033Procedure to startup and Stop CFU.docx

Newfield LDC LUFENG7-2 DPPProcedure to startup and Stop CFUDocument No：SSP-DPP-033Version：0Date：November 9, 2013 Page 10 of 10Approve：Procedure to startup and Stop CFUCFU系统启停操作程序1. Operating purpose:操作目的CFU system comprises CFU package (X-3001A/X-3001B) and waste oil recovery package (X-3002), whose function is to separate the crude oil from produced water ,so that produced water after the treatment standard (OIW 25PPM) discharge, while recovering crude oil separated from produced water, thereby enhancing economic efficiency; in order to ensure the stability of CFU system run efficiently, formulates this program.CFU系统包括CFU装置（X-3001A/X-3001B）和废油回收装置（X-3002），其功能是分离生产水中的原油，从而使生产水经其处理后达标（OIW25PPM）排放，同时回收从生产水中分离的原油，从而提高经济效益；为保证CFU系统稳定高效运行，特制定本程序。2. Operating step:操作步骤1) Check before starting the system:系统启动前检查：a) Communication with CCR, and confirm the CFU device (X - 3001 - A/X - 3001 - B) which will be started;与中控沟通，确认要启动的CFU装置（X-3001A/X-3001B）；b) Check and make sure that the waste oil pump (P-3002A / B) and sewage circulation pump (P-3001A/P-3001B) has been power on, sufficient lubricating bearing housings, oil cup level 2/3;检查并确认废油泵（P-3002A/B）和污水循环泵（P-3001A/P-3001B）已送电，轴承箱润滑油足够，油杯液位2/3；c) CCR operator confirm there is not any alarm from the system, the pressure switch PALL- 3004 /PALL -3008 will be switched to by-pass position;中控确认没有来自本系统的任何报警，将压力开关PALL-3004/PALL-3008打到旁通位置；d) Check the produced water inlet process of CFU system , produced water discharge processes, nitrogen and waste oil recycling processes , confirm the upstream process turned on ahead of (before)produced water inlet shutdown valve (SDV-3011/SDV-3012), the process which from produced water meter (FI-3003) to the downstream open caisson will be turned on, the upstream process ahead of (before)Nitrogen gas inlet shutdown valve(SDV - 3001) will be turned on. and the process which from the back isolation valve of waste oil tank level control valve (LV-3001) to the oil production separator will be turned on;检查CFU系统的生产水进口流程，生产水排放流程，氮气流程以及污油回收流程，确认生产水进口关断球阀(SDV-3011/SDV-3012)之前的上游流程导通，生产水流量计（FI-3003）至下游开排沉箱流程导通，氮气进口关断球阀（SDV-3001）之前的上游流程导通，以及废油罐液位调节阀（LV-3001）的后隔离阀至原油生产分离器的流程导通；e) Check and make sure whether those valves of the whole CFU system are fully open, those valves including: isolation valve of pressure gauges, pressure sensors, level gauges, liquid level sensors, safety valves, etc.Check and make sure whether those valves of the whole CFU system are fully close, those valves including: all drain valve , drain sludge valve, bypass valve of safety valve, and all other valves of CFU.检查确认整个CFU系统上的压力表、压力传感器、液位计、液位传感器、安全阀等的隔离阀是否已完全打开，CFU系统上的所有排放阀、排污阀、安全阀的旁通阀是否已完全关闭，其它所有阀门是否已处于关闭状态。2) System start-up系统启动：a) After checking system, Open the bypass valves of each safety valve at the top of waste oil tank(V-3002) and CFU tank (V-3001A / B or V-3001C / D), open nitrogen inlet shutdown valve（SDV-3001和SDV-3002）,turn on the process from nitrogen pipe to waste oil tank, and each process of CFU. Purge and inert CFU system, Until the oxygen content is qualified , system is fully inert, Close all open valves when inert (This step applies to first start-up system or restart after overhaul the system)系统检查完毕后，打开废油罐（V-3002）和各级CFU罐（V-3001A/B或V-3001C/D）顶部安全阀的旁通阀，打开氮气进口关断球阀（SDV-3001和SDV-3002），导通氮气管至废油罐和各级CFU罐的流程，对CFU系统进行吹 扫惰化，直至排放口检测含氧量达标（O25%），系统惰化完毕，关闭惰化时打开的所有阀门；（本步骤适用于系统初次或停产大修后启动时）b) Open isolation valve of the two self-pressure regulating valve at the top of waste oil tank (V-3002) ,turn on the process from waste oil tank to vent header, open the shutdown valve（SDV-3002） on waste oil tank inlet pipeline which from nitrogen system, regulate waste oil tank pressure ,and make it stability between 60-80 KPaG打开废油罐（V-3002）顶部两个自力式压力调节阀的隔离阀，导通废油罐至冷放空流程，打开氮气管至废油罐的进口关断球阀（SDV-3002），调节废油罐的压力，使其稳定在60-80KPaG之间；c) Communicate with CCR, open shutdown ball valve on produced water inlet pipeline of CFU（X-3001A/X-3001B）package, site operator check and confirm this shutdown ball valve has been opened, and then turn on produced water into CFU process(open a 10”ball valve and two 8”ball valves on inlet pipeline from shutdown ball valve SDV-3011/SDV-3012 to first stage CFU tank V-3001A/V-3001C), produced water will be guided flow into first stage CFU tank slowly, until first stage CFU tank level start to rise (indicating produced water in tank has crossed the weir plate);与中控沟通，打开CFU装置（X-3001A/X-3001B）生产水进口关断球阀(SDV-3011/SDV-3012)，现场操作检查确认关断球阀已打开后，导通生产水进CFU装置流程（打开关断球阀SDV-3011/SDV-3012至一级CFU罐V-3001A/V-3001C的入口管线上的1个10球阀和两个8球阀），将生产水缓慢导进一级CFU罐，直至一级CFU罐上液位计显示液位开始上涨（表明罐内生产水已越过堰板）；d) As the level of first stage CFU tank（V-3001A/V-3001C）reach half of whole range ,turn on the process which produced water flow into second stage CFU tank（V-3001B/V-3001D） from first stage CFU tank (open two 8” ball valves on second stage CFU tank inlet pipeline), produced water will be guided flow into second stage CFU tank slowly, until second stage CFU tank level start to rise (indicating produced water in tank has crossed the weir plate), as the level of second stage CFU tank（V-3001A/V-3001C）reach half of whole range, open isolation valves(front and back) of pressure control valves（PV-3005/PV-3009）,CCR operator regulate pressure control valves（PV-3005/PV-3009） manually in CCR, The first and second stage CFU tank liquid level remain at around 2500 mm, and maintain stable ;当一级CFU罐（V-3001A/V-3001C）液位达到液位计量程的一半时，导通生产水从一级CFU罐至二级CFU罐（V-3001B/V-3001D）流程（打开二级CFU罐的入口管线上的两个8球阀），将生产水缓慢导进二级CFU罐，直至二级CFU罐液位计显示液位开始上涨（表明罐内生产水已越过堰板）；当二级CFU罐液位达到液位计量程的一半时，打开压力控制阀（PV-3005/PV-3009）的前后隔离阀，中控手动调节压力控制阀（PV-3005/PV-3009），将一级和二级CFU罐内的液位维持在2500mm左右，并保持稳定；e) Communicate with CCR, open shutdown ball valve（SDV-3001）on CFU package inlet pipeline which from nitrogen distribution header, after site operator confirm this shutdown ball valve open, respectively turn on the process which nitrogen pressure to every stage CFU tank(open two 1”ball valves and a needle valve on the pipeline which from nitrogen flow meter FI-3001A/B or FI-3002A/B to the top of CFU tank), pressure first stage CFU tank（V-3001A/V-3001C）to 270KPaG ,and pressure second stage CFU tank（V-3001B/V-3001D）to 220KPaG, after pressuring completely, close the 1” manual ball valve beside nitrogen flow meter FI-3001A/B or FI-3002A/B, and then CCR operator switch the control mode of PV-3005/PV-3009 to automatic; during this case, CCR operator and site operator must cooperate well, remain stable level of each stage CFU tank, at the same time preventing tank overpressure.与中控沟通，打开氮气分配管至CFU装置的进口关断球阀（SDV-3001），现场操作检查确认关断阀打开后，分别导通氮气至每级CFU罐的充压流程（打开氮气流量计FI-3001A/B或FI-3002A/B至CFU罐顶的管线上的两个1球阀和一个针阀），使一级CFU罐（V-3001A/V-3001C）充压至270KPaG，二级CFU罐（V-3001B/V-3001D）充压至220KPaG，充压完毕，关闭氮气流量计FI-3001A/B或FI-3002A/B旁的1手动球阀，然后中控将压力控制阀PV-3005/PV-3009打自动；充压过程中，中控与现场要配合好，保持每级CFU罐液位稳定，同时防止罐超压；f) Communicate with CCR, confirm the flow rate of produced water. When the produced water flow rate less than 53m3/h, open two isolation valves(front and back, one is 3”ball valve, another is 3”globe valve) of the corresponding injector of each stage CFU tank, open sewage recirculationpump inlet ball valve, priming and exhaust the pump, start the pump ,open the pump outlet ball valve, EJECTOR will suck gas in CFU tank and generate bubble for floatation. If the gas shortage, turn on nitrogen supplement process(open the 1” manual ball valve beside nitrogen flow meter FI-3001A/B or FI-3002A/B, regulate the opening size of 1”needle valve on the pipeline which from nitrogen flow meter to EJECTOR gently), Gas supplement. 与中控沟通，确认生产水流量。当生产水流量小于53m3/h时，打开每级CFU罐对应的喷射器（EJECTOR）的前后两个隔离阀（一个3球阀、一个3截止阀），打开污水循环泵（P-3001A/P-3001B）进口球阀，对泵进行灌泵排气，然后启动泵，打开泵出口球阀，此时喷射器（EJECTOR）将吸取CFU罐内气体（循环利用）产生气泡进行浮选，若气量不足，则可导通氮气补充流程（打开氮气流量计FI-3001A/B或FI-3002A/B旁的1手动球阀，微微调节氮气流量计至喷射器EJECTOR的管线上的1针阀），进行气量补充；g) When the sewage flow rate is more than 53 m3 / h , turn on nitrogen supplement process (open the 1” manual ball valve beside nitrogen flow meter FI-3001A/B or FI-3002A/B, close 1”needle valve on the pipeline which from nitrogen flow meter to EJECTOR, regulate the opening size of 1”needle valve on the pipeline which from nitrogen flow meter to EJECTOR gently), regulate the flow rate of nitrogen to 10% of produced water inlet flow rate , so that INJECTOR and Bubble distribution plate combined action and generate bubble for floatation.当污水流量大于53m3/h时，导通氮气补充流程（打开氮气流量计FI-3001A/B或FI-3002A/B旁的1手动球阀，关闭氮气流量计至喷射器EJECTOR的管线上的1针阀，微微调节氮气流量计至气体注射器INJECTOR的管线上的1针阀），将氮气流量调节为生产水进口流量的10%，此时每级CFU上气体注射器（INJECTOR）与气泡分配盘共同作用产生气泡进行浮选；h) After CFU package normally working , turn on the process which from CFU tank（V-3001A/B或V-3001C/D）to waste oil tank（V-3002） oil discharge pipeline (open 3” ball valve and 3” globe valve on oil discharge pipeline at the top of each CFU tank, open 6” ball valve on inlet pipeline of waste oil tank), regulate oil discharge valve at the top CFU tank, discharge waste oil.CFU装置开始正常浮选后，导通CFU罐（V-3001A/B或V-3001C/D）至废油罐（V-3002）的排油流程（打开每级CFU罐罐顶排油管线上的3球阀和3截止阀，打开废油罐废油进口管线上的6球阀），调节CFU罐顶部排油阀，进行排油；i) Fluid discharged from CFU flow into the waste tank, the gas flow into the vent header , Liquid phase are gathered in waste oil tank, When the waste oil tank (V - 3002) level rising to the setting height (900 mm), CCR and site operator Cooperate , according to the amount of waste oil, the select switch will be switch to proper position( We will run the waste oil pump P-3002A/B continuously when the large amount of waste oil discharged, the level of waste oil tank is regulated by level control valve LV-3001; When the small amount of waste oil discharged , We will open the bypass valve of LV-3001 and run the waste oil pump discontinuously to regulate the waste oil tank level) , start the waste oil pump（P-3002A/B）,open outlet valve and back flow valve of the pump, open the isolation valves(front and back) or bypass valve of LV-3001, pump the waste oil into production separator. Site operator check the pump running conditions carefully, if there is abnormal, should switch the pump immediately.CFU装置排放的流体进入废油罐后，气相通过排放流程进入冷放空，液相则聚集在废油罐中，当废油罐（V-3002）液位涨到设定高度时（900mm），中控与现场配合，根据废油量将选择开关（HS-3002）打至恰当位置（废油量大时，采用连续运行废油泵P-3002A/B，通过控制液位调节阀LV-3001来调节废油罐液位；废油量小时，打开液位调节阀LV-3001的旁通阀，采用间歇运行废油泵来调节废油罐液位），启动废油泵（P-3002A/B），打开泵出口阀和回流阀，打开液位调节阀（LV-3001）前后隔离阀或其旁通阀，将废油导进原油生产分离器，现场操作注意检查泵运转状况，如有异常，应立即切换泵。j) After CFU system runs stably, CCR operator switch the pressure switch PALL-3004/PALL-3008 to normal, then site operator take sample and do lab test, sample from produced water inlet and outlet of first stage CFU tank（V-3001A/V-3001C）, produced water outlet of second stage CFU tank（V-3001B/V-3001D）. Adjust the volume of nitrogen flow and discharge of oil based on test results, Select single or double tangential swirl tangential cyclone (when producing water flow 265m3 / h, the use of double tangential flow, depending on the actual situation be determined), so that the produced water discharge qualified .CFU系统运行稳定后，中控将压力开关PALL-3004/PALL-3008恢复正常，然后现场操作取样化验，分别取一级CFU罐（V-3001A/V-3001C）生产水进口样和生产水出口样、二级CFU罐（V-3001B/V-3001D）生产水出口样进行化验，根据化验结果调节氮气流量和排油量，选择采用单切向旋流或双切向旋流（当生产水流量265m3/h时，采用双切向流，具体根据实际情况进行确定），从而使生产水经系统处理后达标排放。3) Check after system start-up系统启动后检查：a) Observe and judge whether the running conditions of sewage recirculation pump (P-3001A/P-3001B) and the waste oil pump (P-3002A / B) and pipeline outlet pressure , the bearing lubricant level, the sound of the motor and the pump vibration is abnormal, if abnormal should immediately stop the pump, to be confirmed troubleshooting before restart, when necessary, can be switched to another set of CFU package.观察污水循环泵（P-3001A/P-3001B）和废油泵（P-3002A/B）出口压力及管线情况，轴承滑油液位，电机和泵的声音、振动等是否有异常，如有异常，应立即停泵，待确认故障排除后方可重新启动，必要时，可将CFU装置切换至另一套。b) After the system put into operation, along the direction of pipeline should be done a full routine inspection, ensure no leakage phenomenon and other anomalies.系统投入运行之后，要沿管线方向做一次全面巡检，确认无跑冒滴漏现象及其他异常状况。4) 系统关停： Shutdown systema) Close nitrogen inlet shutdown ball valve SDV-3001 firstly ,and then close manual valve on outlet of sewage recirculation pump（P-3001A/P-3001B）,stop sewage recirculation pump;先关闭氮气进口关断球阀SDV-3001，再关闭污水循环泵（P-3001A/P-3001B）出口手动阀，停污水循环泵；b) Close shutdown ball valves（SDV-3011/SDV-3012） on inlet of CFU package, and close oil discharge valve at the top of CFU tank, close the back isolation valve of pressure control valves（PV-3005/PV-3009）of CFU package, open bottom sludge discharge valve of CFU tank, down the level of CFU tank and close the valve;接着关闭CFU装置生产水进口关断球阀（SDV-3011/SDV-3012），关闭CFU罐顶部排油阀，关闭CFU装置压力控制阀（PV-3005/PV-3009）的后隔离阀，打开CFU罐底部排污阀，将罐内的液位降低后关闭；c) Finally waste oil tank (V-3002) level is reduced, turn off the waste pump (P-3002A / B) outlet manual valve and return valve, stop waste oil pump, close the waste tank nitrogen inlet shutdown valve SDV-3002最后待废油罐（V-3002）液位降低后，关闭废油泵（P-3002A/B）出口手动球阀和回流阀，停废油泵，关闭废油罐氮气进口关断球阀SDV-3002。3. 注意事项matters need attention1) After the system starts pay close attention to the waste oil tank (V-3002) level changes, to prevent high high level lead to the production shut down;系统启动后密切注意废油罐（V-3002）液位变化，防止其液位高高导致生产关停；2) Check open caisson level regularly, to prevent its level is too high, the crude oil into the sea, polluting the environment;中控定期查看开排沉箱液位，防止其液位过高，原油进入海洋，污染环境；3) Produced water samples taken for testing regu