EPCIC CONTRACTOR CONSULTANT

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MAERSK OIL QATAR As

PROJECT TITLE : EPCIC OF MAESRK OIL QATAR FDP 2005 FACILITIES

PACKAGE 16 BE PROCESS & BG UTILITIES PLATFORMS
AND

DOCUMENT TITLE : BRIDGES.

PROCESS CONTROL PHILOSOPHY

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CTR NO : PR-200

0 12/10/07 ISSUED AS FINAL KMS AJ MKT

Rev Date Description Prep Chkd Appd Client
HOLDS LIST

Hold Description Section

1 Interface requirements to minor packages 2.0
2 Deleted
3 Return to inlet separator BA/BD 2.1.2
4 Deleted
5 Set points and vendor data All Tables;

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TABLE OF CONTENTS

HOLDS LIST

1.0 INTRODUCTION 5

1.1 Project Description 5

1.2 Scope of Document 6
1.3 Definitions and Abbreviations 6

2.0 Process Control (SCADA) 8

2.1 Direct SCADA Control 8

2.1.1 Crude Separation (BE) 8
2.1.2 Produced Water Treatment (BE) 9
2.1.3 Crude Stabilisation and Export (BE) 10
2.1.4 Stock Tank Compression (BE) 11
2.1.5 Gas Slugcatcher (BE) 12
2.1.6 LP / IP Compression (BE) 13
2.1.7 Gas Dehydration (BE) 13
2.1.8 HP Compression and Gas Export (BE) 14
2.1.9 Overall Compression Train (BE) 15
2.1.10 Fuel Gas (BE) 17
2.1.11 Seawater (BE / BG) 18
2.1.12 Water Injection (BG) 19
2.1.13 Cooling Medium (BE / BG) 22
2.1.14 Heating Medium (BE + BG) 24
2.1.15 Flare Systems 28
2.1.16 Drain Systems 29
2.1.17 TEG Regeneration System 31
2.1.18 Sand Removal and Treatment (BE) 31
2.2 Package Control (UCP) 32
2.2.1 Stock Tank Compressor (BE) 32
2.2.2 Export / Gas Lift Compressor (BE) 32

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2.2.3 Seawater Coarse Filtration (BE / BG) 33

2.2.4 Seawater Hypochlorination (BE / BG) 33
2.2.5 Water Injection (BG) 33
2.2.6 Main Power Generation (BG) 33
2.2.7 Emergency Power Generation (BG) 34
2.2.8 Compressed Air (BG) 34
2.2.9 Nitrogen (BE) 34
2.2.10 Demineralised Water (BG) 34

REFERENCES 35

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1.0 INTRODUCTION

The Maersk Oil Qatar AS Block 5 Field Development Project 2005 is located at the existing Al
Shaheen facilities for Block 5. The Block 5 reservoirs are shallow with relatively low reservoir
pressure. The wells are therefore produced at low wellhead pressure with gas lift when needed.
Seawater is injected to the reservoirs at all locations to improve oil recovery. Crude oil is
exported via one FSO at the A location and gas compression takes places at the A, B, C and E
locations from where the gas is exported to the North Field Alpha (NFA) platform.

The Block 5 Field Development Project 2005 comprises of 15 platforms, 1 module, 13 bridges
and 2 new SPM buoys for crude export. Approximately 270 km of interfield pipelines are also to
be installed. The development includes drilling of additional wells from the existing locations A-
F and the 3 new locations G, H and I.

This specific project is only for Package 16 of BE Process and BG Utility Platforms which are a
portion of development of Block 5 Field Development Project 2005. The scope of work includes
the design, engineering, procurement, fabrication, onshore commissioning, load out, sea
fastening, transportation to Companys designated offshore location, installation there and
hook-up and commissioning of the facilities.

In order to execute the detailed engineering phase, rnz has been appointed as the engineering
consultant for this project

Project Description

Maersk Oil Qatar AS (MOQ) has commenced with the further development of Block 5 oil & gas
production facilities, offshore Qatar. This phase, the Block 5 Field Development Project 2005,
which is now approved by the Qatari authorities, includes 15 new platforms in addition to inter-
field pipelines and associated Brownfield work.

The existing Al Shaheen facilities for Block 5 comprise six production locations with a
centralised processing centre at the A location and five satellite production complexes at the B,
C, D, E and F locations.

Sime Darby Engineering Sdn Bhd (SDE) has been awarded the EPCIC (Engineering,
Procurement, Construction, Installation and Commissioning) of Package 16, BE Process & BG
Utility Platforms, BE-BD/BG-BC & BG-BD Bridges.

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The BE process platform is comprised of Jacket/Topsides/BE-BD bridge and has the following
main components:

Crude oil stabilisation and export

Gas Compression for gas lift and export

Produced water treatment and disposal

Utility systems.

The BG Utility platform is comprised of Jacket/Topsides/BG-BD bridge/BG-BC bridge. BG

functions as a main utility provider to BE and power station for other parts of the Block 5
Development. It has the following main components:

Power generation

Water injection

Utility systems.

The Block 5 reservoirs are shallow with a relatively low reservoir pressure. The wells are
therefore produced at low wellhead pressure with gas lift when needed. Seawater is injected in
the reservoirs at all locations to improve oil recovery.

Scope of Document

This document primarily defines the process control philosophy for the BE and BG Platforms;
it is the basis upon which the plant control system is based to achieve safe, controlled
operation and production.

Definitions and Abbreviations

API American Petroleum Institute

BDV Blow-down Valve
HP High Pressure
HVAC Heating, Ventilation and Air-Conditioning
IGF Induced Gas Flotation
IP Intermediate Pressure

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LP Low Pressure
MOQ Maersk Oil Qatar
P&ID Piping and Instrumentation Diagram
RP Recommended Practice
SCADA Supervisory Control and Data Acquisition
SDE Sime Darby Engineering SND BHD
TEG Triethylene Glycol
UCP Unit Control Panel
WHRU Waste Heat Recovery Unit
PCV Pressure Control Valve
TCV Temperature Control Valve
FCV Flow Control Valve
MCC Motor Control Centre
VFD Variable Frequency Drive

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2.0 Process Control (SCADA)

The four main functions of the SCADA system are to:

Interface with the ESD and F&G systems for the facilities

Interface with the SCADA systems on other facilities within the Al Shaheen
development complex
Perform all automatic monitoring and control functions for the process and utility
systems on the BE and BG platforms
Interface with the Vendor control systems for packaged equipment on BE and BG,
including:
Stock tank compressor (BE)

Turbine driven export/gas lift compressor (BE)

Turbine driven main power generators (BG)

Turbine driven water injection pumps (BG)

Direct SCADA Control

These systems are controlled directly by the SCADA system without interface to Vendor control
systems.

2.1.1 Crude Separation (BE)

Fluids from the BA and BD platforms flow individually to the BE platform for heating and
separation in separate trains. Fluids from the C location are co-processed with these two flows,
apportioned between the two trains by cascaded pressure -flow ratio control. The master
controller (pressure) will provide the setpoints, which will be biased based on a manual setpoint
(provided by the operator) to each individual flow (slave) controller. Each flow controller will
then adjust the flow to both the trains accordingly.

Each resulting stream flows through two dedicated trim heaters, with the possibility of manually
lining out a spare heater to either one of the flows. Flow of heating medium to each individual
heater is regulated based on the outlet temperature of the production fluids from that heater.
The heated product stream from each location then enters a dedicated oil/water separator, with

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vessel backpressure controlled on the oil outlet stream and vessel interface level controlled on
the water line downstream of the associated produced water hydrocyclones.

The bubble point of the oil is about 5 barg, hence no bubble break out in the oil/water
separators is expected.

Table Process Control (SCADA).1:Crude Separation Control Parameters

Tag Control Parameter Device Nom. Setpoint

C location pressure PCV 36001 8.0 Bar
C location fluid flow - to BA stream FCV360001 Manual
- to BD stream FCV36002 Manual
E-3401 Production fluid outlet temperature TCV340101 75 C
E-3402 Production fluid outlet temperature TCV340201 75 C
E-3403 Production fluid outlet temperature TCV340301 75 C
E-3404 Production fluid outlet temperature TCV340401 75 C
E-3405 Production fluid outlet temperature TCV340501 75 C
V-3403 Separator pressure PCV340302 7.5 barg
Oil-water interface level LCV340301 [HOLD 5] Mm
V-3413 Separator pressure PCV341301 7.5 barg
Oil-water interface level LCV341301 [HOLD 5] mm

2.1.2 Produced Water Treatment (BE)

Produced water from each oil/water separator flows to two associated produced water
hydrocyclone vessels, with the possibility of manually lining out a spare hydrocyclone vessel to
either one of the flow streams. The cleaned water streams are routed to a common IGF vessel,
with reject oil/water routed to the oil skim section of the IGF vessel under differential pressure
ratio control.

Clean water from the hydrocyclones is polished in the IGF vessel by flotation using fuel gas
which will be on manual flow control. The cleaned water is then pumped to either the BD
platform for disposal or overboard via the drain caisson, with overall level control downstream
of the produced water injection pumps. Minimum flow through each produced water injection
pump is individually controlled by recycle of fluids back to the inlet manifold for the IGF vessel.

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Skimmed oil from the IGF vessel, combined with reject oil/water from the hydrocyclones, is
returned to the inlet separators on BA/BD. Level in the skimmed oil section of the IGF vessel is
controlled by gap control for pump start /stop.

Table Process Control (SCADA).2: Produced Water Treatment (BE) Control Parameters

Tag Control Parameter Device Nom. Setpoint

V-2701/02 Differential pressure ratio PDCV [HOLD 5]
V-2703/04 Differential pressure ratio PDCV [HOLD 5]
V-2708 IGF level FY [HOLD 5]
Flow control - to injection FCV [HOLD 5]
- overboard FCV [HOLD 5]
Skimmed oil level P-2711/21 [HOLD 5]

P-2709 Minimum flow FCV [HOLD 5]

P-2719 Minimum flow FCV [HOLD 5]

2.1.3 Crude Stabilisation and Export (BE)

Hydrocarbon fluids from the oil/water separators flow to a common final stage separator, along
with A location fluids (if requiring additional treatment) and fluids from the closed drains drum
(as an alternative destination to returning fluids to BA/BD). The final separation stage stabilises
the fluids for export to the floating storage, with pressure in the vessel set by the stock tank
compression system and limited by blow-off to the LP flare.

The separator operates as a two-phase liquid/gas separator, with level controlled on the line
downstream of the crude export pumps. Minimum flow through each crude export pump is
individually controlled by recycle of fluids back to the inlet manifold for the final stage separator.

The fluids are pumped to the crude oil export manifold, where they commingle with export
crude from the E location and stabilised crude from the A location to be exported via BE. The
composite flow is routed to one of two FSO vessels under individual flow control.

The crude can also be exported to A location via the same pipeline that is used to receive the A
fluids (bi-directional).

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Table Process Control (SCADA).3: Crude Stabilisation and Export (BE) Control Parameters

Tag Control Parameter Device Nom. Setpoint

V-3415 Separator pressure (Dump to flare) PCV341501 2 barg
Liquid level LCV341501 [HOLD 5] mm
P-3611 Minimum flow FCV361101 [HOLD 5] m3/hr
P-3621 Minimum flow FCV362101 [HOLD 5] m3/hr
P-3631 Minimum flow FCV363101 [HOLD 5] m3/hr
P-3641 Minimum flow FCV363101 [HOLD 5] m3/hr
SPM-3 Export flow FCV360401 [HOLD 5] m3/hr
SPM-4 Export flow FCV360501 [HOLD 5] m3/hr

2.1.4 Stock Tank Compression (BE)

Vapour from the final stage separator flows to the stock tank compressor via an inlet suction
scrubber, with any collected liquids routed to closed drains under level control. Being a fixed
speed screw compressor, the stock tank compressor is a constant volume machine with any
shortfall in gas supply made up by recycle of gas based on compressor suction pressure. The
recycled gas is cooled, with flow of cooling medium regulated based on gas temperature
downstream of the recycle valve.

Table Process Control (SCADA).4: Stock Tank Compression Control Parameters

Tag Control Parameter Device Nom. Setpoint

V-4203 Liquid level LCV420301 [HOLD 5]
C-4203 Suction pressure PCV420302 0.7 barg
E-4203 Recycle gas temperature TCV420303 40 C

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2.1.5 Gas Slugcatcher (BE)

Wet gas from the C location flows to the BE platform for separation and compression, with
automatic slug control valve provided at the inlet to the slugcatcher. The slug control valve
(which is normally fully open)] will throttle in on high liquid level and high pressure in the
slugcatcher, limiting the liquid slug arriving into the slugcatcher. The fluids are separated in a
slug catcher vessel, with vessel pressure floating on the inlet pressure of gas lift/export
compression. Excessive gas will be routed to the LP flare via the blow off valve controlled on
vessel pressure. Liquids separated from the gas stream are pumped to combine with the
separately arriving C location liquids, with vessel level controlling the start/stop of the pumps
and minimum flow for each pump individually controlled by recycle of fluids back to the inlet of
the slugcatcher.

Table Process Control (SCADA).5: Gas Slugcatcher Control Parameters

Tag Control Parameter Device Nom. Setpoint

V-3416 Separator pressure PCV341602A 4 Barg
P-2717/27 V-3416 liquid level - duty pump MCC [HOLD 5]
- standby pump MCC [HOLD 5]
P-3417 Minimum flow FCV341701 [HOLD 5] m3/hr
P-3427 Minimum flow FCV342701 [HOLD 5] m3/hr

2.1.6 LP / IP Compression (BE)

Gas streams from the separators on BA/BD, the gas slug catcher and the stock tank
compressor are combined and collectively flow to compression via the LP suction scrubber,
with separated liquids routed to closed drains under level control. The suction pressures of the
LP compressor will be regulated by the compressor capacity control (see Section 2.1.9 and
bounded by the blow pressures of the various inlet separators.).

The compressed gas from the LP compressor is cooled, with the flow of cooling medium
regulated based on gas temperature downstream of the exchanger. The gas then flows to the
IP suction scrubber where separated liquids are routed under level control to a condensate
return header recycling fluids to the BA/BD separators. Gas from the IP suction scrubber is

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further compressed and cooled, with the flow of cooling medium regulated based on gas
temperature downstream of the exchanger.

Table Process Control (SCADA).6: LP / IP Compression (BE) Control Parameters

Tag Control Parameter Device Nom. Setpoint

V-4201 Liquid level LCV420102 [HOLD 5]
E-4201 Hydrocarbon outlet temperature TCV420103 40 C
V-4301 Liquid level LCV430102 [HOLD 5]
E-4301 Hydrocarbon outlet temperature TCV430103 40 C

2.1.7 Gas Dehydration (BE)

Gas from the IP compressor aftercooler is further cooled against seawater in a trim cooler. The
control system will regulate the amount of sea water by maintaining a constant differential
temperature between the sea water inlet and process gas outlet. Condensed liquids are then
removed in a scrubber and routed to the condensate return header to the BA/BD separators
under level control. The gas then flows to the TEG contactor where it is dehydrated through
counter-current contact with lean glycol. Pressure variations within the contactor is limited by
the overall compressor control system which controls the LP compressor suction pressure and
HP compressor discharge pressure. A blow off to the HP flare is provided at the contactor outlet
to vent off spec gas during start up.

Flow of lean glycol is controlled from the glycol regeneration package, with rich glycol collecting
at the base of the contactor and returned to the regeneration system under level control.

Table Process Control (SCADA).7: Gas Dehydration (BE) Control Parameters

Tag Control Parameter Device Nom. Setpoint

E-4302 Differential temperature TCV430201 5 C
V-4102 Liquid level LCV410201 [HOLD 5]
V-4101 Glycol liquid level LCV410101 [HOLD 5]

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Contactor pressure PCV410102 45 barg

2.1.8 HP Compression and Gas Export (BE)

Dehydrated gas from the TEG contactor flows to HP compression via a suction scrubber, with
any residual or carried-over liquids routed to glycol flash vessel (within the TEG Regeneration
System) under level control. The gas is compressed and cooled, with the flow of cooling
medium regulated based on gas temperature downstream of the exchanger. Any required HP
stage recycle flow is then removed and the remaining gas sent to the export system.
Compressor discharge pressure is maintained by the pipeline pressure and bounded by the
back-pressure control valve (to prevent the compressor from the stone wall should the pipeline
pressure fall) and the compressor discharge pressure control (UCP).

Gas from the compression train may subsequently:

Recycle back to the LP suction system as train recycle

Supply the platform fuel gas system

Flow to the BD platform for subsequent use in supplying other platform fuel gas
systems, gas lift or sales export.

Table Process Control (SCADA).8: HP Compression and Gas Export (BE) Control
Parameters

Tag Control Parameter Device Nom. Setpoint

V-4401 Liquid level LCV440102 [HOLD 5]
E-4201 Gas outlet temperature TCV440103 70 C

2.1.9 Overall Compression Train (BE)

The gas compression train consist of 3 stages (LP/IP/HP) with a single variable speed gas
turbine driver. Anti surge recycle valves will be provided over each compression stage to
protect the compressor from surge.

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The parameters of primary interest for gas compression are the train suction and discharge
pressures. Changes in each of these parameters may be rapid under various conditions
suction pressure due to the large differential between LP compressor volumetric rate and
suction volume, discharge pressure due to the amplifying effect of three stage compression on
variations in suction pressure and compressor speed. As a result, robust operation requires
control and several levels of limitation of the key operating parameters.

Primary control

The pressure at the inlet of the compression train (LP) is controlled via regulation of the
compressor speed and overall compression train recycle valve. A low pressure will cause the
compressor to reduce speed initially and once at the minimum speed, the recycle valve will
open. On a high suction pressure, the control system will speed up the compressor to evacuate
the gas. A high pressure override at the discharge of the HP stage will override this control,
reducing the compressor speed initially and finally opening the train recycle valve in the event
of pressure at the discharge of the compressor rises due to reduction in offtake or a blocked
outlet. Discharge pressure from the IP compression stage is bounded by the compressor
curves, and the overall capacity controller which controls the suction pressure (LP compressor)
and HP discharge pressure.

The primary control of low discharge pressure of the HP compressor is performed by back-
pressure control on the gas export line to provide a minimum limit, preventing the compressor
from entering the stone wall region. .

With the potential for extended response times, this control loop will be relatively slow to
minimise the likelihood of control overshoot / compressor pressure trip.

Secondary control

For events that occur too quickly for adequate response by speed control, secondary control of
suction and discharge pressures is provided by:

Blow-off to flare from the source separators to limit high suction pressure

Train recycle from gas export system to limit on low suction pressure

These actions will limit pressure variations until the primary control adjusts the operational point
of the compressor.

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Tertiary control

For very rapid events that may damage the compressor, tertiary control provided by:

Suction pressure maintenance by the LP compressor antisurge system

Discharge pressure limitation by the IP compressor antisurge system
Discharge pressure limitation by the HP compressor antisurge system

These actions will limit pressure variations until primary and secondary control responses catch
up with the operational disturbance.

Table Process Control (SCADA).9: Overall Compression Train (BE) Control Parameters

Tag Control Parameter Device Nom. Setpoint

C-4211 Train suction pressure 2.9 barg
CT-4301 (SC)
Train discharge pressure 128 barg

2.1.10 Fuel Gas (BE)

Dehydrated and compressed gas from the platform export system is cooled, with the flow of
cooling medium regulated based on gas temperature downstream of the exchanger. The gas is
chilled by depressurisation across a control valve, operating on demand based on fuel gas
system pressure. The cold fluids are then separated in a knockout drum, with condensed
liquids being heated prior to entering the condensate return header to the BA/BD separators
under level control. The condensate heater is controlled based on the fluid temperature
downstream of the level control valve. Fuel gas from the knock-out drum is polished via the
filter coalescers and superheated based on a differential temperature across the heater and
flows to the various users based on their individual demands.

Table Process Control (SCADA).10: Fuel Gas (BE) Control Parameters

Tag Control Parameter Device Nom. Setpoint

E-5701 Gas outlet temperature TCV570202 10 C

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V-5702 Liquid level LCV570202 [HOLD 5]

V-5702 Gas Pressure PC570201 33 barg
E-5705 Fluid outlet temperature TC570503 -10 C
E-5704 Gas differential temperature TDC570403 25 C

Sufficient buffer volume is provided in the fuel gas system piping to allow two gas turbines to
change over from fuel gas to diesel.

2.1.11 Seawater (BE / BG)

The seawater lift systems on BE and BG are functionally identical, with minimum flow through
each lift pump individually controlled by dumping water to the overboard caisson. The running
pumps share the respective system demands, with pressure controls imposing backpressure
on the various users.

Table Process Control (SCADA).11: Seawater (BE ) Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-5301 Pump minimum flow FCV530101 [HOLD 5] m3/hr
P-5302 Pump minimum flow FCV530201 [HOLD 5] m3/hr
P-5303 Pump minimum flow FCV530301 [HOLD 5] m3/hr
General System backpressure PCV500303 [HOLD 5] barg

Table Process Control (SCADA).12: Seawater (BG ) Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-5321 Pump minimum flow FCV [HOLD 5] m3/hr
P-5322 Pump minimum flow FCV [HOLD 5] m3/hr
P-5323 Pump minimum flow FCV [HOLD 5] m3/hr
P-5324 Pump minimum flow FCV [HOLD 5] m3/hr

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Tag Control Parameter Device Nom. Setpoint

P-5325 Pump minimum flow FCV [HOLD 5] m3/hr
P-5326 Pump minimum flow FCV [HOLD 5] m3/hr
General System backpressure PCV [HOLD 5]

2.1.12 Water Injection (BG)

The Water Injection System provides fine filtration and deoxygenation of seawater and
distributes water at the necessary supply pressure to the BA & BD wellhead platforms via the
BG-BD bridge and to the E, H &I locations via subsea pipelines.

The Water Injection System comprises 3 x 33% trains. Each train comprises (in order of
process flow):

Fine Filtration

Deaerator Package

Booster Pump

High Pressure Injection Pump

The water injection system comprises a number of packages controlled by UCP integrated via
SCADA.

The descriptions below refer to each injection train.

Overall Process Control

Each water injection train is primarily configured to deliver a constant pressure into the water
injection distribution header. This is achieved by managing the pump delivery pressure via flow
and speed control.

Flow over the water injection train is balanced based on a zero calculated difference between
the HP pump discharge flowrate and the inlet flowrate to the fine filters. A minimum limit to this
control loop is given by the HP pump minimum flow setpoint. This flow control loop takes a
setpoint from the level control on the deaerator column to ensure a constant system inventory
is maintained.

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Fine Filtration Package

The package is on inlet flow control. The total flow setpoint through the package is given via
SCADA from a signal from the water injection flow control loop.

Filter backwash timing and sequencing is controlled by the packages UCP. Differential
pressure control monitoring over each filter is provided for input to the UCP.

Deaerator Package

Level control is provided to ensure the liquid seal is maintained in the bottom of the tower (as
described above).

The deoxygenation performance of the deaerator tower is governed by the UCP [Vendor to
confirm].

Booster Pumps

The Booster Pump raises the water pressure to supply the necessary inlet suction pressure of
the downstream HP Pump. The pump performance floats on the pressure of the deaerator
tower and the flow through the system.

The booster pump is protected by a minimum flow line installed with a FCV. This line dumps
overboard and the FCV control signal is taken directly downstream of the booster pump
discharge.

HP Pumps

The HP pumps raise the water pressure to the Water Injection Systems functional specification
of 124 barg. The pumps are GT driven, and the GTs are fired on fuel gas from supplied from
the BE platform. Water is supplied from the Booster Pumps at sufficient pressure to provide for
the required HP Pump NPSH.

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The primary control of the HP pump is discharge pressure control cascaded into flow control.
The water injection discharge header pressure control setpoint is given to the flow control loop,
and a signal is then sent to the HP pump UCP to modulate the GT speed.

The setpoint for the pressure control function is given to the HP pump UCP as a speed setting
from the SCADA system.

Potential for overpressure is managed by the following:

Shutdown of the pump on high discharge pressure, initiated locally via the UCP.

A strong derivative element in the UCP speed control algorithm. This element mitigates
the potential for turbine speed due to significantly exceeding (overshooting) the GT
speed setpoint during the control action. Turbine speed control to be used as a speed
limiter set as close as is practicable to the over speed trip set point.

Limit on the rate of change of GT speed, ie the governor ramp rate. This is to slow
down the UCP controller, dampening the controller response to transient dips of low
pressure.

Opening of the minimum flow FCV on pump high pressure trip to dump water
overboard.

Over speed is avoided by shutdown of the pump on a high speed trip set at an appropriate
margin from the over speed limit of the machine. This over speed trip system is also to be
initiated by rate of change of speed to mitigate the magnitude of any over speed event

Minimum flow protection is provided by a dump line to sea, installed with an FCV modulating
via SCADA on the pump discharge flowrate. Signal to this control loop is taken from the pump
discharge and the setpoint is the minimum safe flow of the HP pump. This setpoint is
calculated from pump running speed and the minimum safe flow at 100% speed. This setpoint
is also used as a minimum limit to the flow control loop over the water injection train.

On detection of low suction pressure the minimum flow FCV is driven closed to avoid draining
the HP pump casing.

Other internal functions of the HP pump package are also controlled by the UCP. These
include the lubrication system, condition monitoring and all turbine controls including the
governor system.

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Table Process Control (SCADA).13: Water Injection System Control Parameters

Tag Control Parameter Device Nom. Setpoint

General Water Injection Distribution Header GT Governor barg
Pressure
V-3503 Train 1 Deaerator Flow FCV350301 m/h
V-3503 Train 1 Deaerator Level LCV350302 mm
P-3504 Train 1 Booster Pump Minimum Flow FCV350401 m/h
P-3518 Train 1 HP Pump Minimum Flow FCV351801 m/h
V-3523 Train 2 Deaerator Flow FCV352301 m/h
V-3523 Train 2 Deaerator Level LCV352302 mm
P-3524 Train 2 Booster Pump Minimum Flow FCV352401 m/h
P-3528 Train 1 HP Pump Minimum Flow FCV352801 m/h

V-3543 Train 3 Deaerator Flow FCV354301 m/h

V-3543 Train 3 Deaerator Level LCV354302 mm
P-3544 Train 3 Booster Pump Minimum Flow FCV354401 m/h
P-3548 Train 3 HP Pump Minimum Flow FCV354801 m/h

2.1.13 Cooling Medium (BE / BG)

The cooling medium systems on each platform are segregated but essentially similar systems.
On the BE platform cooling medium pumps circulate tempered water, with dedicated minimum
flow control for pump protection. The circulating flow is cooled against seawater, controlled by
the seawater system backpressure on BE (CM being the dominant user) Seawater temperature
is also monitored, with a maximum limit imposed by cooling medium bypass on BE. The
temperature at the tempered water supply header is controlled by regulating a bypass flow
around the Cooling Medium Coolers.

The cooled tempered water is then distributed to the various users as required by the individual
temperature controllers. All temperature control valves are located downstream of the various
heat source to maintain pressure on the heaters, with the exception of the lube oil cooling
duties. To minimize the risk of lube oil contamination, these have the temperature control valves
located upstream of the cooler to ensure that the water side of the cooler operates below lube

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oil supply pressure. Additionally, the supply and return lines are isolated on shutdown of the
respective lube oil systems.

During a low cooling duty demand, any excess tempered water will bypass the users via a
connection between the supplies and return headers, which will be under flow control.

On the BG platform cooling medium pumps circulate tempered water, with dedicated minimum
flow control for pump protection. The circulating flow is cooled against seawater, (CM being a
minor user relative to water injection). Sufficient seawater is provided to adequately cool the
design cooling medium flow at under warm ambient temperatures and maximum cooling
medium duties and this flow is maintained continuously via an appropriately sized restriction
orifices. This arrangement results in improved cooling medium cooling during conditions
removed from the design case. The cooled tempered water is then distributed to the each user
via individual restriction orifices.

Table Process Control (SCADA).14: Cooling Medium BE / Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-8012 Pump minimum flow FCV801201 [HOLD 5]
P-8022 Pump minimum flow FCV802202 [HOLD 5]
P-8032 Pump minimum flow FCV803201 [HOLD 5]
E-8011/ Cooling Medium outlet TCV80101 30 C
8021/8031 temperature
General Overall Flow Control FC [HOLD 5] m3/hr

Table Process Control (SCADA).15: Cooling Medium BG Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-8041 Pump minimum flow FCV804101 50 m3/hr
P-8051 Pump minimum flow FCV804102 50 m3/hr

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2.1.14 Heating Medium (BE + BG)

The heating medium system is an integrated utility with equipment located on both BE and BG.
The heating medium utilised is tempered hot water which supplies heat to the liquid trim
heaters on BE. Heat supply for the heating medium system is derived from the Waste Heat
Recovery Units of the four gas turbine generators on BG platform and the gas compression
turbine on BE. The controls on the system are configured to ensure that the exhaust gas
operating temperatures exceed the exhaust gas acid dewpoint temperatures at all times and to
minimise the trim heater process film temperatures. Exception to this is when the auxiliary
pumps are not operating.

Thus, the main function of control systems in the heating medium is to:

1. To maintain the temperature above the acid gas dew point in the WHRU. This is done by
ensuring heating medium inlet temperatures to the WHRU is normally at 150C.

2. To limit the supply temperature to the trim heaters to 150 C

BG

The heating medium circulation pumps (3x50%) on BG are dedicated to circulating heating
medium to the generator WHRUs on BG prior to being routed to the trim heaters on BE. Each
pump is provided with dedicated minimum flow control for pump protection. The stream
hydraulically distributes across the four generator waste heat recovery units (WHRUs). The
amount of heat collected through each WHRU is determined by an exhaust damper, controlled
on either inlet or outlet temperature (selectable by hand-switch) Normal inlet and outlet
temperature of the WHRUs is set at 150C and 195C respectively. Part of the warm stream
from the WHRUs is diverted to combine with the cool liquid returning from BE normally at
110C with the diverted flow controlled to maintain inlet temperature to the WHRUs at 150C.
The remaining warm stream from the WHRUs flows to BE.

Minimum flow to the WHRUs are maintained by a common differential pressure controller
across the WHRUs. When differential pressure across the WHRUs is below a specified value,
the controller overrides the WHRU inlet temperature control signal to recycle the required
amount of hot water from the WHRU outlet header to the suction header of the circulation
pumps.

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Leakages across the WHRU exhaust dampeners that result in heat collection in excess of that
required by the trim heaters will be rejected to the heating medium dump cooler. Flow to the
cooler is controlled by a temperature controller at the WHRU inlet header and set at 155C
which ensures that flow is routed to the dump cooler only if excess heat is generated by the
WHRUs on BG. The cooling water supply to the dump cooler is always maintained at its design
rate and no automatic controls are provided to maintain cooling water flow rate. In the event
that excess heat pick-up by the cooling water system resulting in cooling water temperature
above 75C, a high temperature override signal will automatically close heating medium supply
to the dump cooler.

The minimum operating pressure and suction pressure to the heating medium circulation
pumps of the system is set by blanket gas pressure controllers at the heating medium
expansion tank located on level 3 of BG platform and ensures that the heating medium does
not boil at any point in the system during all operating modes.

Approximately 5% of the pumping capacity of the BG heating medium circulation pumps is

routed to the heating medium expansion tank via a heating medium filter. Flow through the filter
is manually adjusted.

Table Process Control (SCADA).16: Heating Medium (BG) Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-1112 Pump minimum flow FCV111201 [HOLD 5]
P-1122 Pump minimum flow FCV112201 [HOLD 5]
P-1132 Pump minimum flow FCV113201 [HOLD 5]
E-1111 WHRU inlet temperature 150 C
WHRU damper
WHRU outlet temperature 195 C
E-1121 WHRU inlet temperature 150 C
WHRU damper
WHRU outlet temperature 195 C
E-1131 WHRU inlet temperature 150 C
WHRU damper
WHRU outlet temperature 195 C
E-1141 WHRU inlet temperature 150 C
WHRU damper
WHRU outlet temperature 195 C
General Waste heat recovery differential TCV112101 0.4 bar

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Tag Control Parameter Device Nom. Setpoint

pressure (override)
General Waste heat recovery Inlet 150 C
TCV112101
Temperature
E-1112 WHRU high Inlet Temperature 155 C
Cooling Water High Temp TCV112102 75 C
(override)
V-1102 Blanket gas Inlet Pressure PCV110201 17 barg
V-1102 Blanket gas bleed Pressure PCV110202 17.5 barg

BE

The heating medium circulation pumps (2x100%) on BE are dedicated to circulating heating
medium to the compressor WHRU on BE prior to being routed to the trim heaters. Each pump
is provided with dedicated minimum flow control for pump protection. The amount of heat
collected through each WHRU is determined by an exhaust damper, controlled on either inlet or
outlet temperature (selectable by hand-switch) Normal inlet and outlet temperature of the
WHRU is set at 150C and 195C respectively. Part of the warm stream from the WHRU is
diverted to combine with the cool liquid returning from the trim heaters normally at 110C with
the diverted flow controlled to maintain inlet temperature to the WHRU at 150C. The remaining
warm stream from the WHRU flows to the trim heaters.

Minimum flow to the WHRU are maintained by a differential pressure controller across the
WHRU. When differential pressure across the WHRU is below a specified value, the controller
overrides the WHRU inlet temperature control signal to recycle the minimum required amount
of hot water from the WHRU outlet header to the suction header of the circulation pumps.

A dump cooler is not provided on BE platform, as it is envisaged that the trim cooler will always
be online when the compressor is operated. Leakages of exhaust gas at the WHRU damper
will be significantly less than the operating duty of the trim cooler.

Heating medium from the WHRUs of BG and BE are supplied at a normal temperature of
195C. The auxiliary heating medium circulation pumps (3x50%) on BE re-circulate cooled
water from the outlet to the inlet header of the trim heaters to limit temperatures into the trim
heater to 150C. The re-circulation flow rate is controlled by a temperature controller at the trim

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heater inlet header that throttles a control valve at the pumps discharge header. Each pump is
provided with dedicated minimum flow control for pump protection.

Each trim heater is provided with process fluid temperature control that regulates flow of hot
water to each trim heater. Automatic minimization of the heating medium supply temperature to
the trim heaters, when operating under reduced load is facilitated by the position of the
temperature control valves on each trim heater. The controls are configured such that the trim
heater inlet temperature controller is overridden to actuate the control valve at the discharge
header of the auxiliary circulation pumps based on position of the trim heater outlet control
valve with the highest opening. The override will control the recirculation of heating medium to
maintain maximum opening of control valve at trim heater outlet at 80% opening. Control valve
position signals to the override controller of non-operating trim heaters will be disabled. This will
be manually initiated.

In the event that all the auxiliary heating medium pumps are offline due to trips or maintenance
outage, the set point for the temperature controllers at the inlet and outlet of the WHRUs will be
changed to 130C and 175C respectively both on BE and BG. These will revert to their original
settings once the auxiliary heating medium pumps are started.

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Table Process Control (SCADA).17: Heating Medium (BE) Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-1112 Pump minimum flow FCV111201 [HOLD 5]
P-1113 Pump minimum flow FCV111301 [HOLD 5]
E-11XX Trim cooler Inlet Temperature 150 C
Trim Cooler Inlet Temp. Minimization - -
TCV110109
E-1101 WHRU inlet temperature 150 C
WHRU outlet temperature 195 C
WHRU Differential Pressure TCV111205 0.4 bar
WHRU Inlet Temperature TCV111205 150 C
P-1121 Pump minimum flow FCV112101 [HOLD 5]
P-1122 Pump minimum flow FCV112201 [HOLD 5]
P-1123 Pump minimum flow FCV112301 [HOLD 5]

2.1.15 Flare Systems

HP Flare (BE-)

Gas releases from high pressure systems are routed to the HP flare drum for disposal. Gas
flows to the HP flare tip for combustion, while associated liquids are pumped to the LP flare
system with pump start/stop controlled by HP flare drum level.

Table Process Control (SCADA).18: HP Flare Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-4011/12 V-4020 liquid level - lead pump MCC 500 mm
- lag pump MCC 600 mm

LP Flare (BE)

Gas releases from low pressure systems are routed to the LP flare / Closed Drain drum for
disposal. Gas flows to the LP flare tip for combustion, while associated liquids are pumped to

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the inlet separators on BA/BD with pump start/stop controlled by LP flare drum level. The LP
Flare / Closed Drain Drum is also used to collect liquids from equipment on Deck Level 2 and
Deck Level 3 during maintenance work.

Table Process Control (SCADA).19: LP Flare Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-4021/22 V-4020 liquid level - lead pump MCC 400 mm
- lag pump MCC 600 mm

2.1.16 Drain Systems

Closed Drains (BE)

The closed drain system routes live fluids from the facility equipment on Deck Level 1 during
maintenance to a common collection vessel for degassing to the LP flare. Remaining liquids
are then pumped back to either the inlet separators on BA/BD or the common final stage
separator, with pump start/stop controlled by closed drains drum level.

Table Process Control (SCADA).20: Closed Drains (BE) Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-5011/21 V-5001 liquid level - lead pump MCC 800 mm
- lag pump MCC 900 mm

Open Hazardous Drains (BE)

The open hazardous drain system routes hazardous atmospheric fluids from the facility to a
common collection tank for degassing to atmospheric vent. Remaining liquids are then
pumped back to the closed drain system with pump start/stop controlled by open hazardous
drain tank level.

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Table Process Control (SCADA).21: Open Hazardous Drains (BE) Control Parameters

Tag Control Parameter Device Nom. Setpoint

P-5012/22 T-5002 liquid level - lead pump MCC 800 mm
- lag pump MCC 1050 mm

Open Non-hazardous Drains (BE / BG)

The open non-hazardous drain systems on BE and BG are functionally identical, routing non-
hazardous atmospheric fluids to collection tanks for degassing to atmospheric vent. The liquids
are then pumped to the open hazardous tanks on BE and BD respectively, with pump start/stop
controlled by open non-hazardous drain tank level.

Table Process Control (SCADA).22: Open Non-hazardous Drains (BE / BG) Control
Parameters

Loop Tag Control Parameter Device Nom. Setpoint

[HOLD 6] P-5013/23 T-5003 liquid level - lead pump MCC 800 mm
[HOLD 6] - lag pump MCC 1050 mm
[HOLD 6] P-5024/34 T-5023 liquid level - lead pump MCC 800 mm
[HOLD 6] - lag pump MCC 1050 mm

2.1.17 TEG Regeneration System

The rich TEG from the Contactor is routed to the TEG regeneration system via level control
thus maintaining a level in the TEG Contactor. The rich TEG is heated up by cross heat
exchange with the outgoing lean TEG and any entrained hydrocarbons will be flashed off in the
flash vessel. The pressure controller will maintain the pressure of the flash vessel by routing
any hydrocarbon vapour to the LP flare. The rich TEG is then routed to the reboiler/stripping
column (via level control) where the water vapour is stripped from the rich TEG. The

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temperature of the reboiler is controlled by the electric heater. Lean TEG is then cooled and
pumped back to the contactor, maintaining a temperature difference with the process gas at the
inlet to the TEG contactor

Table Process Control (SCADA).23: TEG Regeneration Control Parameters

Tag Control Parameter Device Nom. Setpoint

Flash Vessel Pressure (HOLD 6) PC[HOLD 5]
Flash Vessel Level (HOLD 6 LC[HOLD 5]
Reboiler Temperature (HOLD 6 TC[HOLD 5]

Note that as this is a vendor package, the setpoints and control philosophy is to be finalised
upon selection of the final vendor.

2.1.18 Sand Removal and Treatment (BE)

Solids may accumulate in a number of different vessels operating at various conditions. These
will be periodically extracted and treated, with cleaning of some vessels being initiated
automatically and others being initiated manually.

As the contract for supply of this system has not been awarded, system control is yet to be
defined.

Package Control (UCP)

While a number of other systems or system components may hand-off data to the SCADA
system, they will be supplied with stand-alone controls:

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2.1.19 Stock Tank Compressor (BE)

While control of the process around the stock tank compressor are controlled by the SCADA
system, a number of internal package functions are controlled by a UCP. These include
compressor sealing, lubrication and condition monitoring systems.

2.1.20 Export / Gas Lift Compressor (BE)

While control of the systems surrounding the gas compressor are controlled by the SCADA
system, the compressor package controls internal functions with a UCP. These include the
lubrication system, seal gas systems, condition monitoring and all turbine controls including the
governor system. While acting in response to a SCADA signal, speed is also controlled by the
UCP.

In addition to operational controls, the compressor package provides antisurge protection for
the compressors. In general terms, this monitors compressor speed, operating flow (corrected
for temperature and pressure) and pressures and, on approach to the surge point, controls the
recycle of fluids from the discharge to maintain safe operation of each compression stage. As
previously described, the antisurge system also acts to limit drawdown of the suction pressure
on the LP stage and the discharge pressures of the IP and HP stages. These are not normal
control actions, but act in extreme situations to minimise the potential for a facility hazard to
arise from very rapid changes in compressor condition and give the normal compressor
controls time to rectify the condition.

2.1.21 Seawater Coarse Filtration (BE / BG)

The seawater coarse filters will undergo on-line backwash, typically on a timed cycle. Control
of the backwash cycle will be automated within the respective packages, with SCADA control
interface limited to sequence start/stop.

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2.1.22 Seawater Hypochlorination (BE / BG)

The hypochlorite system wil be controlled by its own UCP. Amount of hypochlorite to be injected
to each sea water source will be manually set at the outlet of the skid. Control philosophy within
the skid will be confirmed once vendor data is available.

2.1.23 Water Injection (BG)

The majority of the control in the water injection system is via the SCADA system, although the
fine filters, HP pump and the deaerator tower (yet to be resolved) are supplied with UCPs.

Fine filter backwash timing and sequencing is controlled by the packages UCP. Differential
pressure control monitoring over each filter is provided for input to the UCP.

Internal functions of the HP pump package are controlled by its UCP. These include the
lubrication system, condition monitoring and all turbine controls including the governor system.

Refer to section 2.1.12 for a more detailed discussion of the interface between SCADA and the
individual UCPs of the water injection system.

2.1.24 Main Power Generation (BG)

Each main power generator will control all internal functions by UCP, including:

Lubrication systems

Turbine controls

Generator controls

Voltage regulation

Synchronisation

Condition and vibration monitoring

While acting in response to SCADA signal, waste heat recovery dampers will also be controlled
by the UCP.

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2.1.25 Emergency Power Generation (BG)

Emergency generation will control all internal functions by UCP, with the SCADA system taking
no part in active control.

2.1.26 Compressed Air (BG)

Control of the compressed air system supplying the service and instrument air systems will be
automated via a pressure transmitter at the discharge header of the compressor package.
within the packages. Pressure reducing valves, set at 8.0 barg on the utility and instrument air
headers, wil reduce the pressure before the air is routed to the users. A backup PRV, set at 7.6
barg, is installed on the instrument air header in case of failure to the main PRV. Capacity
modulation and unit start/stop will be controlled within the package based on air demand, with
SCADA control interface limited to unit start/stop.

Table Process Control (SCADA).XX: Air Compressor (BG) Control Parameters

Tag Control Parameter Device Nom. Setpoint

A-5411 Compressed air header - lead compressor start PT-540101 10 barg
- lag 1 compressor start PT-540101 9 barg
- lag 2 compressor start PT-540101 8 barg
- all compressors stop PT-540101 11 barg

2.1.27 Nitrogen (BE)

Control of the nitrogen generation system will be automated within the package, unless the
Vendor expresses a preference and identifies advantages in control from the SCADA system.

2.1.28 Demineralised Water (BG)

Control of demineralised water generation will be automated within the package, unless the
Vendor expresses a preference and identifies advantages in control from the SCADA system.

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REFERENCES

[1] API RP 14C 7th Edition March 2001 Recommended Practice for Analysis, Design,
installation and Testing of Basic Surface Safety Systems for Offshore Production
Platforms

[2] ASBGA-08-07031-0001 Rev A BE & BD Platforms Shutdown Logic Diagram

[3] Maersk Oil Qatar AS Design Guideline, Rev. 8, 15/03/06, Fire & Safety Systems

[4] Email: I.Mcleod (MOQ) to C.Bruce (MSTG), 27/03/07, No Subject, Attachment 2 B

location overview_29052006.pdf

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APPENDIX
APPENDIX
APPENDIX
APPENDIX