Process Control Narrative

COMMENTS RESOLUTION SHEET
TRE PROJECT NO.: J63881

PROJECT DESCRIPTION: Nlmr-G Development &Karim West Water Flood Project
Resolution To Document No: NIM-48-102017-PX-5680-00002-0000_ Process Control Narratlve-Nimr G
Rev.03 Comments
No. Reference/
Drawing/
Section
1.1
PDO COMMENTS
Improve the formatting of the document.

For example
1. Page 18, Sec 3.2.2.3; Page 19, Sec
3.2.2.4, the section title was misformated. There are also
many other similar formatting errors in the
content. Please do a better proof-reading
before resubmlttingthe document for
review/approval.
2. Page 24: Sec 5.2 Is a very long section
and hard to read. Add subsections for Sec
5.2 to lmprovethe clarity of the document.
Refer to GU694 for a example of
document structure.
For all control loops, please explain their
objectives relating to the process
requirement. If multipleloops are
Integrated and working together to serve
one purpose, the Interaction of the
controllers shall be described.
For example, L1C3541 NB, FC3502,
FC3520, and L1C3503 Interact with and
depend on each other.
How they work together and affect each
other shall be explained In PCN. 0
Refer to GU694 for quidellnes.
1. Page 7, Section 1.1, Update the
document objective as below:
"The process control narratives document
(PCN) supplements the Process Flow
CRS # Process Control NarraUve-Nimr-G
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Complied.
MU5575
Steve Niu,
UEOA13
Complied.
MU5575
Steve Nlu,
UEOA13
MU5575
Steve Nlu,
UEOA13
Complied. The Interaction of the

controllers for FWKO & CPI are
explained under the respective
subsections. (Sub-section 6.2.1.1
(Water level control) & 5.2.1.2
(Level control)).
Complied
Page1 of 10
12-07-13

TRE PROJECT NO. : J63881
Resolution To Document No: NIM-48-102017-PX-5680-00002-0000_Process Control Narrative-Nimr G
Rev.03 Comments
No. Reference/
Drawing/
Section
.
4
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Schematics (PFS) and the Process Flow

Engineering Schematics (PEFS) to
provide detailed andunambiguous
descriptions on the objectives, strategy,
functionality, Implementation,
andoperation of the process control
system."
Please use PO- GU694 as a checklist for
this project to make sure the key
requirements for theprocess control
system are met.
2. Page 7, Section 1.1: The purpose of
the document is to provide process
control narratives for thedetalled design. It
Is not a description of the process control
philosophy, which was for the
conceptdeslgn phase.
321
Page 16, Sec 3.2.1, diagram 3.4: the text

on the diagram is not legible. please use
a higher resolutiondiagram If available.
5.2
4. Page 23, Paragraph 1: please rewrite

the paragraph, for Improved clarify, as:
"The pressure in T -48350 will be
maintained ... by the pressure control
valves 48PCV-3502A on the blanket gas
lnletand 48PCV-3502B on the outlet
lines".
5. Page 24, Last paragraph: please
provide some justification In the document
CRS # Process Control Narrative-Nimr-G
'
MU5575
Steve Nlu,
UEOA13
This Is maximum clarity for the

document.
MU5575
Steve Nlu,
UEOA13
Complied.
The average level" Is used for
control as this will give more
time for the separator to make
up the level and also the same
type of control Is being used In
NRPS
CPI
the
existing
separators.
Page2 of 10
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Resolution To Document No: NIM-48-102017-PX-5680-00002-0000_ Process Control Narrative-Nimr G
Rev.03 Comments
No. Reference/
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Section
PDQ COMMENTS
on the selection of
"average" level for control. It Is more
typical to use the "maximum" or
"minimum" level for controldepending on
whether operation concerns more on the
potential overflow or underflow of the
liquid.lt Is less common to use "average"
level.
Page 24, Sec 5.2:For the section under
"FWKO Tank, Process Control": Rewrite
this section. The description of the
control purpose and functionality is
absolutely confusing. Change to
something like this
"The pressure in the tank T-48350 is
maintained between 0.5 kPa(g) and 1.0
kPa(g) by dualpressure controllers 48PIC3502A and 48PIC-3502B. The process
value for the two pressure
controllers comes from the same pressure
transmitter 48PT-3502. When the tank
pressure Is above.
1.0 kPa(g), controller 48PIC-3502B will
open the flare valve 48PCV3502B and
send the excess gasln the tank to flare. In
case the tank pressure falls below 0.5
kPa(g), the controller 48PIC-3502A
would open the blanket gas valve
48PCV3502A to bring In more fuel gas to
brlnQ the pressure backto normal range.
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Complied. Process control diagram

(APPENDIX I) Is also updated to
show the dual pressure controllers
for FWKO tank & CPl.
Page3 of 10
12-07-13

PROJECT DESCRIPTION: Nimr-G Development &Karim West Water Flood Project
Resolution To Document No: NIM-48-102017-PX-5680-00002-0000_ Process Control Narrative-Nimr G
Rev.03 Comments
No. Reference/
Drawing/
Section
.
7
PDQ COMMENTS
When the tank pressure is between 0.5

kPa(g) and 1.0 kPa(g), both valves will be
fully closed by the respective pressure
controllers."
Modify the PEFS and control diagram to
show the dual pressure controllers.
The same applies to the description on
Page 27.
Page 25, along with the two low selectors
(between FIC3502 & L 1C-3542, FC3503
& L1C-111),pleaseadd the requirement
for anti-reset windup for the controllers
(FIC3502 & FIC3503).
Page 31 : 1. Water Disposal Control
Strategy: what is the basis for using flow
control with level override, In
comparison with a level to flow to vavle
cascade loop? Is the level override meant
to protect the level
from going too high or too low? How to
achieve it with level override (low override
or high override)?
2. Pump Discharge Pressure Control:
where Is this pressure controller PIC3561
on the controldiagram? How does it
Interact with the flow controller? For the
fixed-speed pump, flow and pressure
are dependent, and you can not control
both the flow and pressure at the same
tlmelll This will network.
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Water
Disposal
pump
discharge flow Is controlled by
the flow controller 48FIC-3520
cascaded with average level
controller (48LIC-3542A) of the
new CPI separators, through a
manual bias 48Y-3512. It Is not
flow control with level override.
Pressure controller PIC-3561 &
subsequently control valve
PCV-3561 are removed from
the motive water line to Solid
handling system, which is
tapped-off from Disposal water
booster
pumps'
discharge
header. Because the flow rate
of motive water will be
controlled to the solid handling
system (I.e. motive water to Jet
pumps and Tores).
Accordingly,
related
Page4 of 10
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Check w1th process engineers on

therequirement of pressure control. If a
minimum pressureneeds to be
maintained, consider flow control with
pressureoverrlde. In addition , if the flow
lsoverriden by the pressure control in
case the pressure goes too low, a
lowerdischarge flow will result. This will
lead to higher level in the tank. How will
the tank be protected from high level?
Page 25, last paragraph: ''The pressure ...
will be maintained ... by pressure control
valves on theblanket gas Inlet line and
gas outlet lines to the CPI". Should It be"
... gas outlet lines to AP flare"?
Page 24, for the section under "Level
Control: Emulsion": Describe the
objectives of the level and
flow controllers (LIC3541 NB, FC3520,
FC3502, LIC3503) and how they worK
together, such as
- L1C3541 A provides the normal level
control by manlpluating the flow rate at
the discharge through a
cascade loop. (why is this shown in the
diagram and described somewhere else
as flow override?
what's the process intent for level to valve
with flow override rather than flow to flow
to valve cascade
---
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description of PIC-3561 has

been
deleted
from
the
document.
Complied.
I
--
--
------
The objectives of the level and

flow controllers (LIC-3542A/B,
FIC-3520 & FIC-3502) are
section
described
under
5.2.1.2, CPI separators level
control.
LIC-3542A Is "average level
controller
for
New
CPI
Separators, which Is cascaded
with flow controller FIC-3520
located
the common
on
discharge of Disposal water
booster pumps.
The functioning of LIC-35428,
FIC-3502 and LICA-3503 are
PageS of 10
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Resolutjon To Document No: NIM-48-102017-PX-5680-00002-0000_Process Control Narrative-Nimr G
Rev .03 Comments
No. I Reference/
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PDQ COMMENTS
control?)
- L1C3541 B provides the high level
protection In case the tank level rise
above a prescribed hlghllmit. In case of
high level, the level control LIC3541 B will
override the Inlet flow controller FC3502,
vlaa low selector, to reduce the Inlet flow
to help bring the tank level to normal.
(explain what protectionis provided forT48350 level If FC3502 Is overridden by
L1C3541 B)
Remove the sentence "The flow is
controlled at set point provided say 8500
m3/d ... ". This is a typicalcascade loop,
and the flow set point Is determined by
the level controller output, and Is varying
all thetime
10
11
I 5.2
The CPI Ievel controller output

manipulates the booster pump discharge
flow, and at the same time,provldes
override to the FWKO Tank level control
(Input). Please provide Implementation
details as the two control actions are
different, one lsREVERSE action, the
other Is DIRECT action.
For both the FWKO tank emulsion
controller and the water level controller,
their outputs are fannedout to multiple
flow controllers. For smooth operation
CRS # Process Control Narratlve- Nimr-G
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provided under subsection

5.2.1.2 of the document.
The sentence "The flow is
controlled at set point provided
say 8500m3/d .... " has been
removed from the document.
Please note that the CPI level

controller (48LIC-3542A) which
provides feed forward signals to
the
flow
controllers
(48FIC3502/3503) is well explained in
section 5.1.1 for control actions.
Implementation part Is explained in
section 5.2.2.5 as part of detailed
control narrative.
Please note that the required
functional block for this project is
well explained In the detailed
control narrative in section 5.2.2.
PageS of 10
12-07-13

Rev.03 Comments
No. I Reference/
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PDO COMMENTS
bumpless transfer blocks should be

Implemented. Since there are bias blocks,
typically the bumpless transfer can be
Implemented In
the bias blocks.
12
Page 26, top: "Bumpless transfer of

controllers shall be possible via the select
switch", which select switch, and how the
bumpless transfer shall be implemented?
13
Page 28, Level Control: the averaging of

the CPI levels shall be shown as a DCS
block. Definecrlppled mode of the
average calculation, that Is, how will the
calculation contlne If one or more of the
level signals become BAD
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As per our understanding BIAS

function block Is different from
BUMPLESS functional block. Also
note that the modem PID
controllers are having Inherent
features with more tan 120 odd
functional blocks. For any PID
controller,
required
functional
blocks to be enabled or configured
as per controller and process
functional requirement.
As per our understanding please
BUMPLESS
note
that
the
functional block is inherent feature
of any PID controller. While
configuring if the block is enabled
the above said function is
available. Definitely it Is not
through selector switch due to the
reason every time while the
operator changes the controller
action from manual to auto mode
he has to select first and then
change the controller mode.
As per PEFS the averaging
function block Is shown with DCS
symbol. The averaging block
receives level Input from the five
CPI
separators
namely
V48350/51/52153/54 and provides
Page7 of 10
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14
15
PDQ COMMENTS
Page 28, Level Control: the description of

the CPI selector is unclear and probably
Incorrect. Please re-check the control
objectives of the two level controllers on
the CPI and re-write the narrative for this
section.
Pages 28 to 29: The level control
narratives are very confusing. Please rewrite. Please provide agood description of
the control objectives and how the
controllers work together.
For example, the CPIIevelis normally
controlled by level controller LIC2541 A
through manipulating
the flow valve at the pump discharge.
(See also previous comment on why not
cascade to flow,instead of override by
flow). In the abnormal condition when the
CPIIevellncreases above a highlimit that
equals to the setpoint of the level
controller LIC2541 B, then LIC2541 B will
act and overridethe CPI Inlet flow
controller FC3502 output, via the low
selector Y3502, to reduce the Inlet flow.
Also check to make sure the correct tag
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averaged output of these signals. If

any one of the Input signal fails,
the averaging function continues
with the other available signals till
the last signal available.
Now the PCN Is updated with
control narrative describing with
controller actions as per the
process requirement and the
detailed control narrative with PID
controller's functional requirement.
Now the CPI level controllers
48LIC-3542A/B)
)which
is
providing feed forward signals to
the
flow
controllers (48FIC3502/3503) in the FWKO tank
water line feeding the existing and
the new CPI separator banks and
the flow controller controlling the
water booster pumps common
discharge line Is well explained in
control
narrative
relating
to
process requirement with controller
actions In section 5.2.1.2, where
as the controller configuration
requirements are well defined in
detailed control narrative In section
5.2.2.5.
PageS of 10
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names are used.
Please note that the PCN Is

updated with reverse flow scenario
in section 5.2.1 .2. The controller
design and configuration will be
same for CPI separators level
control except the absence of flow
controllers located on the new
FWKO tank water flow lines
feeding the new and the existing
CPI seoarators.
Page 30: provide more details on the

"reverse" flow mode. The process Intent,
control objectives,control strategy,
controller design, configuration etc.
16
17
18
19
App II
Gen
Appendix II, Control Diagram

1. For CPI Separators: why Is L1C3541A
defined twice?
To help the readability of the PCN, please
provide elther an overall process control
diagram showing all the key process
control configurations, or a process
control schematic for each unit
The schematic should show the
interaction and Inter-dependency of the
level/flow controllers
between the FWKO tank and the CPI
separators.
MU5575
Steve Nlu,
UEOA13
MU5575
Steve Niu,
UEOA13
i
I
I
One LIC Is deleted and Appendix

is revised.
The Process Control Schematic Is

already provided as Appendix-! of
the document. And Process control
schematic for "reverse flow'' is
provided as Appendix-11.
Page9 of 10
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20
PDQ COMMENTS
For all the detailed control narratives,

please Include Implementation
considerations such as startup/shutdown,
crippled mode, controller action
(dlrecVreverse), anti-reset windup,
bumplesstransfer etc, If they are not selfexplanatory from PEFS.
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Implementation consideration and

Controller configuration details are
Included under Sub-section 5.2.2
(Detailed Control Narrative for
Complex Loops)
Page10 of 10
12-07-13
_ ___.,Lib.
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TR EnglnMring LLC
G11far
GALFAR ENGINEERING &
CONTRACTING SAOG
PETROLEUM DEVaOPMENT OMAN
TR ENGINEERING LLC
PETROLEUM DEVELOPMENT OMAN
NIMR-G DEVELOPMENT & KARIM WESTWATER FLOOD PROJECT

PDQ CONTRACT NO. C311033
PROCESS CONTROL NARRATIVE- NIMR-G
DOCUMENT NO
NIM-48-1 02017-PX-5680-00002 -0000
TRE PROJECT NO
J63881
REVISION
04
DATE
22-09-2013
TR Engineering UC
P 0 Box 1597. PC 112, Ruwi, Sultanate of Oman
Tel: +968 24642100
Fax: +968 24604 414
NIM-48-1 02017-PX-5680-00002-0000
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DOCUMENT REVISION RECORD

II
Criticality Level:
REV
DATE
DESCRIPTION
PREPD
BY
CHKD
BY
APPD
BY
TA
01
23/11/11
Issued for Review
02
14/05/12
Issued for
Review
03
06/03/13
APPD.BY
EM
GEC
STB
RK
RK
VR
STB
RK
RK
DVS
PDO
GEC
Issued as final
22/09/13 As Built from FAT
PDO
GEC
HAZOP
MRM
04
Verification Level:
~~
HRD/JMB
RK
RK
1/t 46
DVS
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GEC
DVS
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REUANCE NOTICE
This report is issued pursuant to an Agreement between JnitecPfantaslndustriales SAU (Member of TR
Group of Companies) and/or its subsidiary or affiliate companies TR Group, and "Gaffar Engineering &
Contracting S.AO.G" on behalf of Petroleum Development Oman (PDO) which agreement sets forth the
entire rights, obligations and liabilities of those parties with respect to the content and use of the report.
Reliance by any other party on the contents of the report shall be at its own risk_ TR Group makes no
warranty or representation, expressed or implied, to any other party with respect to the accuracy,
completeness, or usefulness of the information contained in this report and assumes no liabiUties with
respect to any other party's use of or damages resulting from such use of any information, conclusions or
recommendations disclosed in this report.
NIMR-G DEVELOPMENT & KARIM WEST WATER FLOOD PROJECT

PDO CONTRACT NO. C311033
NIM-48-1 02017 -PX -5680-()0002
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PROCESS CONTROL NARRATIVE - NIMR-G
CONTENTS
FRONT PAGE
DOCUMENT REVISION RECORD
CONTENTS
ABBREVIATIONS
HOLDS
1.0
2.0
INTRODUCTION
1.1
Document Objective
1.2 Project Objective
1.3 Site Location
SCOPE OF WORK
2.1
Nimr-G Field (Off-Plot)
2.2 NRPS (On-Plot)
2.3 Exclusions
10
PROCESSDESC~PTION
11
3.1 Facilities at Nimr-G Field (Off-Plot)
11
3.2 NRPS (On-Plot)
15
4.0
CONTROL SYSTEM
23
5.0
PROCESS CONTROL NARRATJVE
24
5.1 Nimr-G Pipeline Facilities (Off-Plot)
24
5.2 NRPS (On-Plot) Facilities
25
REFERENCES
43
3.0
6.0
APPENDIX I PROCESS CONTROL SCHEMATIC

APPENDIX II PROCESS CONTROL SCHEMATIC (REVERSE FLOW)
NIM48-1 02017-PX-5680-00002
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PROCESS CONTROL NARRATIVE- NIM R-G
ABBREVIATIONS
AP
Atmospheric Pressure
BS&W
Basic Sediment & Water
CCR
Central Control Room
CPI
Corrugated Plate Interceptors
cs
Carbon Steel
CWT
Concentric Wash Tank
DCS
Distributed Control System
DWD
Deep Water Disposal
EORD
Engineering Operation Reference Document
EPC
Engineering Procurement and Construction
ESD
Emergency shutdown
ESP
Electrical Submersible Pump
FAR
Field Auxiliary Room
FCS
Foundation Fieldbus Control System
FOP
Field Development Plan
FEED
Front End Engineering Design
FO
Fibre Optic
F&G
Fire and Gas System
FWKO
Free Water Knockout
GFU
Gas Flotation Unit
GOR
Gas Oil Ratio
GRE
Glass Reinforced Epoxy
HEX
Heat Exchanger
HMI
Human Machine Interface
IPF
Instrumented Protective Function
IPS
Instrumented Protective System
t<JNWF
Karim W est Water Flood
LAN
Local Area Network
N IM-48-1 02017-PX-5680-00002
Page4af43
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LP
Low Pressure
MOS
Maintenance Override Switch
MSV
Multi port Selector Valve
NFA
No Further Activity
NGD
Nimr-G Development
NRPS
Nimr Production Station
ODCB
Out Door Circuit Breaker
OPC
Object Linking and Emedding(OLE) for Plant Control
PAS
Process Automation System
PCV
Pressure Control Valve
PDO
Petroleum Development Oman
PE
Polyethylene
PEFS
Process Engineering Row Scheme
PI
Plant lnfonnation
PLC
Programmable Logic Control
PPM
Parts Per Million
RMS
Remote Manifold Station
SIL
Safety Integrity Level
SOE
Sequence of Events
TRE
TR Engineering LLC
NIM-48-102017-PX-5680-00002
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PROCESS CONTROL NARRATIVE- NIM R-G
HOLDS
1. Deleted.
2. Deleted.
NIM-48-1 02017-PX-5680.00002
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1.0
INTRODUCTION
1.1
Document Objective
The purpose of this document is to provide the process control narratives for Nimr-G
Development Project (NGD Project). This document supplements with the process flow
schematics (PFS) and Process Engineering Flow Schematics (PEFS) to provide detailed
and unambiguous descriptions on the objectives, strategy, functionality, implementation
and operation of the process control system.
1.2
Project Objective
Nimr-G is a part of Nimr field and is located about 5 km North of Nimr Production Station
(NRPS). Nimr-G field will be developed by drilling 140 new wells. The current NFA
production from Nimr-G is 15364 m3 /d and with the planned infill drilling, the peak gross
product.ion is expected to reach 59605 m3 /d in year-2021 with addition of 140 new wells
in the field. The production of gross fluid from the new wells is routed to NRPS for
dehydration. To accommodate the increased gross production, new facilities are required
to be developed, i.e. On-plot & Off-plot facilities at Nimr-G and on-plot facilities at NRPS.
New FWKO tank. CPI Separators (with online solid removal system), Emulsion Transfer
pumps and Water Disposal Booster pumps will be installed at NRPS to adhere to the
tank maintenance philosophy and to avoid deferment
The FEED for the NGD Project was carried out by PDO FEED office.
Galfar Engineering & Contracting SAOG is awarded the EPC contract TR-Engineering
(TRE) Muscat will carry out the Detailed EngineeringD for the EPC contractor. The
project code is "KPH.
1.3
Site Location
A brief overview of the Nimr field is shown in Rg 1.1 below:
NIM-48-102017-PX-5680-00002
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Fig 1.1: Overview of Nimr field
M1Jll NORTH
R-odu ci1g Zo l'le51lti<Pl, ~ , ,6l(p<j and Min

Total113; 88 produceJS, s Pbandoned
NIM48-1 02017-PX-5680-00002
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TR ENGINEERING LLC
2.0
SCOPE OF WORK
Following new major equipment/items will be provided as a part of scope of this job:
2.1
2.2
Nimr-G Field (Off-Plot)
21 MSV units at Nimr-G field distributed in 15 Remote Manifold Stations (RMS).
16 concrete Drain pits at Nimr-G field for collection of maintenance drains from
RMS and Pig Launcher for 24" CS-PE pipeline.
Coriolis and High water cut meter to be installed on each MSV test line.
Two number of gross infield 14 GRE buried pipeline (one 6.8km and 6.2 km long)
from RMS area to Nimr-G for collection of gross fluid from all new MSV units.
C8-PE lined externally 3 LPE coated buried pipeline (24 size and 5.0 km long)
from Nimr G to NRPS for transporting gross from new wells in Nimr G area to
NRPS.
Pig Launcher and Receiver for 24" CS-PE pipeline.
De-emulsifier chemical injection at the start of 24" CS-PE gross fluid pipeline from
a De-emulsifier chemical injection skid ().
NRPS (On-Plot)
Bulk meter/s for Nimr-G new wells gross flow measurement at NRPS.
One FWKO tank of normal capacity of 140000 m3 /day NRPS identical to existing
FWKO tank T -4819.
Emulsion transfer pumps (3 working and 1 standby, each of capacity 8500 m3 /d)
(*).
CPI separator package A-48392 contains CPI separators (4 working and 1

standby). each of design capacity 10000 m3/d along with online solid handling and
removal system.
The Online solid handling & removal system are provided in each CPI separator
for solid handling. The slurry from the CPI'S shall be removed through solid
removal eductors to the Hydro-cyclone & finally routed to the evaporation pond.
Water disposal booster pumps (2 working and 1 standby, each of capacity 20000
m3 /d) r).
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Tie in with the existing utilities like Instrument air, Drain system, flare system , fuel
gas system and chemical injection systems.
Tie in with the existing ring main header for inlet to new FWKO tank, emulsion
transfer pumps discharge header and water disposal booster pumps discharge
header.
Upgrade of Electrical system to accommodate new facilities.
Upgrade of Instrumentation system to accommodate new facilities.
(*)Free Issue items by PDO to Galfar
2.3
Exclusions
Following items are excluded from the scope of this job.
Off-Plot
Well head facilities for 140 wells
Well flow lines from wellhead to the RMS fence
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3.0
PROCESS DESCRIPTION
3.1
Facilities at Nimr-G Field (Off-Plot)
3.1 .1
Existing Facilities
The gross fluid production from existing oil producer wells of Nimr-G flows to NRPS via
an 18", 5 km long CS-PE lined pipeline. Some of the Nimr-G gross fluid flows to Nimr-A
directly through a 12", 4.5 km long GRE pipeline which combines with Nimr-A gross fluid
production and flows to NRPS via a 30", 9 .7 km long, CS-PE lined pipeline as shown (in
blue color) in fig 3.1.
3.1.2
New Nimr-G Field Facilities

Tota1140 new wells will be drilled in Nimr-G area to increase the production from Nimr-G
field. The production from these wells will be routed to 21 new MSV units in the Nimr-G
field. All MSV units are segregated into 15 numbers of RMS. Each RMS consists of either
one MSV unit or two MSV units. Bulk outlet headers from the MSV units will be
connected to GRE buried pipelines. Two 14" GRE buried pipelines of 6.8 km & 6.2 km
length are running into the field to which various RMS outlet bulk headers will be
connected .
To accommodate the increased gross production from the Nimr G field two 14" GRE
headers/pipelines will be routed in two different route alignments. One, 6.4 Km long
buried header-1 , starts from North-west of Nimr-G field, routed towards South-East via 7
new RMS's having 11 new MSV's. The other, 7.2 Km long buried header-2 starts from
North-west of Nimr-G field routed towards South-East via 8 new RMS's having 10 new
MSV's. Both the headers will be terminated at same location in the Nimr G field. This end
will connect to NRPS using 4 .86 km long 24" CS PE lined pipeline.
Existing Off plot facility at Nimr-G and NRPS is currently classified as low risk sour having
an H 2S level of less than 500 ppm. But as per recent report for various well fluid samples
from Nimr-G field the maximum H2 S of 4000 ppm in gas phase was detected hence it
was decided that Nimr-G off plot (MSVs, Drain system, Off plot pipelines) facilities shall
be designed with 25 % margin i.e 5000 ppm concentration in gas phase. Accordingly all
the Off-plot facilities for Nimr-G is considered as high risk sour service.
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Nimr G field
~----------- --- --------- - -------- ---,
:
:
Nimr G existing
G :r'~
1 2_'_'._ _4_.s_k_m~ Nimr-A
I
I
18", Skm, CS +PE
I
I
I
I
I
I
I
30", 9.7km, CS + PE
~ ----- -------------------- - ----
;1
24" , 5km, CS + PE
NRPS
EXISTING LINES
-
NMR G PROJECT SCOPE
Fig: 3.1 Nimr-G Pipeline Network (Existing and New)
The detailed process description of the MSVs, GRE headers and the gross fluid pipeline
are given item wise below.
3.1.3
Typical MSV Skid and Testing Facility:

Each Multi-port Selector Valve skid (MSV) has eight, 3" inlet ports to which flow lines
from seven wells will be connected and port 8 (3") will be blinded and used for inspection
only. MSV unit also has one 6" bulk outlet port and one 3" test outlet port. Bulk line will be
connected to 6" outlet port and test line will be connected to 3" test port. Bulk header from
MSV unit is further routed to 14" Gross GRE header 1 or 2 according to the location of
MSV. Coriolis meter and High water cut meter (in series) will be installed on MSV outlet
test line. The outlet test nne is connected back to Bulk header. Schematic representation
of the GRE header I CS-PE lined pipeline arrangement is given in Fig 3.2 below.
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.
7 new RMS's having 11 New MSV's
14", 6km, GRE

14", 7km, GRE
24", 5.0 km, CS + PE

8 new RMS's having 10 New MSV's
NRPS
Fig: 3.2 GRE header I CS-PE lined Pipeline arrangement in Nimr-G
3.1.4
Drain Pit
As the H2S concentration in process fluid is approximately 4000 ppm in gas phase, it was
decided that Nimr-G off plot (MSV's, Drain system, Off plot pipelines) facilities shall be
designed with 25 % margin i.e 5000 ppm concentration in gas phase. Accordingly all the
off-plot facilities is considered as high risk sour service. Therefore, maintenance drains
from MSV units will be routed to closed drain pit. The vent from each drain pit will be
discharged through elevated vent line so that during venting the H2S concentration at
ground level shall be less than 10 ppm (as per the standards). For each RMS unit. one
drain pit is provided. Therefore, there will be 15 drain pit required for 15 RMS units. One
more drain pit is provided near pig launcher area of 24e CS-PE pipeline. Drains from GRE
header 1 & 2 temporary launcher area to be routed to RMS-8 and RMS-1 drain pit. Drain
pit is sized for collecting the maintenance drains of two MSV units.
3.1.5
RMS Area H2S Detection System

As the H2S gas concentration in process fluid is approximately 5000 ppm in gas phase,
H2S detectors (One H2S detector per MSV) are provided around MSV skid area and drain
pit area to check the leaks. Standard H2 S detection systems with H2 S detectors at MSV
skid and drain pit area are provided. On activation, audible alarms will be generated at
field and at NRPS control room. Similarly beacon lights will provide at field to alert the
personnel at site in case of any leak of H 2S gas at field.
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3.1.6
GRE Headers
Please refer following schematic diagram Fig 3.3 for NIMR-G MSV and locations routing
of GRE headers
A-53104
A-53105
GRE HEADER1
A-53100
A-53101
A-53102
A-53103
A-53118
A-53119
A-53113
A-53114
GRE HEADER2
CS PE PIPELINE
GRE Headers /Pipelines
NRPS
CSPE lined Pipeline
Fig 3.3 Schematic diagram for Nimr-G MSV locations and routing of GRE headers
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GRE header -1 is connected with the following MSV units:

RMS
RMS
MSVTAG No.
RMS
MSVTAG No.
A-53100 & A-53101
MSVTAG No.
A-53106
A-53110
A-53102 & A-53103
A-53107
A-53104 & A-53105
A-53108 & A-53109
GRE header -2 is connected with the following MSV units:

RMS
MSVTAG No.
RMS
MSV TAG No.
RMS
A-53111
11
A-53115
14
A-53112
12
A-53116
15
10
A-53113 & A-53114
13
A-53117
3.1.7
MSV TAG No.

A-53118 & A-53119
A-53120
24" CS-PE Pipeline

CS-PE lined externally 3 LPE coated buried pipeline (24 NPS and 5.0 km long) will be
laid from Nimr-G to NRPS for transporting gross fluid from new wells in Nimr-G area to
NRPS.Permanent pigging facilities like Pig Launcher and Receiver will be provided for
24" CS-PE pipeline.
3.2
NRPS (On-Plot)
3.2.1
Existing Facilities
Gross fluids are received at NRPS in existing three Free Water Knockout (FWKO) tanks,
T -4817, T-4818 & T-4819. The bulk of the water is removed in the FWKO tanks leaving
an emulsion of oil and water. The high viscosity emuJsion , downstream of the FWKO
tanks, is dehydrated in four parallel dehydration trains. In each dehydration train, the
emulsion is heated to break the emulsion and oil-water separation is achieved in a
Concentric Wash Tank (CWT).
Nimr production station schematic with Nimr-G Project scope is shown in fig 3.4 below:
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MIIIRPRODUCTION STATlOM
SOtf;I.&AllC DIAGRAM
Fig: 3.4 Nimr Production Station

The heating system comprises of two exchangers in series. In the Pre exchanger, t.he
emulsion is heated by recovering heat from the washed oil leaving the CWT. This also
serves to cool the dehydrated oil to ensure the pipeline entry temperature specification is
not exceeded.
In the exchanger the emulsion is further heated , using tempered water (water with
corrosion inhibiting chemicals) at 12SOC, to the required CWT temperature by a closed
loop heating system. The emulsion outlet temperature, downstream of the Heat
Exchanger is controlled by modulating the supply of the heating medium. Tempered
water is heated in four fired heaters.
In the CWT. the hot emulsion is separated to the required BS & W specification by gravity
settling. The water at the bottom of the FWKO tanks flows by gravity to one of three
banks of CPis (Corrugated Plates Interceptors). The CPis are meant to reduce the oil
content in the produced water. The treated water from CPis is then pumped to different
deep water disposal (DWD) sites via booster pumps.
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Nimr Production Station (NRPS) has full accommodation, logistics, oil processing and
electric power generation infrastructure.
3.2.2
New Facilities
3.2.2.1
FWKO TANK
T-48350
The gross production from all the Nimr fields and gathering stations are fed to the NRPS
Free Water Knock Out (FWKO) tanks T-4817118/19 where free water is knocked out.
As a part of this project, new FWKO tank (T-48350) will be installed. The inlet tapping for
new FWKO tank will taken from Ring main header which will installed as part of 'NRPS
on plot piping to T -4817, 18 & 19 replacement' ongoing project (Worley Parsons job
number- PAIP00238, Project code - CN ).
The function of FWKO tank T-48350 is:
The FWKO tank is used to de-gas the incoming mixed phase feed stream. The
degassing is done in the outer tank of the concentric FWKO tank. The separated gas is
routed to the AP flare system. The produced water then flows by gravity to downstream
CPI separators, this is to knock out the free water and de-oil the knocked out water to the
lowest possible level of several hundred ppm of oil.
The FWKO tank is identical to existing Nimr-G FWKO tank (T-4819). FWKO tank has two
concentric tanks of diameter 33/39 m (inner I outer tank) and height of 10.45/12.5 m
(inner I outer tank). The water transfer port level has been kept at 300 mm above the tank
bottom to allow for solid settling in the tanks and to prevent solid carry over to the
downstream CPI separators.
Flow to the new FWKO tank is from the gross fluid ring header which also supplies to the
existing FWKO tanks. A motor operated V-notch type throttling ball valve is provided
close to ring header to regulate the inlet flow to the tank to provide hydraulic balance of
flows to the new & existing FWKO tanks. Gross-fluid to T-48350 is evenly distributed to
six nozzles around the tank, to provide a flow pattern that enhances the separation
performance. Each inlet nozzle is provided with a ramp inlet device that assists in
degassing and free-water knockout processes by decreasing the mixing action as the
feed enters the tank. The oil outlet device is a standard oil draw-off pan with a serrated
lip and a vortex breaker to avoid the introduction of gas into the oil stream. The water
draw-off is provided with a vortex breaker and a deflector plate, to minimise the quantity
of oil entrained into the water stream as a result of flow short circuiting from the
dispersion layer above.
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Water from FWKO tank is further routed to two banks of CPI separators i.e. new CPI
separators (40000 m3/d) and existing North CPI separators(80590m3/d). When the
FWKO tank is under maintenance, the new CPI separators will receive water from the
ring main header and aJso from the other existing FWKO tanks currently in operation.
The emulsion will be routed to new emulsion transfer pumps.
Tank Pressure, Oil level and Interface level is available for control & monitoring in the
NRPS FCS.
3.2.2.2
EMULSION TRANSFER PUMPS

P-48350/351/352/353
The separated crude oil from FWKO tank (T-48350) will be pumped via four (3 working +
1 standby) new emulsion transfer pumps (P-48350/351/352/353) to the four existing
parallel emulsion heater (de-hydration) trains. All the emulsion pumps are screw type,
variable speed motor driven pumps. The individual discharge from the four new emulsion
pumps will join the four existing parallel processing trains to the CWT's (one pump
discharge will be joined to one processing train only as per the existing philosophy at
NRPS). The emulsion in each train is heated in a series of two exchangers and the hot
emulsion is then separated in the CWT. The washed oil from the CWTs is pumped to oil
storage tanks.
Each of the four discharge lines from the emulsion transfer pumps is normally connected
to a separate dehydration train. A manifold will be provided on the pump discharge to
provide the flexibility to route any pump to any dehydration train, in order to achieve even
flow distribution between the four dehydration trains
If one of the emulsion pumps trips, the operator will manually line up the standby pump to
the corresponding dehydration (CWT) train of the 'tripped' pump. The ullage that is
provided for operator intervention to start the stand-by pump corresponds to 2 hours. The
design intent is to avoid the gross fluid feed to the new FWKO tank and to avoid the HH
level trip in the tank. This is based on one pump capacity of 8500 m3 /d and FWKO tank
operating at NormaJ level.
The manual line-up (and start) of the standby pump will prevent imbalance of the flow
through the corresponding CWT and heat exchanger trains. The same scenario will
otherwise occur, if the standby pump lined up to a separate CWT train and also when the
pump automatically started.
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3.2.2.3
CPI SEPARATORS
v-48350/351/352/353/354
The Produced water (Oily water) from the FWKO tank (T-48350) will flow by gravity, to
the new CPI separators and also to the existing North CPI separators.
The CPI separator package A-48392 contains CPI separators (4 working and 1 standby),
each of design capacity is 10000 m3/d along with on-line solid handling and removal
system.
CPI Separator reduces the oil in water concentration from 250 ppm to 100 ppm. The
separated oil from new CPI separators is connected to the separated oil header from
north bank CPI separators, which is finally routed to Dry Oil Sump vessel (V-4882) by
gravity flow. The oil-water mixture from dry oil sump vessel will be pumped to the suction
header of existing and new emulsion transfer pumps.
In case, North CPI train is not in operation (which is unlikely scenario), then part of the
produced water can further diverted to both South 'A' and 'B' CPI Separator banks from
the same header which brings water from T-4817/18 tanks to North CPI train.
During the new FWKO tank (T-48350) maintenance, supply of the water to the new bank
D CPI separator shall be routed from the existing FWKO tanks (T-4817 & T-4818). Due to
location of the existing FWKO tank (T-4819), which is far away from the new bank -D CPI
separators, the probability of water being fed from T-4819 is an unlikely event. The flow
will be "reversed" from the water ring main header with a 30" tie-in located upstream of
the existing LCV-0111 B.
Each CPI Separator will have its own on-line Solids handling system to transfer any
settled solids to a downstream solid disposal system. Similar arrangement for receiving
solid from the GFU will be provided under the Karim West Water Aooding Project. Each
CPI separator will have a dedicated solid removal eductor. The outlet of the eductors will
be connected to a common hydro-cyclone to separate solids and water. The common
hydro-cyclone will receive slurry from the all the five CPis as well as from the GFU. The
recovered water will be recycled back to the gross fluid ring header. The solids as slurry
will be routed to evaporation pond. Motive fluid for solid removal system shall be provided
from Water Disposal Booster pumps common discharge header.
Motive water for the operation of the online solid removal system shall be supplied from
the common discharge header of the disposal water booster pump. The header shall
include a pressure control valve for regulating the pressure and the water is distributed to
new CPI separators package (A-48392) and to the Gas Floatation tank T -48301 (to be
installed as part of Karim West Water Flood Project) . For each CPI separators the
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motive water flow rate is-72 m3 /hr including hydrocyclone at a pressure of 15.6 bar(g) at
the package battery limit. The motive water requirement is intermittent nature and shall
operate for approximately 15 minutes per day. Refer CPI vendor's Operating Philosophy
(Ref 4) & Solid handling vendor's Operating and Control Philosophy (Ref 6) for further
details.
3.2.2.4
WATER DISPOSAL BOOSTER PUMPS

P- 48354/355/356
The treated water from new CPI separator train will pumped via three (2 working and one
stand by) water disposal booster pumps P-48354/355/356 to the deep water disposal
header. Each of the water disposal booster pump is designed for a flow rate of 20000
m3 /d. If any duty pump trip due to an individual mechanical fault or low-low suction
pressure, the standby pump automatically will come on line. Whenever, any of the pumps
trips, the ESD valve on the discharge header of the corresponding pump will be closed.
Therefore, when pump P-48354 trips the ESD valve on discharge line 48-UZV-3520 will
close.
3.2.2.5
EVAPORATION POND
An open pond with PE liner is provided outside the NRPS. The Evaporation pond has two
compartments. The evaporation pond will receive slurry from the Hydro-cyclone (part of
the CPI separator package). The Surface area of the pond will be sized for evaporation of
the water received on a daily basis & also to dry the received solids. The solids on drying
will be removed from the evaporation pond by shoveling periodically during maintenance.
3.2 .2.6
UTILITIES AND OFF-SITES

The Utilities and Off-sites required for new project facilities are described below.
Drain and Vent system
Off Plot
Maintenance drains from MSV area for off plot area shall be connected to closed drain pit
inside RMS . One drain pit is provided for each RMS. The drain pits will be decanted by
vacuum Trucks.
The vents from the drain pits will be routed to atmosphere through vent pipes to a safe
location to cater to the H2S limits in atmosphere.
The vent from CS PE line is routed to atmosphere through vent pipe provided at either
end of flange section to a safe location to cater H2S limit in atmosphere.
On Plot
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Process drains from all various new facilities at NRPS and from the PE liner vents shall
be connected to a nearby suitable closed drain header which shall be further routed
underground to LP flare knockout drum (V-4858). The vent from FWKO tank including
level instruments, CPI Separators shall be connected to the nearby vent header which
shall be further routed to LP Flare Knock Out drum (V-4858).
Instrument Air
Off Plot
No requirement
On Plot
Supply of Instrument air for the new facilities for this project shall be taken from the
existing instrument air network at NRPS.
Fuel Gas system
Off Plot
No fuel gas is required in the off plot facility.
On Plot
Fuel gas will be required for new FWKO tank and CPI Separators for blanketing purpose.
This will be tapped from the existing system at NRPS.
AP Flare system
The vents from FWKO tank and CPI units will be connected to the existing AP flare
network.
Chem ical i njection system
Off Plot
De-emulsifier chemical injection is required. The de-emulsifier will be injected
continuously at the start of 24" C$-PE gross fluid pipeline from a De-emulsifier chemical
injection skid (*) .
(*)-Free issue item by PDO to Galfar.
On Plot
The scale inhibitor chemical injection is required for the emulsion outlet line from new
FWKO tank. The scale inhibitor line from the existing chemical injection pumps discharge
manifold will be routed to new FWKO tank.
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Antifoam agent is required for the new Nimr-G pipeline bringing all gross fluid from Nimr
G new wells to NRPS. The antifoam agent injection tapping is provided on this pipeline at
NRPS before joining to Ring main header. The antifoam connection is tapped from
nearby antifoam line joining to ring main header.
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4.0
CONTROL SYSTEM
Two nos. field mounted TUV certified , class AKS, SIL3 PLC based, field IPS (one each
for Nimr-A and Nimr-G pipeline overpressure protection) shall be installed as part of this
project Both the field IPS shall be of same make as the new station IPS at FAR-1 . The
existing Nimr-A pipeline overpressure protection Maglog make IPS shall be replaced with
the new field IPS.
The field IPS for Nimr-G pipeline overpressure protection shall trip the ODCB's supplying
power to existing and new Nimr-G wells. This IPS shall be located approximately 3 kM
from NRPS and shall communicate over FOC.
The field IPS for Nimr-A pipeline overpressure protection shall transfer the Nimr-G wells
shutdown signal to Nimr-G pipeline overpressure protection IPS through FOC which shall
transfer this shutdown signal through hardwire to the ODCB's located in Nimr West
substation which is approximately 500 m away.
The Control and Automation system for the new facilities to be built in NRPS as part of
Nimr-G Development and Karim West Water flood project shall be a stand-alone system
with interface with the existing Foxboro DCS and Triconex IPS for control and
safeguarding signals to & from the existing NRPS facilities.
The new control system shall be Foundation Fieldbus Control System and IPS shall be
PLC based IPS. The F&G shall be part of Station IPS but will be physically and
electrically segregated from station IPS.
The new FCS, IPS and F&G shall be interfaced to the existing control system through FO
cable for control signals and safeguarding signals (including SIL-3 functions).
A new HMI shall be installed in the existing NRPS control. The ESD and MOS switches
shall be installed in the new console installed as part of NRPS Control System Upgrade
Project.
The SOE for the new facilities PAS shall be integrated into the existing SOE so as to
have a single SOE record for complete NRPS.
The existing OPC server shall be utilised for integrating the new facilities PAS with PDO
LAN . This shall be confirmed by PAS vendor. If found not possible additional OPC server
shall be provided by PAS vendor.
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5.0
PROCESS CONTROL NARRATIVE
5.1
Nimr-G Pipeline Facilities (Off-Plot)

(Refer PEFS NIM-53-102017-PX-2365-00001-0001)
MSVs: The operator will able to line up the selected well that to be tested, from the
NRPS. 53HS-1026 (well test selector) shall be used to line up the well for testing. The
well fluid from the selected well will flow through the test meters. The combination of
coriolis meter and High water cut meter will analyse the gross fluid, gross fluid flow
(53FQI-1 001), net oil flow rate (53FQI-1002) and water cut values (5301-1 001) shall be
transmitted to NRPS and Marmul CCR
The MSV motor running status (53GB-1001), the indication of the well number (53GB1002) on which the test is being carried out and MSV failure alarms (53XA-1001AIB,
53XA-1001A) alarm indicate motor running, but no valve movement,53XA-1001 8 alarm
indicate motor running, but valve not correctly aligned ) is also be available at NRPS.
Testing of well can be stopped using a hand switch (53HS-1024).
The RTU also receive the signals from H2 S detector (One H2 S detector per MSV)
installed at respective MSV's (based on 5 ppm H2 S contour) and drain pit. It provides
local audible alarm and beacon light indication and transmit H2 S gas detection alarm to
NRPS through FOC. There will be no automatic shut down based on H2S gas detection
alarm. The emergency response procedure (Ref 5) applicable to NRPS shall be extended
to include RMS.
All the signals to and from MSV skids shall be interfaced with well testing facility at NRPS
through RTU.
Demulsifier Inj ection: There is no FCS control on demulsifier injection system,
Drain pit: Each drain pit is provided with level indicator (for example, 53 LIA-1001). The
level indication will available at NRPS control room and also at the field (shall be 53 Ll1001 ). The level Indication in the field shall be readable from vacuum truck connection
point. For high level in the drain pit, alarms will be generated in the the field as well as at
NRPS station.
The MSVs are fed with gross fluids from wells. which are ESP driven I beam pump
driven. There are no controls provided at the well heads. Similarly, there are no controls
provided at the MSVs, the GRE header and the CS-PE pipeline.
The total gross fluid from the Nimr-G field flows to the 'gross fluid' ring main header which
is then routed to the existing FWKO tanks and the new FWKO tank. The gross fluid
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distribution is hydraulically balanced. There are no FCS controls provided on the gross
fluid line to the existing and new FWKO tanks.
5.2
NRPS (On-Plot) Facilities

Refer to Appendix- I Process Control schematic. (Refer PEFS Nl M-48-1 02017-PX-236500001-0001 to 0018)
5.2.1
Control Description
This section provides the functional description and the design intent of all the control
loops for NRPS (on-plot) facilities. Controls are further categorized equipment /system
wise for ease of understanding.
5.2.1.1
FWKO TANK (T-48350)

Pressure Control:
The pressure control is provided to maintain the FWKO tank (T-48350) pressure.
The pressure in FWKO tank (T-48350) will be maintained in the range of 0.5 to1 .0 kPa(g)
to be well-within the tank design pressure of 2.0/-0.6 kPa(g) by the dual pressure
controllers 48PIC-3502A &B having different set points. The process value for the two
pressure controllers comes from the same pressure transmitter 48PT-3502, which
measures the tank pressure. The set point for 48PIC-3502A & 48PIC-3502B will be 0.5
kPa(g) and1.0 kPa(g) respectively.
48PIC-3502A controller (Reverse acting) regulates the pressure control valve 48PCV3502A located on the blanketing gas inlet to the tank. In case the tank pressure goes
below 0.5 kPa(g), the controller 48PIC-3502A will open the blanket gas control valve
48PCV-3502A to bring in more fuel gas to bring the pressure back to normal range.
48PIC-35028 controller {Direct acting) regulates the pressure control valves 48PCV35028 located on the tank vapour outlet line to AP flare. When tank pressure goes
above 1.0 kPa(g), the controller 48PIC-35028 will open the control valve 48PCV-35028
to vent the excess gas in the tank to flare to maintain the desired pressure in the tank.
When tank pressure is in between 0.5 kPag and 1.0 kPag, both the control valves
48PCV-3502A & B will be fully closed by the respective pressure controllers.
level control: Emulsion
48LIC-3501 is used to maintain and control the oil (emulsion phase) level in the FWKO
tank (T-48350).
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A fixed oil pan will draw-out the oil from FWKO tank (T-48350) to the suction header of
the emulsion pumps (P-48350/48351/48352/48353). 48LIC-3501 (Direct acting) will
maintain oil level in the tank by varying the speed of the emulsion transfer pumps
(P-48350/48351/48352/48353) , cascaded through the flow controllers. Flow element is
located on the discharge of each emulsion pumps. The level controller acts as master
controller and provides remote set point to flow controllers located on the each pump
discharge line. During normal operation, each flow controller set point (for the 3 pumps
operating scenario) is decided by the level controller (Master controller) based on
emulsion level in the tank. Flow controller of each pump (48FICA-3503/3504/3505/3506)
shall provide remote set point to the respective pump speed controllers {48SIC3508/3509/351 0/3511) which will vary the speed of the respective pumps and hence the
emulsion flow across pump to maintain (control) the emulsion level inside the tank. Flow
through each running pump is be totalized in 48FIQ-3507, providing the total emulsion
flow from the tank to dehydration system.
The level control range in the FWKO tank shall be from 7400 mm to 7900 mm referenced
from Tank BTL The set point of the level controller will be 7650 mm from tank BTL
FWKO tank (T-48350) level controller 48LICA-3501 is cascaded to the emulsion pump
discharge flow controllers provided via a manually set 'bias' control, similar to the existing
emulsion pump system. The 'bias' function will enhance flexibility to set uniform or
desired flow through each pump, to the downstream dehydration train. The 'Bias' values
shall be set during commissioning and will not be changed during normal operation.
Access to change of 'bias' values shall be provided to authorised personnel only.
When the emulsion level is increased the emulsion draw rate is increased by increasing
the speed of the emulsion transfer pumps through the respective flow I speed controllers.
When the emulsion level is decreased the emulsion draw rate is decreased by reducing
the speed of the emulsion transfer pumps through the respective flow I speed controllers.
The variable speed range of the emulsion pumps is from 400 to 960 rpm. The speed of
900 rpm is at the rated flow rate of 8500 m3/d.
An additional oil level transmitter (48LI-3500) is provided to measure the emulsion level in
the tank. 48Y-3500 compares level measured by both level transmitters (48LI-3500 and
48LICA-3501 ) and it gives deviation alarm 48LA-3504 if difference between both
readings is more than 400 mm. This indicates that operator action is required for the
re-calibration of the level instruments.
Level control : Water
48LIC-3503 is used to maintain and control the water-emulsion interface level in the
FWKO tank (T-48350).
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The water-emulsion interface level is controlled by 48LICA-3503 (direct acting), by

regulating the water flow through individual control valves 48FCV-3502 & 48FCV-3503
mounted on the 42" water transfer line to the new CPI separators and 42" transfer line to
the existing CPI separators respectively. 48LICA-3503 (master controller) provides a
remote set point to both the flow controllers 48FIC-3502 and 48FIC-3503.
Row controllers (48FIC-3502 and 48FIC-3503) will provide signaJ to respective low
selector block (48Y-3502 and 48Y-3511) which will compare the signal input from tank
level-flow cascade controller (48LIC-3503- 48FIG-3502 and 3503) and the feed forward
signal from existing I new CPI separator average level controller (48UC-111 and 48LIC3542B). The low signal selector output from the respective block regulates the flow rate
through the control valves 48FCV-3502 and 48FCV-3503 respectively.
The produced water flow rate to the new CPI is 40000 m3/d (for the current project). This
will be further increased to 80000 m3 /d with installation of new CPis in future. The ftow
rate to the existing water inlet header leading to the existing CPI is 80000 m3/d. The total
produced water flow (to existing and new CPis) is generated using 48FIQ-3501 which
adds flows measured by 48FIC-3502 and 48FIC-3503.
The interface level in the FWKO tank varies from 2100 mm to 3100 mm referenced from
the tank BTL. The set point of the LIC-3503 is set at 2600 mm from BTL.
The FWKO tank interface level controller (Direct acting) 48LICA-3503 is cascading to the
flow controller's 48FIG-3502 for new the CPI separators and 48FIC-3503 for the existing
North CPI separators. They are provided via a manually set 'bias' function block. The
bias function is introduced to build in the flexibility for the operator to regulate the water
flow rates to new the train CPI units and the existing North train CPI units, based on
availability of the downstream CPI separators and the booster pumps. 'Bias' values shall
be set during commissioning and will not be changed during normal operation. Access to
change the 'bias' values shall be provided to authorised personnel only.
When the FWKO tank interface level is increased the water draw rate is increased by
increasing the flow of the water to CPI Separators cascading through the flow controllers
48FIC-3502 and 48FIC-3503, unless otherwise there is no much variation in the CPI
(new/existing) separators level. Interfacing with CPI level controls and details are further
described in CPI level controller section.
When the interface level is decreased the water draw rate is decreased by decreasing
the flow of the water to CPI Separators cascading through the flow controllers 48FIC3502 and 48FIC-3503, unless otherwise there is no much variation in the CPI (new
/existing) separators level. Interfacing with CPI level controls and details are further
described in CPI level controller section (5.2.1.2).
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In addition to the above control functions, local pressure gauges (48PG-3501), level
indicators (48LI-351 0/3511) are available for field monitoring.
Tank T -48350 is provided with two different type of level sensing instrument, Differential
Pressure (DP) and Admittance probe to measure the interface level. The operator selects
via a FCS manual select switch 48HS-3500 either of the two level transmitters for
interface level measurement and control. The switching between the two different types
of interface level measurement shall be done through manual transfer. The admittance
probe type of transmitter shall be used for daily control and production. The DP type shall
be used for the stock calculation in future.
5.2.1.2
CPI SEPARATORS (V-48350/51/52153/54)

Pressure Control:
The pressure control is provided to maintain the CPI separators (V-48350/51/52/53/54)
pressure.
Each of the new CPI separators has identical pressure control. A typical pressure control
for CPI V-48350 is explained below, (Refer PEFS NIM-48-102017-PX-2365-00002-0001}
and the same is applicable for other CPI units.
The pressure in each CPI separator will be maintained in the range of 0.5 to 1.0 kPa(g},
to be well-within the vessel design pressure of 2.0/-0.6 kPa(g) by the dual pressure
controllers 48PIC-3540A & B having different set points. The process value for the two
pressure controllers comes from the same pressure transmitter 48PI-3540, which
measures the vessel pressure. The set point for 48PIC-3540A & 48PIC-3540B will be 0.5
kPa(g) and 1.0 kPa(g) respectively.
48PIC-3540A controller (Reverse acting) regulates the pressure control valve 48PCV3540A located on the blanketing gas inlet to the vessel. In case the vessel pressure goes
below 0.5 kPa(g), the controller 48PIC-3540A will open the blanket gas control valve
48PCV-3540A to bring in more fuel gas to bring the pressure back to normal range.
48PIC-3540B controller (Direct acting) regulates the pressure control valve 48PCV3540B located on the vessel vapour outlet line to AP flare. When vessel pressure goes
above 1.0 kPa(g}, the controller 48PIC-3540B will open the control valve 48PCV-3540B
to vent the excess gas in the vessel to flare to maintain the desired pressure in the
vessel.
When vessel pressure is in between 0.5 kPag and 1.0 kPag, both the control valves
48PCV-3540A & B will be fully closed by the respective pressure controllers.
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There is no control on the on-line solid removal system fitted in the CPI separator. It is an
intermittent operation of removal of solids accumulated in the bottom of CPI separator.
The control philosophy of the online solid removal system is provided in an independent
Process control philosophy. (Ref: 6).
Level Control
48LIC-3542AJB is used to maintain and control the water level in the CPI Separators
48350/51/52/53/54).
0/-
The new CPI units will receive water from new FWKO tank. The individual CPI level
controllers (48LIA-3521/26/31/36/41) output signal will be averaged by a averaging
function block (48-Y-3508) for the CPI separators which are in operation. This averaged
level signal from the above averaging function block, shall be connected to two separate
level controllers 48LIC-3542A (Direct acting) and 48LIC-3542B (Reverse acting). The
"average level signal is used for level control, as this will give more time for the separator
to make up the level. Similar control philosophy is being used in the in the existing NRPS
CPI separators.
48LIC-3542A will have lower setting where as 48LIC-3542B will have a higher setting.
The set point of the LIC-3542A is preliminary set at 1300 mm from BTL and the same of
LIC-3542B is preliminary set at 1700 mm from BTL. The controller "A" will regulate the
control valve (48FCV-3520) on the common discharge header of water disposal booster
pumps and the controller B" will regulate control valve 48FCV-3502 through a low
selector 48Y-3502 on T-48350 water outlet line to going to new CPI train.
Similarly, produced water flow from FWKO tank to the existing CPI separators (48FCV3503) is controlled through a low selector 48Y-3511 function block, which compares the
signal input from level-flow cascade loop pertaining to the FWKO tank (T-48350) and the
existing CPI separators average level controller (48LIC-111) output signal.
A duty/stand by selector switch (48HS-3552/53/54/55/56) has been provided for each of
the CPI separator. The signal from individual CPI level indicator will be activated and will
be averaged once; the respective CPI separator's selector switch has been selected for
duty mode.
Low selector function block 48Y-3502 is provided for comparing flow controller 48FIC3502 output and CPI separators average level output (48LIC-3542B) and low selector
value will be used for regulating control valve 48FCV-3502 located on the FWKO tank
water outlet line going to new CPI separators.
When the average level of the new CPI increases above set point of 48LIC-3542 8 the
inlet flow rate of the water to new CPI separators is decreased by giving the net signal
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P,ROCESS CONTROL NARRATlVE- NIMR-G
input to a low selector 48Y-3502, comparing the inputs from FWKO tank level-flow
cascading controller. When the average level of the new CPI decreases below set point
of 48LIC-3542 B the inlet flow rate of the water to new CPI Separators is increased by
giving the net signal input to a low selector 48Y-3502, comparing the inputs from FWKO
tank level-flow cascading controller. In case, at the same time, FWKO tank level
controller (48LICA-3503) or flow controller (48FIC-3502) operating above their respective
set points then low selector (48Y-3502) will not allow opening of control valve in order to
control the desired level / flow in the FWKO tank.
The FWKO tank volume (approx 14900 m3) is very high compared to the individual CPI
volume (approx 210 m3 } . Hence, the level in the FWKO tank does not vary much with
respect to the CPI level range. The change in new and the existing CPI level are very
much dynamic and in most times the low select on the 48FCV-3502 and 48FCV-3503 will
mostly be functional based on CPI separator average level controls when compared to
the level-flow cascade control of FWKO tank.
The control valve (48FCV-3503) on the water outlet line going to existing north CPI units
will be controlled by interface level (48LICA-3503) of new FWKO tank T-48350 and also
by level in the existing north CPI separators (48LIC-111 ). The FWKO tank interface level
control signal is cascaded to the flow controllers (48FIC-3503) located on the tank outlet
water line going to north CPI separators via a manually set 'bias' control. The bias
function is introduced to build in the flexibility for the operator to regulate the water flow
rates to each CPI banks based on availability of the downstream CPI separators and the
booster pumps. Low selector block 48Y-3511 is provided for comparing Flow controller
49FIC-3503 output and north CPI separators average level output (48LIC-111 ) and low
selector value will be used for regulating control valve 48FCV-3503 located on the FWKO
tank outlet water line going to north CPI separators.
Average level control of existing CPI separators also follows same philosophy as
described above for new CPI separator.
Reverse Flow Scenari o

This scenario is envisaged when the new FWKO Tank (T-48350} is under maintenance
(not lined-up) and the produced water from existing FWKO tank shall be routed to new
CPI separators vide ring main headers. Flow shall be routed through 48FCV-3502 to new
CPI separators. During the "reverse" flow from the water ring main header the level
control of the new CPI separator (V-48350/51 /52153/54) shall be achieved through
cascading action of "average" level controller 48LIC-3542B on 48FCV-3502. The
"average" level controi48LIC-3542B act on 48FCV-3502 through low selector 48Y-3502,
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which compares signal from the level controller 48LIC-3503 {on T-48350). Since, the
"reverse" flow happens when the FWKO tank T-48350 is under maintenance, the signal
from the T-48350 to low selector Y-3502 shall be overridden by selecting FIC-3502 in
manual selection mode, with 100% output so that the 48FCV-3502 receives signal only
from "average" level controller 48LIC-3542B. Also during this scenario, the 48FCV-3503
should be forced to open (100%) and 48-USV-3504 (on T -48350 produced water outlet
header) shall be closed (de-energized) using T-48350 shutdown signal, flow is routed
through FCV-3502. The other controls shall remain same. Refer to the Appendix - II:
Process Control Schematic (for Reverse flow operation) for more details.
Change-over from Reverse flow scenario to Normal flow scenario
During changeover from reverse flow scenario to normal flow scenario, the following
steps need to be carried out:
5.2.1.3
Switchover flow controller 48FIC-3502 initially in auto and then to cascade

selection mode
Flow controller 48FIC-3503 and flow control vatve 48FCV-3503 shall be switched
to normal operating mode, i.e. cascade control mode.
48USV-3504 shall be energized automatically from IPS
Close isolation valves.
WATER DISPOSAL BOOSTER PUMPS (P-48354/355/356)

Flow Control:
48FIC-3520 is used to maintain and control Disposal water pipeline flow rate going to
DWD header.
Water disposal booster pumps common discharge header is provided with a flow control
valve (48FCV-3520). All Water disposal booster pump's (P-48354/55/56) discharge will
be connected to a common header and then routed to the existing DWD header. The
water flow from the common discharge will be controlled by the flow controller 48FIC3520 cascaded with CPI separator's average level controller (48LIC-3542A).
The CPI separator's average level controller 48LIC-3542A (master controller) shall
provide a remote set point to the common discharge flow controller 48FIC-3520 (Direct
acting).
When the average level of the new CPI is raised above set point of LIC-3542 A, the outlet
water flow rate from new CPI Separators is increased by cascading through the flow
controller 48FIC-3520 which will regulate the opening of FCV-3520.
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PROCESS CONTROL NARRATNE- NIM R-G
When the average level of the new CPI falls below set point of LIC-3542 A , the outlet
water flow rate from new CPI Separators is decreased by cascading through the flow
controllers 48FIC-3520 which will regulate the opening of FCV-3520.
Minimum Recirculation Flow Control:

Each of the Water disposal booster pump is provided with similar minimum flow
circulation control. A typical minimum circulation flow control for pump P-48354 is
explained below, (Refer PEFS NIM-48-102017-PX-2365-00006-0001) the same shall be
applicable for other pumps.
The objective of this controller is to protect the Water disposal booster pump (P-48354)
against a minimum stable continuous flow of 356 m3 /h. This is maintained by
manipulating the control valve 48FCV-3509 on the recycle line.
The minimum flow as required by the pump is set as set point to 48-FICA-3509, which is
soft PID control algorithm with I-PO settings. As long as the actual flow is more than the
set point, the control valve is in closed condition. When the flow demand from Wells
control is less and flow through the pump is below 356 m3/h, the control valve 48-FCV3509 opens letting the required amount of water back into the new CPI separator (V48350).
48FICA-3509/11/13 is configured as Reverse acting , Proportional-Integral (PI) action
controllers.
Disposal Water as motive water to Solid rem oval system:

Motive fluid for solid removal system shall be provided from Water Disposal Booster
pump's common discharge header. The quantity of motive water flow required for solid
handling & removal system shall be 1728 m3 /d, which is supplied from the water disposal
booster pump discharge header at a pressure of 1800 kPa(g) (Reverse acting) Inside the
vendor package battery limit, the motive water further will be distributed to solid removal
educator (one per CPI) & Tares (12 no's) of each CPI separator for online solid handling
through Tares & slurry removal through solid removal eductors. The operation of the
online solid handling and removal system shall be intermittent but shall be automatic
based on vendor package PLC. The operation of the online solid handling and removal
system shall operate for approximately 15 minutes per day. Further details of Operating I
Control philosophy for the online solid removal system shall be provided in CPI Separator
vendor Operating Philosophy (Ref -4).
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A suction strainer is provided with differential pressure indicator (48PDIA3536f3538/3540) in FCS and suction I discharge pressure gauge (48PG3520/21/22/23/24/25) is available for field monitoring.
5.2.1.4
EMULSION TRANSFER PUMPS (P-48350/351/352/353)

As part of this project, four nos. emulsion pumps will be installed. Out of which, three
emulsion pumps will be configured in duty mode where as the fourth pump shall be in
stand-by mode. The emulsion Pump flow control philosophy described in section 5.2.1 .1.
When any one of the running pumps trips, the operator will align the standby pump by
manually opening the valves from field on the pump discharge manifold. The manifold
manual valves are provided with limit switches to indicate the valve position in FCS and
the alignment of emulsion pumps to each
train.
cwr
The suction strainer will be provided with differential pressure indicator (48PDIA3505/3510/3515/3524) in FCS and suction I discharge pressure gauge (48PG3503/04/05/06/07/08/09/1 0) shall be available for field monitoring, also FCS indication for
discharge (48PIA-3507/12/17/21) is available.
At each emulsion pump discharge total flow indication 48FIQ-3507 shall be provided in
FCS with high alarm.
5.2.2
Detailed Control Narrative for Complex Loops

Following shall be identified as complex control loops in the NRPS (on plot) and detailed
narrative for the same shall be described in the sub-sections in line with OG 00.20489
(ver. 2) guidelines (Ref -7).
5.2.2.1
);>
FWKO Tank Blanket Gas Pressure Control.
);>
FWKO Tank Emulsion level Control Loop cascaded with Flow control & Pump
speed control.
);>
FWKO Tank Water (Interface) Level Control Loop cascaded with Flow control &
CPI Separators level control.
);>
CPI Separator Pressure Control.
);>
CPI Separator level Control loops.
FWKO TANK BLANKET GAS PRESSURE CONTROL LOOP

Objective: The objective of this control loop is to control and maintain the blanket gas
pressure within the range of 0.5 kPag to 1 kPag in the FWKO tank (T-48350).
Function Description:
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The blanket gas pressure is measured with 48-PI-3502. The 48-PICA-3502A and 8
controllers modulates the control valves 48-PCV-3502A and 8 respectively to maintain
the blanket gas pressure within the range of 0.5 kPa(g) to 1.0 kPa(g).
See the control overview diagram in Appendix I for an illustration.
Controller Design and Configuration:
Algorithm
48PIC-3502A&B shall be configured with PID control algorithm enabling PI settings.
Controller Action
48PIC-3502A is Reverse Acting controller and 48PIC-35028 is Direct Acting controller.
PV tracking
PV tracking shall be disabled to retain set point value during mode change.
Alarming
48PIA-3502 shall be configured with low and high alarms.
Calculations
None
Anti-Reset Wind Up Protection
Not applicable
Bump-less transfer
No explicit bumpless transfer block is needed.
Special considerations
None
Operational and Implementation Aspects:
Start-up: Both the controllers are kept in AUTO mode with a fixed set point during
start-up.
Normal Operation: These controllers (48PIC-3502A &35028) are normally locked in

AUTO mode with fixed set points.
Cripple Mode of Operation: In case of input signal failure (bad process input or input
signal failure). the mode of the controller would be changed to manual and the output
set equal to 100%. When the input signal returns back to the healthy condition I the
fault is cleared, the controller shall be put back to AUTO mode by operator.
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5.2.2.2
Shutdown: Both the controllers are kept in AUTO mode with a fixed set point during
shutdown.
Operator Interface: The controller is managed by means of its detailed PID action
group display. The operator access for auto/ manual mode change is available during
crippled mode of operation.
History: Data archiving is incorporated in the DCS. In addition, 48-PICA-3502A/B.PV,

48-PICA-3502AIB.SP, 48-PICA-3502A/B.OP and 48-PICA-3502AIB.MODE to be
logged in the PI Historian database for long-term data storage.
Special Consideration: Not applicable
FWKO TANK EMULSION LEVEL CONTROL LOOP

Objective: To control the level of emulsion in the FWKO tank (f-48350).
Function Description: The FWKO tank emulsion level controller 48LIC-3501 resets the
set point of 48FIC-3503/3504/3505/3506 which regulates the emulsion flow rate by
varying the speed of the Emulsion Transfer Pumps (P-48350/48351/48352/48353).
Algorithm
48LIC-3501 shall be configured with PID control algorithm enabling PI settings.
Controller Action
Direct Acting.
PVtracking
It is not enabled; controller remains in auto mode and has a fixed level set point, to retain
set point value during mode change.
Alarm
The controller (48LIC-3501) shall be configured with low and high alarms.
Calculations
Manual bias is provided for level controller output to flow controller.
This emulsion level control does not need anti-reset windup. For proper back-initialization
of the controller, back calculation is needed.
NIM-48-1 02017-PX-5680-00002
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Bumo=tess transfer
Applicable, for controller changeover from manual to auto mode.
None
5.2.2.3
Start-up: 48LIC-3501 initially in manual mode and then switched to automatic mode
and cascaded with 48FIC-3503/3504/3505/3506.
Normal Operation: The FWKO tank emulsion level controller 48LIC-3501 is

cascaded to 48FIC-3503/3504/3505/3506.
Cri pple Mode of Operation: In case of input signal failure (bad process input or input
signal failure) in any of the loops LIC or FtC then the controller output signal shall be
automatically frozen to the last value. When the input signal returns back to the
healthy condition I the fault is cleared , the controller shall put in AUTO mode by
operator, the changeover shall be bump less.
Shutdown: No special provisions are required for the LIC, but for the FlC switch the
controller mode to Manual and set the controller output to zero.
History: Data archiving is incorporated in the DCS. In addition, 48-LIC3501 .PV, 48FIC3503/04/05/06.PV,
48-SIC3508/09/1 0/11 .PV,
48-LIC3501 .SP,
48FIC3503/04/05/06.SP,
48-SIC3508/09/10/11 .SP,
48-LIC3501-0P,
48FIC3503/04/05/06.0P, 48-SIC3508/09/10/ 11 .0P and 48-LIC3501 .MODE, 48FIC3503/04/05/06.MODE, 48-SIC3508/09/10/11 .MODE to be logged in the PI
Historian database for long-term data storage.
FWKO TANK WATER (INTERFACE) LEVEL CONTROL LOOP

Objective: To control the level of emulsion- water (interface) in the FWKO tank (T48350).
Function Description: The FWKO tank interface level controller 48LIC-3503 resets the
set point of 48FIC-3502 (flow to new CPI separators) and 48FIC-3503 (flow to existing
CPI separators) and provide the input to respective Low signal selector block (48Y-3502
NI~8-102017~X-5680~002
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for new CPI & 48Y-3511 for existing CPis}, which will compare the FWKO tank level-flow
cascade signal input with t he signal from the average level controller (48LIC-3542B &
48LIC-111 } of the new I existing CPI separators. The low signal selector output from t he
respective block regulates the flow rate through the control valves 48FCV-3502 and
48FCV-3503 respectively.
Algorithm
48LIC-3503 shall be configured with PID control algorithm enabling PI settings.
Controller Action
Direct Acting.
PV tracking
It is not enabled ; controller remains in auto mode and has a fixed level set point, to retain
set point value during mode change.
Alarm
The controller shall be configured with low and high alarms.
Calculations
Applicable, Manual bias provided to divert water to North-D or existing CPI separators.
Low selector is provided for FCV-3502 and FCV-3503.
During normal operation, the output of level controller LIC3503 is not selected by the low
selector, and anti reset windup protection needs to be configured for controller LIC3503.
The feedback for the anti-reset windup shall come from the valve position FCV3502/03.
In Foxboro, the anti-reset windup can be achieved by proper config uration of backcalculation originating from the valve.
Bumo=less transfer
Applicable, for controller changeover from manual to auto mode.
None
NIM-48-1 02017- PX-5680-()0002
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Start-up: 48LIC-3503 in automatic mode and switch the 48FIC-3502 and 48FC-3503
from manual to Auto/cascade based on healthy condition of the FWKO tank.
Normal Operation: The FWKO tank interface level controller 48LJC-3503 shall be
cascaded to 48FIC-3502 and 48 FIC-3503.
signal failure) in any of the loops LIC or FIC then the controller output signal shall be
automatically frozen to the last value, the operation mode of the controllers shall be
changed to manual, upon automatic control resumption, the changeover shall be
bump less.
Shutdown: No special functional will be required for the LIC, but for the FIC, switch
the controller mode to Manual and set the controller output to zero.
group display. The operator access for auto/ manual mode change Is available during
History: The mode, set point, measurement, and output values of all controllers
LJC3503, FIC3502, FIC3503 shall be configured to be historized in the historian
database (PI). The output of the low selector Y3502 and Y3511 shall be historized as
well.
5.2.2.4
CPI SEPARATORS PRESSURE CONTROL LOOP

A typical pressure control for CPI V-48350 explained below, the same shall be applicable
for other CPI units.
Objective: The objective of this control loop is to control and maintain the blanket gas
pressure within the range of 0.5 kPag to 1 kPag in the CPI separator (V-48350).
Function Description:
The blanket gas pressure is measured with 48-PI-3540. The 48-PICA-3540A and B
controllers modulates the control valves 48-PCV-3540A and B respectively to maintain
the blanket gas pressure within the range of 0.5 kPa(g) to 1.0 kPa(g).
See the control overview diagram in Appendix I for an illustration.
Algorithm
48PIC-3502A&B shall be configured with PID control algorithm enabling PI settings.
NIM-48-1 02017-PX-5680-00002
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Controller Action
48PIC-3540A is Reverse Acting controller and 48PIC-3540B is Direct Acting controller.
PV tracking
PV tracking shall be disabled to retain set paint value during made change.
Alarming
48PIA-3540 shall be configured with low and high alarms.
Calculations
None
Anti-Reset Wlnd Up Protection
Nat applicable
Bumo=less transfer
No explicit bumpless transfer block is needed.
None
Start-up: Both the controllers are kept in AUTO mode with a fixed set point during
start-up.
Nonnal Operation: These controllers (48PIC-3540A & B) are normally locked in

AUTO mode with fixed set points.
signal failure), the mode of the controller would be changed to manual and the output
set equal to 100%. When the input signal returns back to the healthy condition I the
fault is cleared, the controller shall be put back to AUTO mode by operator.
Shutdown: Both the controllers are kept in AUTO mode with a fixed set paint during
shutdown .
History: Data archiving is incorporated in the DCS. In addition, 48-PICA-3540A/B.PV,

48-PICA-3540A/B.SP, 48-PICA-3540A/B.OP and 48-PICA-3540A/B.MODE to be
logged in the PI Historian database for long- term data storage.
NIM-48-10201 7-PX-5680-00002
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PROCESS CONTROL NARRATNE- NIMR-G
5.2.2.5
CPI SEPARATORS LEVEL CONTROL LOOPS

Objective: To control and maintain the average CPIIevel within the desired range.
Function Description: The CPI level controller LIC3542A is designed to maintain the
average level of the four CPI separators within the desired setpoinl The level average is
provided by a calculation block Y3508.
A secondary protective controller UC3542B is also provided to prevent the level from
going excessive high during operation upsets.
The CPI level is normally controlled with the level controller UC3542A by manipulating
the CPI outlet flow rate, via the flow controller FIC3520 on the CPI outlet at the boost
pump discharge.
In case of major upset, the average CPI level may rise above the high limit set by the
setpoint of the secondary controller LIC3542B, the protective controller UC3542B
becomes active, and would override the inlet flow controller FIC3502, via the low selector
Y3502, to reduce the inlet flow to the CPI separator.
The controllers 48UC-3542A & 48LIC-3542B shall be provided with different settings.
Setpoint of 48LIC-3542A shall be the desired level during normal operation, while the
setpoint of 48UC-3542B shall be the high limit on level that shall not be exceeded.

Algorithm
The level controllers 48LIC-3542A & B and the flow controller FIC3520 shall be
configured as PID control algorithms with PI equation Both level controllers 48LIC3542A
and B shall be configured to be I-PO (Integral on control error, and PO on PV changes
only). The flow controller FIC3520 shall be configured as Pl-0 type (PI on control error
and 0 on PV changes}.
Direction of Action
Direct Acting for LIC-3542A & Reverse Acting for LIC-35428. The flow controller FIC3520
shall be configured as Reverse Acting .
PV tracking
NIM-48-1 02017-PX-5680-00002
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Both level controller UC3542A and LIC3542B shall be configured to NOT allow Setpoint
to track measurement when switched to MAN. The flow controller FIC3520, however,
shall be configured to enable PV tracking to avoid bump during mode change.
Alarm
Both low and high alarms shall be configured on the average level (Y3506).
Calculations
The level measurement is taken as the average of all the CPI levels U3521 , Ll3526,
Ll3531, Ll3536, and U3541 . In case any of the inputs to the Average calculation goes
BAD, the average calculation continues with the remaining good inputs. Alarm shall be
issued for the BAD level measurement.
During normal operation, the output of level controller LIC3542B is not selected by the
low selector, and anti reset windup protection needs to be configured for controller
LIC3542B. The feedback for the anti-reset windup shall come from the valve position
FCV3502. In Foxboro, the anti-reset windup can be achieved by proper configuration of
back-calculation originating from the valve.
No explicit anti-reset windup configuration is needed for LIC3542A.
Bump Less transfer
No additional bumpless transfer block is needed.
None
Start-up: 48LIC-3542B in automatic mode and switch the 48FIC-3502 from manual
to Auto/cascade based on healthy condition of the CPI Separator.
48LIC-3542A in automatic mode and switch the 48FIC-3520 from manual to
Auto/cascade based on healthy condition of the CPI Separator & Disposal Water
Booster Pumps.
Nonnal Operation: Both level controller LIC3542A and LIC3542B shall be in AUTO
mode during normal operation. LIC3542A provides normal regulatory control on the
CPI level by manipulating the flow controller FIC3520. In case of plant upset, and the
CPIIevel rises above the high limit set by LIC3542B set point, the protective controller
LIC3542B may override the CPI inlet flow controller FIC3502 via the low selector
Y3502, and reduces the inlet flow to bring the CPI level back to normal range.
NIM-48 102017-PX-5680-00002
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Cripple Mode of Operation: In case of input signal failure (bad PV value or input
card failure) in any of the loops LIC or FIC then the controller output signal shall be
automatically frozen to the last value, the operation mode of the controllers shall be
changed to manual, When the input signal returns back to the healthy condition I the
fault is cleared the controller shall be put back to AUTO mode by operator.
Shutdown: No special provisions are required for the LIC, but for the FtC, switch the
controller mode to Manual and set the controller output to zero.
Operator lnterfac.e: The controller is managed by means of its detailed PID action
group display. The operator access for auto/ manual and cascade mode change is
available during crippled mode of operation.
History: The mode, set point, measurement, and output values of all controllers
LIC3542A, LIC35428, FIC3520 shall be configured to be historized in the historian
database (PI}. The output of the low selector Y3502 shall be historized as well.
NIM-48-102017-PX-5680-00002
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6.0
REFERENCES
Docum ents
1. Project Design Basis- Nimr-G (NIM-48-102017-AA-n04-00001-0000).
2. Control and Automation Philosophy (NIM-48-102017-IN-5505-00001-0000)
3. FEED Process Control Narrative (NIM-370-PX-5680-00001-0001 Rev A01)
4. Operating Philosophy for CPI Separators Package (NIM-48-104473-0A-5522-000010001)
5. H2S Management Procedure (PR-1 078)
6. Operating & Control Philosophy- Solid Handling System (NIM-48-104473-0A-552200001-0003)
7 . Narrative Writing Guideline, OG 00.20489, Version 2.0.
NIM-48-1 02017-PX-5680-00002
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APPENDIX I
PROCESS CONTROL SCHEMATIC
NIM-48-1 02017-PX-5680-00002-0000
Append1x r
Rev1saon 04
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APPENDIX II
PROCESSCONTROLSCHEMATIC (REVERSEFLOVij
NIM-43-102017-PX-5680-00002
Appendoc- II
Revtslon 04
22-09-2013
PROC ESS CONTROL SCHEMATIC
NIMR - G (REVERSE FLOW OPERATION)

ll:t>U
.......-. ........... .,.
._._..
'I
....._
.. .,.. i
'
Tank 17
'
Bank8
-------
..... ....
_.
'I'
'
Tank 18
LtUII
I
I
: ------- -----l
'
I
I
I
I
I
--r-.
I
I
'
:
l :
Tank 19
BankC
- -,
$----w-----rL~ :I~
FEED FROW
GRQSS FWID
INLET HEADER
T-48350
FWKOTANK
1........._
~ - ..u
_..J
:
I
"=
i - - -- ----------- - ---
____ _ _ _ _ _ _ _ _ __ _ _JI
~~~.....
-~ KUrJ
,.J
P\JIIP IIIHIWUW FUlW
TANK UNDER MAINlENANCE
- - ~1.1!SE
now
WATER DISPOSAl
BOOSTER PUMP
(P-48354/55/56)
_j
NIMR G
PROCESS CONTROL SCHEMA TIC

TO~ RARE ------------------------------~
c--------------------------1I
EWl.t.SK>
BLANKET CAS _______...,
~~
~~;!_'!!(~ ~~~
I
r--- -~---(TYPICAI.)
I
L
~~--------~----------------------------------------~--------------~__.TOHEATEX~AN~S
TRAINS
FEED FROM
GROSS FLUIO~IN~LET~H'""E""'AD
"""ER=--,---.1
I
r--""~--~
~
~-1
I
I
I
I
I
I
I
I
L_
--~
P-48350/51/52/53
L _ -+--9:-----.~
(OAA.SJaN
!RNISF[A
PUIM'S)
T-48350
FWKO TANK
ro~
RARE .------------------------,
BlANKET CAS - - - - - - - - -
r-----------
I
I
I
I
I
-----,
I
I
~~
r -----~
A~9--w-~
~!'Cl
l----L..!!ULJ-~
(llPICAL.)
~-------------------,
I
I
I
(V-48350/51 I
52/53/54-)
NEW CPI
SEPARATORS
(4W+1S)
(BANK D)
I
I
FCV 3509
(nPicAl)
PU~P ~NlMU~
FROI.I AVERAGE t\IEL OF

: - - - -- --------EXISTING CPI SEPARATOR (UC-111)
- ----,
I
~.Q-
I
I
~~
WATER RING
HEADER
WATER DISPOSAL
BOOSTER PUMP
(P-48354 /55 /56)
I
I
I
I
I
I
I
I
I
I
IL __________ _____________ IL __________ _
( lli'ICAI.)
FLOW

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COMMENTS RESOLUTION SHEET

TRE PROJECT NO.: J63881

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CRS # Process Control NarraUve-Nimr-G

Complied. The Interaction of the

COMMENTS RESOLUTION SHEET

Schematics (PFS) and the Process Flow

Page 16, Sec 3.2.1, diagram 3.4: the text

4. Page 23, Paragraph 1: please rewrite

CRS # Process Control Narrative-Nimr-G

This Is maximum clarity for the

COMMENTS RESOLUTION SHEET

CRS # Process Control Narrative-Nimr-G

Complied. Process control diagram

COMMENTS RESOLUTION SHEET

When the tank pressure is between 0.5

CRS #Process Control Narrative-Nimr-G

TRE / GEC RESPONSES

COMMENTS RESOLUTION SHEET

Check w1th process engineers on

CRS # Process Control Narratlve-Nimr-G

TRE / GEC RESPONSES

description of PIC-3561 has

The objectives of the level and

COMMENTS RESOLUTION SHEET

The CPI Ievel controller output

CRS # Process Control Narratlve- Nimr-G

provided under subsection

Please note that the CPI level

COMMENTS RESOLUTION SHEET

bumpless transfer blocks should be

Page 26, top: "Bumpless transfer of

Page 28, Level Control: the averaging of

CRS # Process Control Narratlve-Nimr-G

TRE I GEC RESPONSES

As per our understanding BIAS

COMMENTS RESOLUTION SHEET

TRE PROJECT NO.: J63881

Page 28, Level Control: the description of

CRS # Process Control Narrative-Nimr-G

TRE I GEC RESPONSES

averaged output of these signals. If

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TRE PROJECT NO.: J63881

names are used.

Please note that the PCN Is

Page 30: provide more details on the

Appendix II, Control Diagram

CRS # Process Control Narrative-Nimr-G

One LIC Is deleted and Appendix

The Process Control Schematic Is

COMMENTS RESOLUTION SHEET

For all the detailed control narratives,

CRS # Process Control Narralive-Nimr-G

Implementation consideration and

PETROLEUM DEVaOPMENT OMAN

PETROLEUM DEVELOPMENT OMAN

NIMR-G DEVELOPMENT & KARIM WESTWATER FLOOD PROJECT

PROCESS CONTROL NARRATIVE- NIMR-G

NIM-48-1 02017-PX-5680-00002 -0000

GALFAR ENGINEERING &

PETROLEUM DEVELOPMENT OMAN

PROCESS CONTROL NARRATIVE- NIMR-G

DOCUMENT REVISION RECORD