PPA Platform BGEPIL, India Section 7.

BG EXPLORATION AND PRODUCTION INDIA LTD

PPA PLATFORM

OPERATION & MAINTENANCE MANUAL

SECTION 7.2

SEAWATER SYSTEM

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Contents

SEAWATER SYSTEM

ISSUE AND AMENDMENT RECORD

ABBREVIATIONS
UNITS OF MEASUREMENT

1.1 GENERAL DESCRIPTION

1.2 DESIGN BASIS
1.3 PROCESS DESCRIPTION
1.4 SYSTEM START-UP
1.4.1 NORMAL START UP
1.4.2 NORMAL OPERATING CONDITIONS
1.5 NORMAL SHUTDOWN
1.6 EMERGENCY SHUTDOWN
1.7 TROUBLE SHOOTING
1.8 ANNEXURE
1.8.1 P&IDs
1.8.2 ELECTRICAL MOTOR LIST
1.8.3 EQUIPMENT LIST
1.8.4 INSTRUMENT LIST
1.8.5 TRAINING AND COMPETENCIES

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ISSUE AND AMENDMENT RECORD

Chapter Pages Amendment description Rev. Date Revised Approved

No. Amended No. by by
All All For Approval Rev A1 17-05-06 AKPG
All All For Final Issue Rev 1 8-09-06 AKPG
All All Updated for Rev 1C 04.03.13 WP
incorporating changes
of ESD migration
project
All All Updated for Rev D 30.12.14 WP
incorporating changes
of ESD migration
project

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ABBREVIATIONS

BGEPIL B G Exploration and Production India Limited

BDV Blow Down Valve
B/V Block Valve
CV Control valve
D/S Downstream
ESD Emergency Shutdown
FE Flow Element
FQI Flow Quantity Indicator
FRP Fibreglass Reinforced Plastic
FV Full Vacuum
KPGI Kvaerner Powergas India Pvt Ltd
LC Level Controller
LP Low Pressure
LTS Low Temperature Separator
MDEA Methyl DiEthanol Amine
MMSCFD Million Standard Cubic Feet per Day
NRV Non Return Valve
ONGC Oil and Natural Gas Commission
PCV Pressure Control Valve
PDI Pressure Differential Indicator
PPA Panna Production Platform
PS Pressure Switch
PSE Pressure Safety Element
PSH Pressure Switch High
PSL Pressure Switch Low
PSV Pressure safety Valve
PFD Process Flow Diagram
PSV Process Safety Valve
RV Relief Valve
RVP Reid Vapour Pressure
SDV Shut Down Valve
SAFE Chart Safety Analysis Functional Evaluation Chart
SOP Standard Operating Procedure
TAH Temperature Alarm High
TAL Temperature Alarm Low
TE Temperature Element
TI Temperature Indicator
TEG Tri Ethylene Glycol
U/S Upstream

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UNITS OF MEASUREMENT

Sr. No. Parameter Unit Alternative

1 Dimension m, mm In, ft
2 Area m2 Ft2
3 Volume m3 Ft3
4 Time h, s
5 Pressure(absolute) kPa (abs) psia, bara
6 Pressure(gauge) kPag psig, barg
7 Liquid head m In
8 Pressure loss/unit length kPa/m Mm Hg
9 Static pressure mm water Inch, WC
10 Temperature o
C, k o
F
11 Mass flow rate kg/h Lb/h
12 Gas volumetric flow rate(standard conditions) sm3/h MMscfd
13 Liquid volumetric flow rate m3/h Bpd
14 Liquid volumetric flow rate(stock tank conditions) m3/h st bpd
15 Actual flow rate m3/hr
16 Amount of substance kmole
17 Density kg/m3 lb/ft3
18 Dynamic viscosity cP
19 Kinematic viscosity cSt
20 Weight kg lb
21 Thermal conductivity W/m.oC
22 Fouling factor m2oC/kW m2oC h/kcal
23 Velocity m/s
24 Surface tension mN/m Dyne/cm
25 Speed rpm
26 Particle size mm Micron
27 Solid/sediment concentration g/l
28 Contaminant concentration(mass) mg/kg ppm(w)
29 Contaminant concentration(volume) mg/l ppm(v)
30 Heat kW Kcal
31 Latent heat kJ/kg Kcal/kg
32 Specific heat kj/kgoC kcal/kgoC
34 Heat transfer coefficient kW/m2oC kcal/h-m-2oC
35 Heating value(liquid) MJ/kg kcal/kg
36 Heating value (gas) MJ/sm3 kcal/sm3
37 Power kW Hp
38 Noise dB(A)

Note that
Standard conditions Defined at 15.6o C and 101.3 kPa abs)
Normal conditions Defined at 0o C and 101.3 kPa (abs)

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1.0 SEAWATER SYSTEM

1.1 GENERAL DESCRIPTION

B G Exploration and Production India Limited (BGEPIL) operates Panna

Production Platform (PPA). PPA is designed to process Oil and Gas
produced from Panna and Mukta Oil fields. Gas produced is dispatched to
ONGC’s Hazira Terminal via sub-sea Departing Export Pipeline and oil is
transported to tankers.

Oil produced is processed to make it free of water and gas in various

equipment provided with safety devices such as pressure relief valves,
rupture discs, pressure control systems and manual venting arrangements.

Seawater System is a facility used for cooling oil & gas in heat exchangers.
Two Seawater Lift Pumps, PBE-6800/6810 are employed to supply
Seawater, one in operation mode and other in standby mode.

The Seawater is circulated by Seawater Lift Pumps PBE-6800 / 6810 to the

following users.
1. Dry Oil Cooler A (HBG-4380)
2. Dry Oil Cooler B (HBG-4390)
3. Trim cooler A (HBG-4400)
4. Trim cooler B (HBG-4410)
5. Trim cooler C (HBG-4420).

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1.2 DESIGN BASIS

The design parameters for the major equipments of the Seawater System
are given below:

Seawater Lift Pumps PBE-6800 / 6810

Sr. No. Parameter Details

1) Type Vertical Turbine Pump
2) Capacity 3300 GPM.
3) Operating Pressure 105 psig at 86F.
4) Material Casing – Ni Al Bronze.
5) RPM *****
6) Design Pressure 145 psig at 150°F

Seawater Filters MAJ-9470 / MAJ-9480

Sr. No. Parameter Details

1) Type Vertical basket type.

2) Capacity 3300 GPM.

3) Material C.S / SS316L

4) Operating Pressure 105 psig @ 73-86F

5) Design pressure 144 psig @ 150F.

6) Design code ASME Section VIII Division 1

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1.3 PROCESS DESCRIPTION

In Panna Capacity Enhancement Project, seawater is used as a cooling

media in Dry Oil Coolers for cooling dry oil and in Trim Coolers for cooling
process gas. Seawater System comprises of two Seawater Lift Pumps, one
operating and other standby. The discharge line of Seawater Lift Pumps is
equipped with two Seawater Filters (one working + standby) having filter
mesh size of 80 micron to arrest any foreign particles. A differential pressure
indicator is provided across the filters to check the differential pressure for
deciding filter changeover. A Cupron Seawater Corrosion Inhibition System
using impressed current is provided in the Seawater System. An independent
panel is provided for Cupron Seawater Corrosion Inhibition System.

Seawater streams to Dry Oil Coolers are equipped with flow indicators,
temperature indicators and pressure indicators.

Seawater streams to Trim Coolers are equipped with flow indicators and
temperature indicators.

SEAWATER PUMP

 PI-7011/7012 is provided on the discharge line of PBE-6800/6810 for

pressure measurement.
 Pressure transmitters (PT-7011A/7012A) with high pressure trips
PSHH-7011A and PSHH-7012A set at 120 Psig and low pressure
trips PSLL-7011A and PSLL- 7012A set at 75 55 Psig are provided
on the discharge line to actuate shutdown / trip actions if the set
limits are reached.
 A differential pressure indicator PDI-7007 measures the pressure
drop across the Seawater Filters. When the pressure drops
increases the permissible value switch over to the standby filter &
isolate the inline filter for cleaning.
 FI-7009 measures the Seawater flow pumped by the Seawater Lift
Pump to the Dry Oil Coolers and Trim coolers.
 PT-7041A with PAL is located on the Seawater discharge line sends
an alarm at 58 Psig on panel if the Seawater pressure is found low.

SEAWATER TO DRY OIL COOLERS

 FE-7011/7012 measures the Seawater flow to the Dry Oil Coolers

HBG-4380/4390 from Seawater Lift Pump.
 Pressure gauges PI-4381 and PI-4382 indicates pressure in the
Seawater inlet and outlet line to Dry Oil Cooler HBG-4380.
 Pressure gauges PI-4391 and PI-4382 indicates pressure in the
Seawater inlet and outlet lines to Dry Oil Cooler HBG-4390.
 Temperature gauges TI-4381 and TI-4382 measures the inlet and
outlet temperatures of the Seawater through Dry Oil Cooler HBG-
4380.

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 Temperature gauges TI-4391 and TI-4392 measures the inlet and

outlet temperature of the Seawater through Dry Oil Cooler HBG-
4390.
 A RO-4381 is installed in the outlet line of the Seawater from Dry Oil
Cooler to return overboard to prevent sudden depressurisation.

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SEAWATER TO TRIM COOLERS

 Another stream from the Seawater Lift Pump discharge goes to the
Trim Coolers A, B and C (HBG-4400, 4410, 4420). The trim coolers
are shell and tube type heat exchangers where the process gas is to
be cooled to 100oF with Seawater as the cooling media.
 FE-7003, FE-7002 and FE-7008 measures the Seawater inlet flow
through the Trim Coolers A, B and C.
 TI-4401 and TI-4402 are provided to measure the inlet and outlet
temperatures of Seawater through the Trim Cooler A.
 TI-4411 and TI-4412 are provided to measure the inlet and outlet
temperatures of Seawater through the Trim Cooler B.
TI-7005 and TI-7007 are provided to measure the inlet and outlet
temperature of Seawater through the Trim Cooler C.

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1.4 SYSTEM START-UP

1.4.1 NORMAL START UP

Normal start-up means the start-up after short shutdown.

STATUS OF VALVES & INSTRUMENTS ON THE PROCESS

LINES AND ON EACH EQUIPMENT needs to be checked as per
the check-list provided below.

This Check List is to be filled-up/used before restarting the unit,

which has stopped for a short period only, and the following
conditions are fulfilled.
1. Running plant is stopped for a short duration due to some
minor problem.
2. The problem is duly identified.
3. The cause of stoppage corrected.
4. All the utilities are available.
5. The time between shutting plant and restarting is reasonably
short.
6. System is still close to operating Pressure and Temperature
conditions.
7. Various vessels are still holding Liquid levels.
8. All the safe shut down actions on the panel are completed
(valves are manually taken in safe shutdown mode)
9. Gas cloud / liquid hydrocarbon spillage, if any, during the
stoppage is cleared.
10. No major isolation of equipments and/or instruments is
carried out during stoppage.
11. No major change is carried out in the Process line-up of the
Unit. The crew is fully aware of changes done in process
line-up.

NORMAL START-UP CHECKLIST - 1

1. All the instruments, measuring Temperature, Pressure, Pressure

Differential, Level and Flow are operational. No sensor is
isolated.

2. Alarm and Tripping system is healthy.

3. All Pressure relief valves, rupture discs, pressure switches, level

switches are healthy and commissioned. A pre start-up check
and log is to be completed.

4. For various control valves in the section, with plant/section shut-

down the CV U/S and D/S valves are likely to have been closed,
specially if the CV are not fully closing or passing i.e. pressure
dropping, level rising or falling, flow seeping through etc. Before
restarting verify each of these control valve and line them up
following sequential steps as outlined under initial start-up. The
steps are not being repeated here.

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SEAWATER LIFT PUMPS: (PBE-6800 AND PBE-6810)

5. Ensure that Seawater Lift Pumps are operationally ready.

6. Check PI-7011 and PI-7012 on the discharge lines of PBE-6800
and PBE-6810 for their correct pressure indication.
7. PSHH-7011A/7012A and PSLL-7011A/7012A alarms are
functional.
8. Check PDI-7007 on the filters in the discharge line for differential
pressure across the filters on full load. If it is within the
permissible range then there is no need to change the filter
otherwise start the standby filter and isolate the filter online for
cleaning.
9. Check FI-7009 on the discharge line for its correct indication.
10. Check for FE-7011 and FE-7012 on the inlet and outlet lines of
the Dry Oil coolers A & B (HBG-4380/4390) Check that their
upstream and downstream isolation butterfly valves are open
and flow elements are reading correctly.
11. Check for FE-7003, FE-7002 and FE-7005 on the Seawater inlet
lines of Trim Coolers A, B and C their upstream and downstream
isolation valves are open and flow indication is correct.

NORMAL START-UP

For writing this procedure it is assumed that the Seawater System has
been stopped due to some problem. Undertake the following start-up.

 Put on the lift pump in operation as per the Vendor’s instruction

manual.
 Ensure that the discharge valve on the Seawater Lift Pump
discharge line is closed.
 Make sure that the Dry oil coolers are line up to receive Seawater.
 Make sure that the Trim coolers are line up to receive Seawater.
 Check PI-7011 and PI-7012 located on Seawater Lift Pumps PBE-
6800/6810 for pressure reading. As the discharge pressure of pump
rises above the low pressure set point ensure that PSLL alarm is
clear.
 Check the differential pressure on PDI-7007 located on the filter unit
in the discharge line of Seawater Lift Pumps, if it is high, switch over
to standby filter & isolate the online filter for cleaning.
 Check the flow on FI-7009, which is located on the discharge line of
Seawater Filters, is indicating correctly.
 Ensure that PAL-7041A on discharge line of Filters alarm is clear.
 Verify that the flow of seawater on FE-7011 and FE-7012, installed
on the Dry Oil Cooler inlet line is correct.
 Check that PI-4381/4391 & TI-4381/4391 located on the inlet line of
Seawater to Dry oil coolers HBG-4380/4390 are indicating correctly.
 Check that PI-4382/4392 & TI-4382/4392 located on the outlet line of
Seawater to Dry oil coolers HBG-4380/4390 are indicating correctly.
 Keep a watch on the flow of Seawater through FE-7003, FE-7002
and FE-7005 which are installed on the Seawater inlet lines of Trim
Coolers A, B and C. Check that the readings are correct.

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 Check the inlet and outlet temperature of Seawater passing through

the Trim Coolers A, B and C on TI-4401, TI-4402, TI-4411, TI-4412,
TI-7005 and TI-7007. Verify that the cooling is appropriate and adjust
the flow of Seawater accordingly.
1.4.2 NORMAL OPERATING CONDITIONS

Normal operating conditions relate to stabilised plant operation and

relate to plant full throughput rate or design rates. These also cover
operation for various cases when the system is required to operate at
varying feed or product compositions.

In the Seawater System normal operation relate to operation of

Seawater Lift Pump at a capacity of 3300 USGPM. The design
pressure of Seawater Lift Pump is 145 psig at 150°F and pumping
temperature of Max-86F & Min-73F.

During the normal operation, the process conditions are monitored

and controlled to achieve the desired quality of the gas / oil.
Seawater System is provided for achieving the desired operation of
the unit. Please refer section 1.8.4 for instrument list, where the
values for normal operation are also given. Any deviation from the
normal values will give alarm for the critical parameters. The
corrective actions need to be taken by the operating staff in case of
process deviation. Section 1.7 gives the guidelines for Trouble
shooting.

1.5 NORMAL SHUT-DOWN

SHUT DOWN PROCEDURE

Unit may be required to be stopped because of a variety of reasons like,

1. Production requirement.
2. Planned maintenance.
3. Equipment Failure.
4. Failure of an essential utility.

The philosophy of normal process shutdown is to leave the plant in a

condition from which it can be restarted in the minimum time with the
minimum loss of production. This is achieved by shutting down the system
with normal pressures in the equipments.
Once clear instruction is obtained to shut down Seawater System, following
guidelines are used.

 As required by process, close the Seawater supply to Dry Oil Coolers

& Trim Coolers.
 Stop Seawater pump as per Vendor instruction manual.
 Close the discharge valves of the pump and isolate the Seawater
filter on the discharge line.
 Drain the filter by opening the second drain valve and remove it for
cleaning.

1.6 EMERGENCY SHUTDOWN

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An emergency shutdown can be triggered by any of the following safety

systems, when the limit is lost:

For the various systems limits please refer instrument list.

SEAWATER LIFT PUMPS: (PBE-6800 AND PBE-6810

Pressure transmitter (PT-7011A/7012A) with PSHH-7011A / 7012A and

PSLL-7011A/7012A are installed on the discharge line of PBE-6800 / 6810.
Activation of these trips carry out the following actions through the control
panel.

Table: 1 Emergency Shut Down (ESD) actions.

Device number Action no. Action performed.

PSHH-7011A / Following actions are carried out.
7012A
1 Stop Seawater Lift Pumps PBE-
6800/6810.
2 Alarm on the panel.

Table: 2 Emergency Shut Down (ESD) actions.

Device number Action no. Action performed.

PSLL-7011A/ Actions numbers 1 to 2 as in Tabel:1
7012A above are carried out.
PAL-7041A Actions numbers 2 as in Tabel:1 above
are carried out.

1.7 TROUBLE SHOOTING

As detected by the measuring Instruments

PBE-6800 / 6810. Seawater Lift Pumps

Detection Set Point Trouble & possible Remedy
cause
PSHH-7011A/ 120 psig Pump discharge pressure 1. Check PSHH indication
7012A high: and rectify if faulty.
1. PSHH-7011A/7012A 2. Check discharge
indications are faulty. valves and keep them
2. Pump discharge valves fully open.
closed or partly open. 3. Check differential
3. Seawater filter in the pressure on PDI-7007,
discharge line chocked if it is high, start the
(MAJ-9470/9480). standby filter and
4. Both the users are clean the inline filter.
closed. 4. Check that 8” butterfly
valves going to both
Dry Oil Coolers & Trim
Coolers are open.
PSLL-7011A/ 75 55 psig Pump discharge low: 1. Check
7012A 1. PSLL-7011A/7012A PSLL-7011A/7012A
indications are faulty. indication. Rectify if

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2. Suction line valves are faulty.

partly closed. 2. Check and ensure that
3. Pump vapour locked. suction line valves are
fully open
3. Follow vendor’s
instructions in
catalogue.

PDI-7007 0-150 psig High pressure differential

1. Filter fouled. 1. Check PDI.
2. Filter PDI. 2. By-pass, isolate
depressurize and
change filters.

PAL-7041A 58 psig Low pressure in the 1. Check motor

discharge line of Seawater connection.
Lift Pump. 2. Check differential
1. Pump failure. pressure on PDI-
2. Filter fouled. 7007. If high, start
3. Flow element choked standby filter & clear
the inline filter.
3. Check the flow
elements, if chocked
isolate it and open its
bypass valve. After
cleaning the FE open
the isolation valve
and close the bypass
valve.

1.8 ANNEXURE

1.8.1 P & ID

Sr.No. Description Drawing No.

01 New Seawater Lift Pumps
BGEP-LNTA-P121-
PPAX-PR-11-158-7014-
D

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1.8.2 EQUIPMENT LIST

Tag Title Description Design Operating

No.
Pressure Temp. Pressure Temp.
psig O
F psig O
F
PBE- Seawater Type: 145 150 105 73-86
6800/ Lift Pumps Centrifugal
6810 vertical
MOC: casing-
Ni Al Bronze
Impeller: Ni Al
Bronze.
MAJ- Seawater Type: Basket 145 150 105 73-86
9470/ Filters type.
9480 MOC: CS /
SS316L

1.8.3 ELECTRICAL MOTOR LIST

Equipment Description Motor details Ref. P&IDs

PBE-6800/6810 Seawater Lift 2 nos, 415 V, 7014

Pumps 3 phase, 50
Hz.

1.8.4 INSTRUMENT LIST

Item Tag No. Values

Normal Alarm Trip
Seawater Lift Pumps: PDB-6800/6810

Flow FI-7009 2922 GPM

FE-7011 1000 GPM
FE-7012 1000 GPM
FE-7003 268 GPM
FE-7002 268 GPM
FE-7008 537 GPM
Pressure TI-7011 *****
PI-7012 *****
PSHH-7011A - 120 120 psig
psig
PSHH-7012A - 120 120 psig
psig
PSLL-7011A - 75 55 75 55 psig
psig
PSLL-7012A - 75 55 75 55 psig
psig
PAL-7041A 58 psig
PI-4381 *****
PI-4382 *****
PI-4391 *****
PI-4392 *****

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PDI-7007 0-150 psig

Temperature TI-4381 86 °F – 113 °F
TI-4382 86 °F – 113 °F
TI-4391 86 °F – 113 °F
TI-4392 86 °F – 113 °F

1.8.5 TRAINING AND COMPETENCIES

Requirement Description Remarks

Qualification Engineering background in Chemical /

Petrochemical petroleum /Mechanical

Experience Adequate experience in Oil & Gas/

Petrochemical / Refinery / chemical /
LNG / Power Industry

Skill Set * Should be conversant and proficient

with
- Plant control System
- - Gas Separation Technologies

* Should have practical knowledge in

Basic Engineering

* Should have the working knowledge

of offshore oil & gas operation

* Should have exposure to HSE

Management Systems, Emergency
Response plan, HAZOP & HAZID
studies, and Risk assessment.

* Should have working knowledge of

MS office

* Should possess good communication

skill, observation skill and report
Writing skill.

Competencies * Ability to access understand,

interpret, check, practice and
implement
- The basic process
- Basic engineering / equipment
details
- Operating parameters.
- P & ID
- Vendor drawings
- Instrument loop diagrams
- Control logic and interconnecting
diagrams.
- Start-up / shut-down procedures
- Cause and effect Logic

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* Ability to:
- Detect the deviation
- Continuously and patiently monitor
the operations
- Communicate to the group involved
in the process
- Trouble shooting
- Take corrective action
- Report the deviation
- Follow SOP's

* HSE: Ability to identify, understand,

interpret and implement
- Potential hazardous situation
- Mitigate the Risk
- Emergency response Procedure
- Adhere to HSE procedures
- Adhere to PTW

Training * Technical
- Plant Control System

* Non Technical
- Report writing skills
- Communication skills

* HSE
- HSE Management

* IT
- MS Office

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