0014 HAZOP Automate the BRA & BRD Hydrocyclone Backflush Valves Rev.00_signed

Report Doc No: TML-HAZOP-2014-0014

AUTOMATE THE BR-A & BR-D HYDROCYCLONE BACKFLUSH

VALVES

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HAZOP No : TML-HAZOP-2014-0014

AFA No : PM3S-BRA-2013-0220

Date : April 3rd, 2014

Venue : Level 29 Meeting Room 1, Menara Citibank

Contents : 1. Introduction

2. Objective / Scope

3. Basis of Study

4. Results

5. Appendix

Introduction Currently, both produced water system at BR-A and BR-D are running close to its maximum capacity which cause the retention time through the system are minimized. Therefore to maintain the quality of the produced water, the hydrocyclones (V-3310 & 7V-3310) must operate at their optimum. Currently and in the past, the hydrocyclones have been flushed as required and more recently are flushed once a shift by the operations team by means of manual backflush valves. This is a relatively easy process but is sometimes forgotten or left unattended. As such the water quality can deteriorate and not meet the required standard and then once they do remember the backflushing, it is already late. So, it is not too effective. By replacing these two manual backflush valves on the hydrocyclones system with automatic valves, these will enable the hydrocyclones to be flushed automatically by control from DCS and maintain their optimum operation, thus maximizing throughput through the produced water system and ensuring the quality is kept within specification. The brief scope of work for automated BR-A & BR-D hydrocyclone backflush valves are as below:-

1. Remove manual valves (MV-33657 & 7MV-3010) and replace it with new actuated ball valves (XV-3312 & 7XV-3312).

2. XV-3312 & 7XV-3312 new instrument tie-in points (Instrument air, DCS signals) 3. Configure new timer logic for XV-3312 & 7XV-3312 automated operation (flushing

frequency) in DCS 4. XV-3312 & 7XV-3312 testing & commissioning.

To ensure that this modification package is safe and operable, a HAZOP (Hazard and Operability) study was undertaken within the Talisman Malaysia office on 3rd April 2014, the study being performed by a team consisting of multi-disciplined engineers from TML. The study was undertaken as total of two (2) nodes, with one (1) node each for modification on BR-A and BR-D respectively. The HAZOP session raised a total of 12 recommendations, six (6) recommendations each for BR-A and BR-D modifications respectively, which required to be closed out or be addressed prior to the modification. The recommendations together with the action party have been summarised in Section 4



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of this report. In accordance with all significant modifications, alterations and/or additions to the process of an established facility, the modification shall be subject to a critical review by way of a HAZOP Study, and this report is a record of that study.

Objective / Scope

The objective of the modification HAZOP Study is to subject the proposed process and its associated instrumentation, control and mechanical features to a critical review by a team of experienced multi-disciplined engineers, whereby the proposed design would be studied using a systematic approach against a set of guidewords and their deviations, to identify hazards and operability concerns, and where possible to make recommendations to mitigate them. This HAZOP procedure shall be applied to the flow-line as a whole and the associated upstream and downstream interfaces. The findings of the HAZOP shall be recorded on HAZOP Worksheets, and shall include recommendations. The HAZOP Review was undertaken in the Talisman Malaysia, Kuala Lumpur office on 3rd April 2014 by a team comprising of: Chok Yun Vun (CYV) Process Safety Engineer TML (Facilitator) Mohamad Faizal Nurdin (MFN) Process Safety Engineer TML (Scribe) Te Choon Chiam (TCC) Instrument Engineer TML (Job Eng.) Aw Sei Howe (ASH) Process Engineer TML Nigel Cross (NC) Senior Ops Engineer TML

Basis of Study HAZOP Concept The HAZOP process is based on the principle that a team approach to hazard analysis will identify more problems than when individuals working separately combine results. The HAZOP team is made up of individuals with varying backgrounds and expertise. The expertise is brought together during HAZOP sessions and through a collective brainstorming effort that stimulates creativity and new ideas, a thorough review of the process under consideration is made. HAZOP Process The HAZOP team focuses on specific portions of the process called "nodes". Generally these are identified from the P&ID of the process before the study begins. A process parameter is identified, say flow, and an intention is created for the node under consideration. Then a series of guidewords is combined with the parameter "flow" to create deviations. For example, the guideword "no" is combined with the parameter flow to give the deviation "no flow". The team then focuses on listing all the credible causes of a "no flow" deviation beginning with the cause that can result in the worst possible consequence the team can think of at the time. Once the causes are recorded the team lists the consequences, safeguards and any recommendations deemed appropriate. The process is repeated for the next deviation and so on until completion of the node. The team moves



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on to the next node and repeats the process. HAZOP Process The following assumptions were applied to the process that was HAZOPed.

All manual valves are set in their correct operating position.

Line rupture is not considered unless there is a defined credible scenario.

Results The HAZOP Study considered the modifications as two (2) nodes, and resulted in a total of 12 recommendations, with six (6) recommendations each for BR-A and BR-D modifications respectively, as summarised in the following table..

No. Issues / Notes Action / Remarks Due Date

Recommendations for BR-A Modifications

1. Ensure auto backflush sequence is on hold during crude PSD. Process Engineer Open

2. To provide alarm in preventing XV-3312 stays open longer than 2 minutes.

Job Engineer Open

3. To confirm the required backflushing frequency and incorporating into the logic and SSP.

Senior Ops Engineer Open

4. To include maintenance of XV-3312 into Maximo. Job Engineer Open

5. To replace Note 8 with Note 13 on P&ID BRA-DR-F-0200. Process Engineer Open

6. To indicate XV-3312 position as NC on P&ID BRA-DR-F-0200. Process Engineer Open

Recommendations for BR-D Modifications

1. Ensure auto backflush sequence is on hold during crude PSD. Process Engineer Open

2. To provide alarm in preventing 7XV-3312 stays open longer than 2 minutes.

Job Engineer Open

3. To confirm the required backflushing frequency and incorporating into the logic and SSP.

Senior Ops Engineer Open

4. To include maintenance of 7XV-3312 into Maximo. Job Engineer Open

5. To replace Note 8 with Note 11 on P&ID BRD-DR-F-0200. Process Engineer Open

6. To indicate 7XV-3312 position as NC on P&ID BRD-DR-F-0200. Process Engineer Open



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APPENDIX A

Piping and Instrument Diagrams


AUTOMATE THE BR-A & BR-D HYDROCYCLONE

BACKFLUSH VALVES

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BACKFLUSH VALVES

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BACKFLUSH VALVES

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BACKFLUSH VALVES

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BACKFLUSH VALVES

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BACKFLUSH VALVES

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BACKFLUSH VALVES

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APPENDIX B

HAZOP Worksheet



BACKFLUSH VALVES

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Company : Talisman Malaysia Ltd.

Drawing Title :

1. P&ID 2nd Stage Separator 2. P&ID Produced Water Booster Pump 3. P&ID 1st Stage Separator 4. P&ID Hydrocyclones 5. P&ID Degasser/Skimmer Vessel

Project : To automate the BR-A Hydrocyclone backflush valve

Node : 1 From downstream of 2nd Stage Separator SDV-1131 flowing through Produced Water Booster Pump system (P-3320A/B/C) to the downstream of Hydrocyclone SDV-3310 and from downstream of 1st Stage Separator SDV-1125 to the downstream of Hydrocyclone SDV-3310.

Design Intent : Enable the hydrocyclones to be flushed automatically by control from DCS and maintain their optimum operation

Drawing Number

:

1. BRA-DR-F-0113 2. BRA-DR-F-0201 3. BRA-DR-F-0112 4. BRA-DR-F-0200 5. BRA-DR-F-0202

Rev Z6 Z6 Z6 Z6 Z6

Parameter : Operating condition: Flowing Pressure = 800 kPag Flowing Temp = 80 C Current Flow rate = 57350 BPD produced water Composition: Produced water Material of piping: Carbon steel

Members:

Chok Yun Vun (CYV) Mohamad Faizal Nurdin (MFN) Te Choon Chiam (TCC) Aw Sei Howe (ASH) Nigel Cross (NC)



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Deviation Cause Consequence Safeguard Note, Query or Recommendation Ref. No.

No Flow MV-33655 closes. No backflush water available. Upstream productivity issue.

Oily water carryover to the FSO.

LCAI-1121 H/L

LZAI-1121 LL

LCAI-1131 H/L

LZAI-1131 LL

Degasser vessel V-3300 receives less produced water.

LICA-3303 H/L

LZA-3302 LL

LICA-1121 fails. No backflush pressure available. Upstream productivity issue.

Oily water carryover to the FSO.

LCAI-1121 H/L

LZAI-1121 LL

LCAI-1131 H/L

LZAI-1131 LL


LICA-3303 H/L

LZA-3302 LL

Crude PSD. No oil production hence no produced water flowing to the hydrocyclone.

Ensure auto backflush sequence is on hold during crude PSD.

Action by Job Engineer.

R1

More Flow None perceived.

Less Flow SDV-1125 closes. See No Flow

MV-33033 blocked. See No Flow



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SDV-1131 closes. See No Flow

Manual valves (MV-33001/ MV-33003/ MV-33006/ MV-33007/ MV-33019/ MV-33021/ MV-33023/ MV-33025) on produced water booster pumps closed.

See No Flow. Valve line-up procedure in operating manual to ensure correct and safe operation for all start-up/ shutdown/ pump switch over scenarios.

Check valves (MV-33002/ MV-33004/ MV-33020/ MV-33024/ MV-33005) on produced water booster pumps blocked.

See No Flow.

Produced water booster pumps trip.

See No Flow.

LICA-1131 fails. Degasser vessel V-3300 receives less produced water.

LICA-3303 H/L

LZA-3302 LL

Reverse Flow None perceived.

Misdirected Flow XV-3312 stuck open. Constant backflush of hydrocyclone leading to potential high oil in water content.

Limit switch to indicate valve open/close position.

Valve is fail close.

To provide alarm in preventing XV-3312 stays open longer than 2 minutes.


R2



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More Pressure None perceived.

Less Pressure None perceived.

More Temperature None perceived.

Less Temperature None perceived.

More level Not applicable.

Less level Not applicable.

Composition change

None perceived.

Contaminants None perceived.

Corrosion / Erosion None perceived.

Instrumentation None perceived.



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Relief None perceived.

Personnel Safety None perceived.

External factors (fire, vibration)

None perceived.

Operations Backflushing frequency is not specified.

Potential for no backflush water available as required. Upstream productivity issue, oily water carryover to the FSO.

To confirm the required backflushing frequency and incorporating into the logic and SSP.

Action by Senior Ops Engineer.

R3

Maintenance Maintenance of XV-3312. To include maintenance of XV-3312 into Maximo.


R4

Drawing Note 8 on P&ID BRA-DR-F-0200 does not represent the XV-3312 operations.

To replace Note 8 with Note 13 on P&ID BRA-DR-F-0200.

Action by Process Engineer.

R5

XV-3312 position is not indicated on P&ID BRA-DR-F-0200.

To indicate XV-3312 position as NC on P&ID BRA-DR-F-0200.


R6



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Company : Talisman Malaysia Ltd.

Drawing Title :

1. P&ID 1st Stage Separator 2. P&ID Hydrocyclones

Project : To automate the BR-D Hydrocyclone Backflush Valve.

Node : 2 From downstream of 1st Stage Separator SDV-1123 to the downstream of Hydrocyclones (7V-3310) SDV-3310.

Design Intent : Enable the hydrocyclones to be flushed automatically by control from DCS and maintain their optimum operation.

Drawing Number

:

1. BRD-DR-F-0113 2. BRD-DR-F-0200

Rev Z5.1 C1

Parameter : Operating condition: Flowing Pressure = 800 kPag Flowing Temp = 80 C Current Flow rate = 12650 BPD produced water Composition: Produced water Material of piping: Carbon steel

Members:

Chok Yun Vun (CYV) Mohamad Faizal Nurdin (MFN) Te Choon Chiam (TCC) Aw Sei Howe (ASH) Nigel Cross (NC)



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Deviation Cause Consequence Safeguard Note, Query or

Recommendation Ref. No

No Flow 7MV-33012 closes. No backflush water available. Upstream productivity issue. Oily water carryover to the FSO.

LICAI-1121 H/L

LZAI-1123 LL

Degasser vessel V-3300 receives less produced water

LICA-3303 H/L

LZA-3302 LL

SDV-1123 closes. No backflush water available. Upstream productivity issue. Oily water carryover to the FSO.

LICAI-1121 H/L

LZAI-1123 LL

Degasser vessel V-3300 receives less produced water

LICA-3303 H/L

LZA-3302 LL

LICA-1122A/B fails. No backflush water available. Upstream productivity issue. Oily water carryover to the FSO.

LICAI-1121 H/L

LZAI-1123 LL


LICA-3303 H/L

LZA-3302 LL

Crude PSD. No oil production hence no produced water flowing to the hydrocyclone.

Ensure auto backflush sequence is on hold during crude PSD.


R1

More Flow None perceived.

Less Flow See No Flow.



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Reverse Flow None perceived.

Misdirected Flow 7XV-3312 stuck open. Constant backflush of hydrocyclone leading to potential high oil in water content.

Limit switch to indicate valve open/close position

Valve is fail close

To provide alarm in preventing 7XV-3312 stays open longer than 2 minutes.


R2

More Pressure None perceived.

Less Pressure None perceived.

More Temperature None perceived.

Less Temperature None perceived.

More level Not applicable.

Less level Not applicable.

Composition change Not applicable.



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Contaminants None perceived.

Corrosion / Erosion None perceived.

Instrumentation None perceived.

Relief None perceived.

Personnel Safety None perceived.

External factors (fire, vibration)

None perceived.

Operations Backflushing frequency is not specified.

Potential for no backflush water available as required. Upstream productivity issue, oily water carryover to the FSO.

To confirm the required backflushing frequency and incorporating into the logic and SSP.

Action by Senior Ops Engineer.

R3

Maintenance Maintenance of 7XV-3312. To include maintenance of 7XV- R4



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3312 into Maximo.


Drawing Note 8 on P&ID BRD-DR-F-0200 does not represent the XV-3312 operations.

To replace Note 8 with Note 11 on P&ID BRD-DR-F-0200.


R5

7XV-3312 position is not indicated on P&ID BRA-DR-F-0200.

To indicate 7XV-3312 position as NC on P&ID BRD-DR-F-0200.


R6



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APPENDIX C

HAZOP Workshop Signed Attendance Sheet



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S30clr214040810270.pdf2222.pdf

Documents

0014 HAZOP Automate the BRA & BRD Hydrocyclone Backflush Valves Rev.00_signed