valves
are removed.

(24) The LP separator is available for entry when the appropriate


Vessel Entry Permit has been issued.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 78 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.07.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) CONFIRM that all equipment has been removed from the vessel
and the internal trim is in place and secure.

(2) CLOSE the Access Hatch Doors M1A and M1B.

(3) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or turning spectacled
blinds.

(4) SWING Spectacled Blind SB1 on the inlet header to the OPEN
position.

(5) SWING Spectacled Blind SB2 on the gas outlet line to the OPEN
position.

(6) SWING Spectacled Blind SB3 on the oil outlet line to the OPEN
position.

(7) SWING Spectacled Blind SB4 on the produced water outlet line
to the OPEN position.

(8) DIVIDE the minimum flowline for the crude oil transfer pump at
Nozzle N5 and REMOVE Spade S5 then MAKE UP the flange
faces.

(9) LEAVE Spectacled Blind SB6 on the crude oil outlet drain line in
the CLOSED position.

(10) DIVIDE the Sandwash line at Nozzle N10A and REMOVE Spade
S10A then MAKE UP the flange faces.

(11) DIVIDE the Sandwash line at Nozzle N10B and REMOVE Spade
S10B then MAKE UP the flange faces.

(12) DIVIDE the Sandwash line at Nozzle N10C and REMOVE Spade
S10C then MAKE UP the flange faces.

(13) DIVIDE the Sandwash line at Nozzle N10D and REMOVE Spade
S10D then MAKE UP the flange faces.

(14) DIVIDE the Sandwash line at Nozzle N10E and REMOVE Spade
S10E then MAKE UP the flange faces.

(15) DIVIDE the Belly Drain line at Nozzle N11A and SWING
Spectacled Blind SB11A to the OPEN position then MAKE UP the
flange faces.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 79 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.07.3 (16) DIVIDE the Belly Drain line at Nozzle N11B and SWING
Reinstatement Procedure Spectacled Blind SB11B to the OPEN position then MAKE UP the
(Continued) flange faces.

(17) DIVIDE the Belly Drain line at Nozzle N11C and SWING
Spectacled Blind SB11C to the OPEN position then MAKE UP the
flange faces.

(18) DIVIDE the Belly Drain line at Nozzle N11D and SWING
Spectacled Blind SB11D to the OPEN position then MAKE UP the
flange faces.

(19) DIVIDE the Belly Drain line at Nozzle N11E and SWING
Spectacled Blind SB11E to the OPEN position then MAKE UP the
flange faces.

(20) DIVIDE the Blowdown line at Nozzle N7 and REMOVE Spade


S7 then MAKE UP the flange faces.

(21) DIVIDE the Relief line at Nozzle N8 and REMOVE Spade S8


then MAKE UP the flange faces.

(22) If the Pressure Relief valves 10-PSV-0303A and B have been


removed for recertification, REMOVE Blind Flanges BF12 and
BF13 from the flare side pipe flanges and REFIT the relief valves.

The LP separator, V-1003 has now been reinstated. The oil processing
facilities boundary isolations are still in place and should not be removed
until all maintenance work is complete within the boundary.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 80 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.07.4 Spading Checklist V-1003


BLIND LOCATION LINE No DATE SIG DATE SIG
No FITTED PULLED

SB1 Nozzle N1 20in-F-10010-HA2D

SB2 Nozzle N2 16in-G-10006-HA2D

SB3 Nozzle N3 12in-F-10011-HA2D

SB4 Nozzle N4 3in-WP-10004-HA1E-


HC25

S5 Nozzle N5 4in-F-10013-HA2D

SB6 Nozzle N6 2in-D-10033-HA1C

S7 Blowdown Line 4in-V-10021-HA2D

S8 Nozzle N8 4in-V-10019-HA2D

S10A Nozzle N10A 1in-WW-10004-HA2D

S10B Nozzle N10B 1in-WW-10004-HA2D

S10C Nozzle N10C 1in-WW-10004-HA2D

S10D Nozzle N10D 1in-WW-10004-HA2D

S10E Nozzle N10E 1in-WW-10004-HA2D

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 81 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.07.4
Spading Checklist V-1003 (Continued)

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

SB11A Nozzle N11A 2in-D-10028-HA1C

SB11B Nozzle N11B 2in-D-10029-HA1C

SB11C Nozzle N11C 2in-D-10030-HA1C

SB11D Nozzle N11D 2in-D-10031-HA1C

SB11E Nozzle N11E 2in-D-10032-HA1C

BF12 13-PSV-0303A 6in-V-10020-HA1C

BF13 13-PSV-0303B 6in-V-10020-HA1C

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 82 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.08 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


Produced Water Transfer UNDERSTOOD BEFORE ATTEMPTING TO CARRY
Pumps P-1002A/B OUT ANY ACTION.

6.08.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the produced water transfer pumps have been water flushed,
as described in Section 6.01 of this volume

This procedure is undertaken within the oil facilities boundary


isolations as listed under the Boundary Isolation Valve Checklist

This procedure is written with the viewpoint that the produced water
transfer pumps have been shut down as part of the overall oil
processing facilities shutdown. However, the produced water
transfer pumps are rated for 100% duty and normally operate on a
Duty/Standby basis. As such, any one pump can be shut down for
maintenance leaving the other pump on-line.

In the stand-alone maintenance isolation situation the off-line pump


will require to be valve isolated, depressurised and drained,
followed by being isolated by spading before intrusive maintenance
can commence.

The following procedure describes the isolation for either stand-


alone or boundary isolation situations on the understanding that in
the stand-alone situation the off-line pump still has to be
depressurised and drained and the alternative pump is operating
normally

This procedure should be used in conjunction with the Boundary


Isolation Valve Checklist and Spading Checklists, P-1002A and B in
the case of maintenance within the boundary

This procedure should be used in conjunction with the Valve


Isolation Checklists, P-1002A and B and Spading Checklists
P-002A and B in the case of stand-alone maintenance during
normal operations

Note: In the stand-alone isolation procedure, ENSURE that the pump is


electrically isolated with the Electrical Isolation Certificate issued
before any mechanical isolation of the pump is started.

The Spade Schedules and Valve Isolation Checklists should be


used in conjunction with the marked up P&ID CUR-MAS-PM-
20045-501 included at the end of the procedure

ID: M-CPH-1171-01417_EN_Section_6.doc Page 83 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.08.2 This procedure is written for Produced Water Transfer Pump P-1002A.
Isolation Procedure The same procedure can be used for identical Pump P-1002B utilising
the valve tag numbers included in the Valve Isolation Checklist.

Note: Steps 1 to 4 describe the necessary valve isolations for a stand-


alone maintenance isolation. Steps 5 to 6 describe the turning of
the various spectacle blinds and removal of maintenance spools
as required in either case (Boundary or Stand-alone Isolation).

(1) CLOSE, LOCK and TAG the 3in Isolation Ball Valve for the
pump suction line.

(2) CLOSE, LOCK and TAG the 2in Isolation Ball Valve for the
pump discharge line.

(3) OPEN the in Drain Valve for the pump suction line to SLOWLY
DEPRESSURISE and DRAIN the pipework and pump casing.
ENSURE that all drainings are directed to the Hazardous Area
Open Drains for safe disposal and CLOSE the drain valve on
completion.

(4) ENSURE that there is no pressure trapped in the pump body by


ISOLATING Pressure Gauge 10-PG-0326 for the pump
discharge, REMOVING the instrument and CAREFULLY
RE-OPENING the isolation valve. REPLACE the pressure gauge
once the pump is confirmed as fully depressurised.

(5) REMOVE the pump suction maintenance spool and Y-type


strainer for cleaning then INSTALL Blind Flange BF1 to the
upstream pipe flange.

Note: Ensure that the suction line is blanked off at the pump once the
maintenance spool is removed.

(6) REMOVE the pump discharge maintenance spool and non-


return valve then INSTALL Blind Flange BF2 to the downstream
pipe flange.

Note: Ensure that the discharge line is blanked off at the pump once
the maintenance spool is removed.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 84 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.08.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or spades (in the
case of a boundary isolated maintenance activity).

(2) REMOVE Blind Flange BF1 and REFIT the pump suction
maintenance spool. Ensure that the inlet strainer is replaced and
the blank is removed from the pump suction line.

(3) REMOVE Blind Flange BF2 and REFIT the pump discharge
maintenance spool. Ensure that the non-return valve is replaced
and the blank is removed from the pump discharge line.

In the case of the boundary isolated maintenance activity, this completes


the reinstatement of the pump. The oil processing facilities boundary
isolations are still in place and should not be removed until all
maintenance work is complete within the boundary.

In the case of the stand-alone isolation of the pump, the following valves
require to be opened to return the pump to service:

(4) REMOVE the TAG, UNLOCK and OPEN the 3in Isolation Valve
for the pump suction line.

(5) REMOVE the TAG, UNLOCK and OPEN the 2in Isolation Valve
for the pump discharge line.

(6) PARTIALLY OPEN the in Drain Valve to prime the pump.


CLOSE the drain valve as soon as the pump is primed.

The produced water transfer pump has now been reinstated following
stand-alone isolation and can be returned to service once the Electrical
Isolation Certificate and Work Permit have been signed off.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 85 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.08.4
Valve Isolation Checklist P-1002A (Stand-alone)

VALVE LOCATION LINE No ISOLATED SIG/


TAG No POSITION DATE

HV-10174 Pump suction line 3in-WP-10004-HA1E-HC25 CLOSED

HV-10176 Pump discharge line 2in-WP-10005-HA1E-HC25 CLOSED

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 86 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.08.5
Valve Isolation Checklist P-1002B (Stand-alone)

VALVE LOCATION LINE No ISOLATED SIG/


TAG No POSITION DATE

HV-10171 Pump suction line 3in-WP-10004-HA1E-HC25 CLOSED

HV-10173 Pump discharge line 2in-WP-10005-HA1E-HC25 CLOSED

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 87 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.08.6
Spading Checklist P-1002A

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

BF1 Pump suction line 3in-WP-10004-HA1E-


HC25

BF2 Pump discharge line 2in-WP-10005-HA1E-


HC25

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 88 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.08.7
Spading Checklist P-1002B

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

BF1 Pump suction line 3in-WP-10004-HA1E-


HC25

BF2 Pump discharge line 2in-WP-10005-HA1E-


HC25

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 89 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.09 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


Crude Oil Transfer Pumps UNDERSTOOD BEFORE ATTEMPTING TO CARRY
P-1001A/B OUT ANY ACTION.

6.09.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the crude oil transfer pumps have been water flushed, as
described in Section 6.01 of this volume

This procedure is undertaken within the oil facilities boundary


isolations as listed under the Boundary Isolation Valve Checklist

This procedure is written with the viewpoint that the crude oil
transfer pumps have been shutdown as part of the overall oil
processing facilities shutdown. However, the crude oil transfer
pumps are rated for 100% duty and normally operate on a
Duty/Standby basis. As such, any one pump can be shut down for
maintenance leaving the other pump on-line

In the stand-alone maintenance isolation situation the off-line pump will


require to be valve isolated, depressurised and drained, followed by
being isolated by spading before intrusive maintenance can
commence

The following procedure describes the isolation for either stand-alone or


boundary isolation situations on the understanding that in the
stand-alone situation the off-line pump still has to be depressurised
and drained and the alternative pump is operating normally

This procedure should be used in conjunction with the Boundary


Isolation Valve Checklist and Spading Checklists, P-1001A and B in
the case of maintenance within the boundary

This procedure should be used in conjunction with the Valve


Isolation Checklists, P-1001A and B and Spading Checklists
P-1001A and B in the case of stand-alone maintenance during
normal operations

Note: In the stand-alone isolation procedure ENSURE that the pump is


electrically isolated with the Electrical Isolation Certificate issued
before any mechanical isolation of the pump is started.

The Spade Schedules and Valve Isolation Checklists should be


used in conjunction with the marked up P&ID CUR-MAS-PM-
20045-501 included at the end of the procedure

ID: M-CPH-1171-01417_EN_Section_6.doc Page 90 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.09.2 This procedure is written for Crude Oil Transfer Pump P-1001A. The
Isolation Procedure same procedure can be used for identical pump P-1001B utilising the
valve tag numbers included in the Valve Isolation Checklist.

Note: Steps 1 to 5 describe the necessary valve isolations for a stand-


alone maintenance isolation. Steps 6 to 7 describe the turning of
the various spectacle blinds and removal of maintenance spools
as required in either case (Boundary or Stand-alone Isolation).

(1) CLOSE, LOCK and TAG the 12in Isolation Ball Valve for the
pump suction line.

(2) CLOSE, LOCK and TAG the 8in Isolation Ball Valve for the
pump discharge line.

(3) OPEN the in Drain Valve for the pump suction line to SLOWLY
DEPRESSURISE and DRAIN the pipework and pump casing.
ENSURE that all drainings are directed to the Hazardous Area
Open Drains for safe disposal and CLOSE the drain valve on
completion.

(4) OPEN the in Drain Valve for the pump discharge line to
SLOWLY DEPRESSURISE and DRAIN the discharge pipework.
ENSURE that all drainings are directed to the Hazardous Area
Open Drains for safe disposal and CLOSE the drain valve on
completion.

(5) ENSURE that there is no pressure trapped in the pump body by


ISOLATING Pressure Gauge 10-PG-0322 for the pump
discharge, REMOVING the instrument and CAREFULLY
RE-OPENING the isolation valve. REPLACE the pressure gauge
once the pump is confirmed as fully depressurised.

(6) REMOVE the pump suction maintenance spool and Y-type


strainer for cleaning then INSTALL Blind Flange BF1 to the
upstream pipe flange.

Note: Ensure that the suction line is blanked off at the pump once the
maintenance spool is removed.

(7) REMOVE the pump discharge maintenance spool and non-


return valve then INSTALL Blind Flange BF2 to the downstream
pipe flange.

Note: Ensure that the discharge line is blanked off at the pump once
the maintenance spool is removed.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 91 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.09.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or spades (in the
case of a boundary isolated maintenance activity).

(2) REMOVE Blind Flange BF1 and REFIT the pump suction
maintenance spool. Ensure that the inlet strainer is replaced and
the blank is removed from the pump suction line.

(3) REMOVE Blind Flange BF2 and REFIT the pump discharge
maintenance spool. Ensure that the non-return valve is replaced
and the blank is removed from the pump discharge line.

In the case of the boundary isolated maintenance activity, this completes


the reinstatement of the pump. The oil processing facilities boundary
isolations are still in place and should not be removed until all
maintenance work is complete within the boundary.

In the case of the stand-alone isolation of the pump, the following valves
require to be opened to return the pump to service.

(4) REMOVE the TAG, UNLOCK and OPEN the 12in Isolation Valve
for the pump suction line.

(5) REMOVE the TAG, UNLOCK and OPEN the 8in Isolation Valve
for the pump discharge line.

(6) PARTIALLY OPEN the in Drain Valve on the pump suction line
to prime the pump. CLOSE the drain valve as soon as the pump
is primed.

The crude oil transfer pump has now been reinstated following stand-
alone isolation and can be returned to service once the Electrical
Isolation Certificate and Work Permit have been signed off.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 92 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.09.4
Valve Isolation Checklist P-1001A (Stand-alone)

VALVE LOCATION LINE No ISOLATED SIG/


TAG No POSITION DATE

HV-10162 Pump suction line 12in-F-10011-HA2D CLOSED

HV-10168 Pump discharge line 8in-F-10012-HA2D CLOSED

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 93 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.09.5
Valve Isolation Checklist P-1001B (Stand-alone)

VALVE LOCATION LINE No ISOLATED SIG/


TAG No POSITION DATE

HV-10165 Pump suction line 12in-F-10011-HA2D CLOSED

HV-10169 Pump discharge line 8in-F-10012-HA2D CLOSED

COMMENTS
NOTE:

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 94 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.09.6
Spading Checklist P-1001A

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

BF1 Pump suction line 12in-F-10011-HA2D

BF2 Pump discharge line 8in-F-10012-HA2D

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 95 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.09.7
Spading Checklist P-1001B

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

BF1 Pump suction line 12in-F-10011-HA2D

BF2 Pump discharge line 8in-F-10012-HA2D

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 96 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.10 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


Electrostatic Coalescer UNDERSTOOD BEFORE ATTEMPTING TO CARRY
OUT ANY ACTION.
V-1004

6.10.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the electrostatic coalescer has been flushed, drained and
nitrogen purged, as described in Section 6.01 of this volume

This vessel entry procedure is undertaken within the oil facilities


boundary isolations as listed under the Boundary Isolation Valve
Checklist

Prior to vessel entry the electrostatic coalescer requires to be


physically disconnected from the associated pipework by either the
rotation of spectacle blinds or the removal of maintenance spools
within the process side blinded with correctly rated blind flanges

It is assumed that the coalescer pressure safety relief valve will be


removed for certification. The flare side flanges must be isolated by
suitably rated blind flanges

Prior to vessel entry the hydrocarbon and nitrogen gases must be


displaced until the atmosphere within the vessel contains 21%
oxygen and less than 0.25% (volume) hydrocarbons

WARNING: ANY VENTING OF NITROGEN TO ATMOSPHERE


SHOULD BE TREATED WITHIN EXTREME CARE, AS
IN HIGH CONCENTRATIONS, INHALATION WILL
CAUSE UNCONSCIOUSNESS ALMOST
IMMEDIATELY. THEREFORE, NO LOCAL
CONTINUOUS VENTING OF EQUIPMENT SHOULD
TAKE PLACE UNLESS IT IS PIPED TO A SUITABLE
LOCATION WHERE PERSONNEL ARE NOT
EXPOSED.

While a nitrogen atmosphere remains within the vessel, any work


entailing the splitting of pipe flanges (turning of spectacled blinds
etc) may require to be undertaken with personnel wearing positive
pressure Breathing Apparatus sets

This procedure should be used in conjunction with Spading


Checklist, V-1004 and marked up P&ID CUR-MAS-PM-20046-501
included at the end of this procedure

ID: M-CPH-1171-01417_EN_Section_6.doc Page 97 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.10.2 (1) REMOVE the blank then carefully OPEN the vent valve for the
Preparation for Vessel Level Gauge Glass 10-LG-0414. This will ENSURE that there is
Entry Procedure no pressure trapped in the coalescer.

Note: Any remaining gases in the coalescer must be vented to a safe


area suitable for the disposal of hydrocarbon gases.

(2) SWING Spectacled Blind SB1 on the oil inlet to the CLOSED
position.

(3) SWING Spectacled Blind SB2 on the dry oil outlet line from the
coalescer to the CLOSED position.

(4) DIVIDE the separated water outlet line at Nozzle N3 and


INSERT Spade S3 to the flange faces.

(5) DIVIDE the Sample line at Nozzle N6A and INSERT Spade S6A
to the flange faces.

(6) DIVIDE the Sample line at Nozzle N6B and INSERT Spade S6B
to the flange faces.

(7) DIVIDE the Sample line at Nozzle N6C and INSERT Spade S6C
to the flange faces.

(8) DIVIDE the Sample line at Nozzle N6D and INSERT Spade S6D
to the flange faces.

(9) DIVIDE the Sample line at Nozzle N6E and INSERT Spade S6E
to the flange faces.

(10) SWING Spectacled Blinds SB7A-E at Nozzles N7A-E


respectively on the belly drain lines to the CLOSED position.

(11) DIVIDE the Relief line at Nozzle N8 and INSERT Spade S8 to


the flange faces.

(12) OPEN the Vessel Manway Doors M1A and M1B.

(13) POSITION an air mover within each manway door ENSURING


the exhaust ducting vents are led away to a safe area.

(14) Use the air mover to displace the gases within the coalescer until
the atmosphere inside the vessel contains 21% oxygen and less
than 0.25% hydrocarbons.

(15) If the Coalescer Relief Valves 10-PSV-0403A and B are to be


removed for recertification, the flare pipework must be blinded off
using Blind Flanges BF9 and BF10 and included on Spading
Checklist V-1004.

(16) The electrostatic coalescer is available for entry when the


appropriate Vessel Entry Permit has been issued.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 98 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.10.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) CONFIRM that all equipment has been removed from the vessel
and the internal rods are in place and secure.

(2) CLOSE the Manway Doors M1A and M1B.

(3) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or turning spectacled
blinds.

(4) SWING Spectacled Blind SB1 on the oil inlet line to the OPEN
position.

(5) SWING Spectacled Blind SB2 on the dry oil outlet line to the
OPEN position.

(6) DIVIDE the produced water outlet line at Nozzle N3 and


REMOVE Spade S3 then MAKE UP the flange faces.

(7) DIVIDE the Sample line at Nozzle N6A and REMOVE Spade
S6A then MAKE UP the flange faces.

(8) DIVIDE the Sample line at Nozzle N6B and REMOVE Spade
S6B then MAKE UP the flange faces.

(9) DIVIDE the Sample line at Nozzle N6C and REMOVE Spade
S6C then MAKE UP the flange faces.

(10) DIVIDE the Sample line at Nozzle N6D and REMOVE Spade
S6D then MAKE UP the flange faces.

(11) DIVIDE the Sample line at Nozzle N6E and REMOVE Spade
S6E then MAKE UP the flange faces.

(12) SWING Spectacle Blinds SB7A-E at Nozzles N7A-E respectively


on the belly drain lines to the OPEN position.

(13) DIVIDE the Relief Line at Nozzle N8 and REMOVE Spade S8


then MAKE UP the flange faces.

(14) If the coalescer Relief Valves 10-PSV-0403A and B have been


removed for recertification, REMOVE Blind Flanges BF9 and
BF10 on the flare side pipe flange and REFIT the relief valves.

The electrostatic coalescer has now been reinstated. The oil processing
facilities boundary isolations are still in place and should not be removed
until all maintenance work is complete within the boundary.

ID: M-CPH-1171-01417_EN_Section_6.doc Page 99 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.10.4 Spading Checklist V-1004


BLIND LOCATION LINE No DATE SIG DATE SIG
No FITTED PULLED

SB1 Nozzle N1 8in-F-10012-HA2D

SB2 Nozzle N2 8in-F-10014-HA2D

S3 Nozzle N3 3in-WP-10006-HA1E-
HC25

S6A Nozzle N6A in-D-10048-HA2D-HC25

S6B Nozzle N6B in-D-10047-HA2D-HC25

S6C Nozzle N6C in-D-10046-HA2D-HC25

S6D Nozzle N6D in-D-10045-HA2D-HC25

S6E Nozzle N6E in-D-10044-HA2D-HC25

SB7A Belly Drain Line 2in-D-10037-HA1C

SB7B Belly Drain Line 2in-D-10055-HA1C

SB7C Belly Drain Line 2in-D-10056-HA1C

SB7D Belly Drain Line 2in-D-10057-HA1C

SB7E Belly Drain Line 2in-D-10058-HA1C

S8 Relief Line 4in-V-10025-HA2D

BF9 10-PSV-0403A 4in-V-10024-HA1C

BF10 10-PSV-0403B 4in-V-10024-HA1C


COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

ID: M-CPH-1171-01417_EN_Section_6.doc Page 100 / 105


MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.11 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


Export Crude Oil Cooler UNDERSTOOD BEFORE ATTEMPTING TO CARRY
OUT ANY ACTION.
E-1004

6.11.1 The boundary isolations for the oil processing facilities are in place,
Preconditions and the export crude oil cooler has been flushed and drained, as
described in Section 6.01 of this volume

This procedure is undertaken within the oil facilities boundary


isolations as listed under the Boundary Isolation Valve Checklist

This procedure is written with the viewpoint that the export crude oil
cooler has been shut down as part of the overall oil processing
facilities shutdown. The export crude oil heater is in continuous use
to regulate the temperature of the dehydrated crude oil from the
electrostatic coalescer passing to the cargo oil tanks at 30oC

The following procedure describes the mechanical isolation


(spading) required for boundary situations

This procedure should be used in conjunction with the Boundary


Isolation Valve Checklist, Spading Checklist E-1004 and marked up
P&ID CUR-MAS-PM-20047-501, included at the end of this
procedure

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.11.2 (1) Carefully OPEN the vent valve for the crude inlet to the export
Isolation Procedure crude oil cooler. This will ENSURE that there is no pressure
trapped in the warm side of the cooler.

(2) Carefully OPEN the drain valve for the crude outlet from the
export crude oil cooler. This will ENSURE that there are no liquids
trapped in the warm side of the cooler.

Note: Any remaining drainings from the warm side of the cooler must
be directed to the skid drip pan which is suitable for the disposal of
liquid hydrocarbons.

(3) SWING Spectacled Blind SB1 on the crude inlet to the CLOSED
position.

(4) SWING Spectacled Blind SB2 on the crude outlet to the


CLOSED position.

(5) Carefully OPEN the vent valve for the cooling medium outlet
from the export crude oil cooler. This will ENSURE that there is no
pressure trapped in the cold side of the cooler.

Note: Any remaining drainings from the cold side of the cooler must be
directed to the skid drip pan which is suitable for the disposal of
cooling medium.

(6) SWING Spectacled Blind SB3 on the cooling medium inlet to the
CLOSED position.

(7) SWING Spectacled Blind SB4 on the cooling medium outlet to


the CLOSED position.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.11.3 Note: Flanges that have been disturbed must have new replacement
Reinstatement Procedure gaskets of the correct specification installed.

(1) RECONFIRM the boundary isolations on the Boundary Isolation


Checklist before removing any blind flanges or turning spectacled
blinds.

(2) SWING Spectacled Blind SB1 on the crude inlet to the OPEN
position.

(3) SWING Spectacled Blind SB2 on the crude outlet to the OPEN
position.

(4) SWING Spectacled Blind SB3 on the cooling medium inlet to the
OPEN position.

(5) SWING Spectacled Blind SB4 on the cooling medium outlet to


the OPEN position.

(6) ENSURE that the drain valves for the cooling medium inlet and
crude outlet lines are CLOSED.

(7) ENSURE that the vent valves for the crude inlet and cooling
medium outlet lines are CLOSED.

The Export Crude Oil Heater E-1004 has now been reinstated. The oil
processing facilities boundary isolations are still in place and should not
be removed until all maintenance work is complete within the boundary.

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.11.4
Spading Checklist E-1004

BLIND LOCATION LINE No DATE SIG DATE SIG


No FITTED PULLED

SB1 Crude oil inlet 8in-F-10014-HA2D

SB2 Crude oil outlet 8in-F-10015-HA2D

SB3 Cooling Medium inlet 6in-CM-45001-HA1C

SB4 Cooling Medium outlet 6in-HM-45002-HA1C

COMMENTS
BF = Blind Flange
SB = Spectacled Blind
S = Spade

OPERATOR SIGNATURE:

DATE:

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MAERSK CURLEW - Book B: Oil Processing Facilities
Isolation/Reinstatement Procedures 002 / MAY 2010

6.12 WARNING: THIS PROCEDURE MUST BE READ AND FULLY


Oil Processing Facilities UNDERSTOOD BEFORE ATTEMPTING TO CARRY
Boundary Reinstatement OUT ANY ACTION.

6.12.1 The oil processing facilities have been shutdown, drained and
Introduction depressurised in preparation for major maintenance activities as
described in the planned shutdown procedure included in Section 6.01 of
this book.

The oil processing facilities were boundary isolated, flushed with utility
seawater and purged with nitrogen, as described in Section 6.01 of this
book.

The equipment within the oil processing facilities has undergone


intrusive maintenance activities which required physical isolation by
spading/blinding, air displacement of the nitrogen before vessel entry,
followed by a despading reinstatement activity of each facility within the
boundary isolation as described in Sections 6.02 to 6.11.

With all maintenance activity complete, the Boundary Isolation can be


reinstated as follows:

6.12.2 Following the completion of all maintenance/inspection workscopes, the


Boundary Reinstatement crude oil processing facilities require to be pre-start pressure tested
utilising a nitrogen/helium trace gas to prove system containment
integrity. This operation is undertaken by specialist contract personnel.

The boundary reinstatement of the oil processing facilities takes place


only after the pre-start pressure tests above have been successfully
completed and witnessed by operations supervision. The cold start-up
procedure in Section 5.01 of this volume details the removal of the
boundary by use of the Cold Start-up Valve Checklist.

Reference must now be made to Section 5 of this manual for these


operating procedures.

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