Restricted

Saih Nihayda Depletion Compression

Phase 1
Process Control Narrative

Rev.

Date

Description

Originator

Checker

Approver

CONTENTS:
1.0
2.0
2.1
2.2
2.3
2.4
3.0
3.1
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5.0
6.0

OBJECTIVE................................................................................4
INTRODUCTION........................................................................4
Background.............................................................................4
Objective.................................................................................4
Project Description.................................................................4
Design Capacity......................................................................6
CONTROL PHILOSOPHY (GENERAL).......................................6
Process Control Narrative......................................................6
PROCESS DESCRIPTION & CONTROL NARRATIVE................7
Inlet manifold..........................................................................7
Inlet Separators (V6801, V-6802)...........................................8
Compressor suction header pressure controller..................11
Suction Coolers (E-6811, E-6821 & E-6831)........................12
Compressor Suction Scrubbers (V-6811, V-6821 & V-6831) 13
Booster Compressors (K-6810, K-6820 & K-6830)................15
Compressor After Coolers (E-6812, E-6822 & E-6832)........17
Condensate Separator (V-6803)............................................19
REFERENCE............................................................................23
ATTACHMENTS.......................................................................23

ABBREVATIONS
AADL
CCR
CESD
COGS
CPSD
DCS
EPC
ESD
FAR
FCS
FEED
FGS
HMI
IPS
LCP
MADL
MMSCFD
MMSCMD
PAS
PDO
PEFS
PFS
PLC
PSD
SGS
SNDC-1
SNGP
SNOS
SNS
SROS
UCP

Average Annual Daily Load

Central Control Room
Controlled Emergency Shutdown
Central Oman Gas System
Controlled Process Shutdown
Distributed Control System
Engineering Procurement & Construction
Emergency Shutdown
Field Auxiliary Room
Field Bus Control System
Front End Engineering Design
Fire & Gas Detection System
Human Machine Interface
Instrumented Protective System
Local Control Panel
Maximum Annual Daily Load
Million Metric Standard Cubic Feet per Day
Million Metric Standard Cubic Meter per Day
Process Automation System
Petroleum Development Oman
Process Engineering Flow Scheme
Process Flow Scheme
Programmable Logic Control
Process Shutdown
Safeguarding System
Saih Nihayda Depletion Compression
Saih Nihayda Gas Plant
Saih Nihayda Oil station
Saih Nihayda Shuaiba
Saih Rawl Oil Station
Unit Control Panel

1.0 OBJECTIVE
The objective of this document is to provide a Process Control
Narrative of the Depletion Compression Facility (Project Phase I) at
Saih Nihayda Gas Plant. It is expected that this document will be
kept up to date during FEED and detailed engineering stage.

2.0 INTRODUCTION
2.1 Background
The Saih Nihayda Deep Field is located within the cluster of nonassociated gas fields in the central Oman. The field is situated 28 km
north east of the Saih Rawl Central Processing Plant and 20 km west
of the Qarn Alam Oil station. The field has been producing via the
Saih Nihayda Gas Plant (SNGP) since Q1 2005. Based on the current
forecasts the reservoir pressure will begin to decline below the
current inlet pressure of the SNGP within the next 6 years. At this
point, the 1st Stage of Saih Nihayda Depletion Compression (SNDC1) Project will be required to deliver the gas from the wells to the
required inlet pressure of the SNGP.
2.2 Objective
The principal objective of the SNDC-1 Project is to receive about 21
MMSCMD gas and the accompanying condensate, at pressures from
70 to 38 bara, separate the condensate, compress the gas and
deliver compressed gas to the existing Gas Plant Wet gas Cooler E6212 at the conditions matching design of the existing gas plant.
The SNDC-1 involves installation of 3 nos of gas compressor units at
upstream of the existing inlet wet gas cooler E-6212. This will enable
the SNGP to continue exporting to the Central Oman Gas System
(COGS), a sustainable Maximum Annual Daily Load (MADL) of 20
MMSCMD gas. The planned on-stream date is January 2013.
Based on the 2008 Gas Business Plan, the SNGP is to produce an
Annual Average Daily Load (AADL) of 12 MMSCMD from the SN
Deep reservoirs (Barik, Miqrat & Amin), with a potential upside of
14 MMSCMD. However, in either case the compression facility must
meet MADL at 20 MMSCMD while being capable of turndown to 6
MMSCMD at high energy efficiency.
2.3

Project Description

The SNDC-1 facility will be installed downstream of the Plant Inlet

Manifold and the upstream of Wet gas Cooler E-6212, bypassing the
two existing SNGP Inlet Separators
V-6211/12. Upstream and
downstream facilities remain unaffected by this project except for
tie-ins.

In order to meet the above project requirements, a 3-compression

train configuration has been selected for the SNDC-1, with each
train being able to deliver, at the early stage of operation, 50% of
MADL (10 MMSCMD)
The SNDC-1 Project will comprise the following major processing
equipment:

Inlet Separators (V-6801, V-6802)

Suction Coolers (E-6811, E-6821 & E-6831)

Suction Scrubbers (V-6811, V-6821 & V-6831)

Booster
Compressor
package
units
(A-6810/20/30)
consisting of compressors
(K-6810, K-6820 & K-6830)

Compressor Aftercoolers (E-6821, E-6822 & E-6832)

Condensate Separator.(V-6803)
The overall schematic of process equipment lineup of the new
SNDC-1 facility is shown in the Figure 2.1.1 below.
Figure 2.1.1: SNDC-1 Facility Schematic

SNDC-1 facility need to perform the following gas and liquid

processing functions:
1.

Equally split the field production from the Plant Inlet

Manifold between 2 new Inlet Separators, by use of
symmetrical piping and automatic control.

2.

Separate bulk liquids from the inlet fluid in two Inlet

Separators and send water and condensate to their
respective destinations in the SNGP plant.

3.

Apportion the separator gas equally among running

compression trains, each train consisting of a Suction
Cooler, Suction Scrubber, Booster Compressor and After
cooler.

Each train will be performing the following functions:

a. Cool, by means of an air cooled Suction Cooler, the
incoming gas to minimum achievable but not less than
30oC to avoid hydrate formation.
b. Separate, in a Suction Scrubber, the condensed
liquids with >99% efficiency and send the liquids to a
new common condensate separator.
c. Compress the gas from Suction Scrubber to a
pressure sufficient for the SNGP to meet the 20
MMSCMD gas off-take from the plant.
d. Cool the compressed gas in an after cooler to 100 oC
and deliver it to the inlet of existing gas plant Inlet
Cooler E-6212.

2.4

4.

Collect all liquids from Suction Scrubbers in a new

Condensate Separator operating at about 4 bar below of
the common compressor suction manifold operating
pressure to minimize flashing and separate the
condensate.

5.

Dispose of the Condensate Separator streams into the

current gas plant tie-in points as follows: send flashed
gas to off gas Pipeline, condensate to Condensate Cooler
E-6213, and produced water to Produced water
degassing vessel V-6214.

Design Capacity
The table below summarises the existing SNGP design
capacities

Existing System

Capacity

Saih Nihayda Gas Plant Gas throughput

Saih Nihayda Gas Plant Condensate
production
Saih Nihayda Gas Plant - Water production

20 MM Sm3/d
10000 m3/d
1000 m3/d

48 Export Gas Pipeline (SNGP-48 Pipeline)

12 Interfield Condensate Pipeline (SNGPCPP)
4 Water SNGP-SNOS Pipeline
4 Off Gas Pipeline SNGP-SNOS Pipeline

20 MM Sm3/d
10000 m3/d
1000 m3/d
0.016 MM Sm3/d

3.0 CONTROL PHILOSOPHY (GENERAL)

3.1

Process Control Narrative

The philosophy shall adhere to the requirements outlined in the

following documents:

Saih Nihayda Depletion Compression Phase-1, Basis for

Design (Ref-1)

OG-00.20489- Guidelines for preparing process control &

IPF narratives Version-2.0

Process control refers to automatic manipulation of the process in

order to meet process objectives (e.g. production rate, product
qualities and safety).
The main purpose of the Process Control Narrative is:

Ensuring an appropriate and well-considered functional

design of the process control.

Establishing a design document to be used for:

1. Control & Automation to develop the functional analysis
and to define the operating philosophy.
2. General process control aspects and background

Classes of process control can be distinguished as follows:

I.

Regulatory control (keep process variables at steady

point of operation)

II.

Integrated Capacity & Antisurge Control ( For Booster

Compressors operation)

III.

Optimizing control (adjusts process variables in order

to achieve optimum point of operation)

IV.

Constraint Control (Pressure constraint for well heads

and compressor systems , Power constraint for
compressor motor)

V.

Safeguarding Control (bring the process to safe state

when a potential hazard with SIL level L1 is detected)

VI.

Sequence Control for automation of start-up and

shutdown.(one permissive from compressor package
and other from main system)

The functional design of process control relates to normal operating

modes (for continuous processes essentially regulatory controls and,
if applicable, optimizing controls) and is performed in parallel with
the PFSs, PEFSs and documented in this Process Control Narrative.

4.0 PROCESS DESCRIPTION & CONTROL NARRATIVE

4.1

Inlet manifold
Refer the following PEFS:
1) SNG-249-PX-2365-68001-0001
2) SNG-1-6213-001

4.1.1 Process
During SNDC-1 Station commissioning and transition period, both
ends of the manifold will be active, supplying gas simultaneously to
both SNDC-1 and SNGP facilities. Since SNGP process requires inlet
pressures well in excess the upper operating limit of the SNDC-1
inlet pressure, a pressure let down valve (68PCV-0006) is provided in
the common outlet header of the inlet separators (V-6801/02.)
During the transition, the let down valve will be modulated by a
pressure controller installed on common inlet header of compressor
units.
SNDC-1 Compressors will operate at constant speed during the
transition period. The high pressure constraint controller (68PICA0003) to the well head will remain inactive during transition period.
The existing high pressure constraint controller (62PICA-103) will
protect the flow lines, manifold and inlet piping.
Past the transition period, the entire field production will feed the
SNDC-1 Facility and the pressure letdown valve (68PCV-0006) will
be bypassed. The control of SNDC-1 inlet pressure from now on will
be from the pressure controller (68PICA-0003) on the feed line to
inlet separators.
4.2

Inlet Separators (V6801, V-6802)

Refer the following PEFS.
0001

1) SNG-249-PX-2365-68002-

2) SNG-249-PX-2365-68002-0002
4.2.1 Process
Plant Inlet Separators are the first component of SNDC-1 Facility
and will operate as vertical 3-phase separators. The upstream
system consists of gas producing wells, production gathering flow
lines, and Plant Inlet Manifold.
The Plant Inlet Manifold will be extended on its top and a new
header will be installed to direct well production to SNDC-1 area.
The symmetrical inlet piping is considered for both inlet separators.

An additional measure for flow balancing, a flow control valve and a

flow transmitter are provided in each of the Inlet Separator gas
outlet lines.
Each of the inlet separators is a vertical 3-phase separator with an
inlet Schoepentoeter, mistmat, swirldeck and plate pack. The
separator is also designed to receive transient liquid flow (slugs)
from the bulk header.
The control narrative for one inlet separator V-6801 is discussed in
this document and the same is applicable for the other inlet
separator V-6802.
4.2.2 Condensate Level Control Logic
68LICA-0107B-Condensate level controller
68FICQ-0102-Condensate flow controller
4.2.2.1

Objective

To control condensate level in the separator.

4.2.2.2

Functional Description

The V-6801 condensate level control is performed by 68LICA-0107B

(master controller). To achieve better control, level control is
cascaded to slave flow controller 68FICQ-0102 which regulates the
control valve 68FCV-0102 located on condensate outlet line.
Opening & closing of 68FCV-0102 is linked to the opening/closing of
PSD valve (68UZV-0101) which is located upstream of 68FCV-0102.
4.2.2.3

Operational and Implementation Aspects

I. Start-up
During start-up the controller shall be in manual mode.
However opening of 68UZV-0101 will drive 68FCV-0101 in
auto mode.
II. Normal Steady-State
Level transmitter is tracking the actual value.
III. Crippled mode operation
In case of input signal failure the level cotroller will be put in
manual mode. Valve opening and closing will be done
manually.
IV. Shut down
During the PSD or ESD of the inlet separator, upstream PSD
valve
(68UZV-0101) will close and activates 68XS-0101
which will close 68FCV-0102.

V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.
4.2.3 Gas flow Control Logic
68LICA-0107A-Condensate level controller
68FICQA-0101-Gas flow controller
68Y-0101-Low selector
4.2.3.1

Objective

To control the flow of gas passing through inlet separator.

4.2.3.2

Functional Description

The V-6801 outlet gas flow control is performed mainly by

68FICQA-0101. The output of 68FICQA-0101 is sent to the
low selector 68Y-0101. The low selector also receives signal
from high condensate level controller 68LICA-0107A. The
output of low selctor signal regulates the control valve
68FCV-0102 located on gas outlet line.
Normally flow control valve 68FCV-0101 is regulated by gas
flow controller
68FICQA-0101. When condensate level
reaches high value, then 68LICA-0107A overrides the flow
signal and it will start controlling 68FCV-0101 to avoid liquid
carryover to the outlet gas line. When condensate level
reaches below set point, then the control is handed over to
flow controller 68FICQA-0101.
4.2.3.3
I.

Operational and Implementation Aspects

Start-up
During start-up the controller shall be in manual mode and
after stabilisation of operation, it will be put in the auto mode.

II.

Normal Steady-State
Flow transmitter is tracking the actual value.

III.

Crippled mode operation

In case of input signal failure, the flow cotroller will be put in
manual mode. Valve opening and closing will be done
manually.

IV.

Shut down
During station ESD, 68FCV-0101 will be opened.

V.

Operator interface
DCS graphic displays will show all real time process data.

VI.

Calculation
No calculations are required.

VII.

Special consideration
None.

VIII.

History
None.

4.2.4 Produced Water Level Control Logic

68LICA-0103- Produced water level controller
4.2.4.1

Objective

To control the produced water (interface) level in the inlet separator.

4.2.2.4

Functional Description

Inlet separator (V-6801) produced water level control is performed

by 68LICA-0103 which regulates the control valve 68LCV-0103
located on produced water outlet line.
Opening and closing of 68LCV-0103 is linked to the opening/closing
of PSD valve (68UZV-0102) located upstream of 68LCV-0103.
On high interface level, the liquid level switch 68LS-0104 will
regulate corrosion inhibitor injection pumps P-6372A/B to inject
corrosion inhibitor to condensate header to avoid corrosion. If the
interface level increases then one of the corrosion inhibitor injection
pumps (P-6372 A/B) is started automatically and stopped when the
level comes down.
4.2.2.5
I.

Operational and Implementation Aspects

Start-up
During start-up the controller shall be in manual mode.
However opening of 68UZV-0102 will drive 68LCV-0103 in
auto mode.

II.

Normal Steady-State
Level transmitter is tracking the actual value.

III.

Crippled mode operation

In case of input signal failure the level cotroller will be put in
manual mode. Valve opening and closing will be done
manually.

IV.

Shut down
During the PSD or ESD of the inlet separator , upstream PSD
valve
(68UZV-0102) will close and activates 68XS-0102
which will close 68LCV-0103.

V.

Operator interface
DCS graphic displays will show all real time process data.

VI.

Calculation
No calculations are required.

VII.

Special consideration
None.

VIII.

History
None.

4.3

Compressor suction header pressure controller

Refer the following PEFS:

1. SNG-249-PX-2365-68003-0001
4.3.1 Process
The gas leaves Inlet Separators and shall be routed to suction
scrubbers V-6811 /6821/6831 through suction coolers
4.3.2 Suction header pressure Control Logic
68PICA-0006-Compressor Suction common header pressure.
4.3.2.1

Objective

During transition period, the inlet manifold pressure is 100 barg and
compressor can not be started with such a high suction pressure.
Therefore 68PICA-0006 and 68PCV-0006 will be used to control
compressor common suction header pressure in order to achieve the
required pressure at compressors suction (i.e. approximately 70
barg).
4.3.2.2

Functional Description

During the transition period, the suction pressure header controller

68PICA-0006 regulates the pressure let down valve 68PCV-0006.
68PICA-0006 also actuates creep valve (68USV-0014) located on
common suction header. During PSD of compressors, there is
possibility of rise of pressure in this header. 68PICA-0006 maintains
the pressure of suction header below 70 barg with the help of creep
valve.
When the pressure on the common suction header is more than 70
barg, the pressure controller shall open the creep valve 68USV-

0014, located on the common header and releases excess gas to

flare header.
When the common header pressure reaches 65 barg, the pressure
controller shall close the creep valve.
4.3.2.3

Operational and Implementation Aspects

I. Start-up
During start-up the controller shall be at manual mode. The
pressure letdown valve 68PCV-0006 shall be opened
manually. Then the controller will be changed to AUTO mode.
II. Normal Steady-State
During normal operation, the controller shall be in auto mode
and regulates the pressure letdown valve.
III. Crippled mode operation
No special provisions are required
IV. Shut down
No special provisions are required.
V. Operator interface
DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.
4.4

Suction Coolers (E-6811, E-6821 & E-6831)

Refer the following PEFS:

2. SNG-249-PX-2365-68010-0001
3. SNG-249-PX-2365-68020-0001
4. SNG-249-PX-2365-68030-0001
The control narrative for a suction cooler E-6811 is discussed in this
document and the same is applicable for the other suction coolers
(E-6821 & E-6831).
4.4.1 Process
The gas leaves Inlet Separators at about 100C and requires cooling
before it is compressed. This is accomplished in an air-cooled
suction cooler. The cooler consists of 4 bays, each housing 2 bundles

and cooled by 2 fans, both on variable speed drives. It is the design

intent to cool the gas but not less than 30C to prevent hydrate
formation. Cooler outlet fluid containing varying amounts of
condensed water and hydrocarbons then proceeds to suction
scrubber (V-6811).
4.4.2 Suction Cooler Outlet Temperature Control Logic
68TICA-1102-Suction Cooler Outlet Temperature
4.4.2.1

Objective

To control the suction cooler fans in order to achieve the required

temperature of the gas at the outlet of the inlet separator.
4.4.2.2

Functional Description

The only parameter requiring control is the outlet temperature.

When outlet temperature of the gas is at 40C, both the cooler fans
shall be running at the minimum possible speed. If the cooler outlet
temperature reduces further to a temperature 35C, 68TICA-1102
will stop one of the running fan and at the temperature 30C, it will
also stop the other fan.
The outlet temperature starts rising due to stopping of both fans.
When outlet temperature of the gas is at 35C, 68TICA-1102 will
start first stopped fan and at the temperature 40C, it will also start
the other fan.
4.4.2.3

Operational and Implementation Aspects

I. Start-up
During start-up the low low temperature trip (68TZA-1103)
shall be overridden. The temperature controller 68TICA-1102
implemented in the DCS is configured with a default setting
with 0.0 % output and will "only" transfer to AUTO mode and
local set point on having received a request to start the fin
fans from the start-up sequence
II. Normal Steady-State
Temperature transmitter will control the variable speed
drives of the cooler fans in order to keep the outlet
temperature of the gas between 60 to 30 deg C.
III. Crippled mode operation
Temperature transmitter will be put in manual mode. Start /
stop of the cooler fans will be done manually.
IV. Shut down
No special provisions are required.
V. Operator interface

DCS graphic displays will show all real time process data.
VI. Calculation
No calculations are required.
VII. Special consideration
None.
VIII. History
None.
4.5

Compressor Suction Scrubbers (V-6811, V-6821 & V6831)

Refer the following PEFS:

1. SNG-249-PX-2365-68010-0001.
2. SNG-249-PX-2365-68020-0001.
3. SNG-249-PX-2365-68030-0001.
4.5.1

Process

The control narrative for compressor suction scrubber V-6811 is

discussed in this document and the same is applicable for the other
suction scrubbers (V-6821 & V-6831).
Compressor Suction Scrubber is a vertical 2-phase separator which
receives fluids from cooler outlet, separates the gas and liquid. The
bulk liquid is sent to the common condensate separator (V-6803).
Gas leaves the scrubber top and proceeds to the Booster
Compressor (K-6810).
The scrubber is designed in accordance with DEP to achieve liquids
removal better than 99% of the inlet liquid volume, and is equipped
with a Schoepentoter, mistmat, swirldeck, and second mistmat.
(SMSM).
4.5.2 Liquid Level Control Logic
68LICA-1101-Liquid level controller
4.5.2.1

Objective

To control liquid level in the suction scrubber.

4.5.2.2

Functional Description

The compressor suction scrubber (V-6811) liquid level control is

performed by
68LICA-1101 which regulates the control valve
68LCV-1101 located on liquid outlet line.
Opening & closing of 68LCV-1101 is linked to the opening/closing of
PSD valve (68UZV-1120) located upstream of 68LCV-1101.

4.5.2.3
I.

Operational and Implementation Aspects

Start-up
During start-up, the controller shall be in manual mode.
However, opening of 68UZV-1120 will drive 68LCV-1101 to
auto mode.

II.

Normal Steady-State
Level transmitter is tracking the actual value.

III.

Crippled mode operation

In case of input signal failure the level cotroller will be put in
manual mode. Valve opening and closing will be done
manually.

IV.

Shut down
During the PSD or ESD of the suction scrubber, upstream
PSD valve
(68UZV-1120) will close and activates 68XS1140 which will close 68LCV-1101.

V.

Operator interface
DCS graphic displays will show all real time process data.

VI.

Calculation
No calculations are required.

VII.

Special consideration
None.

VIII.

History
None.

4.6

Booster Compressors (K-6810, K-6820 & K-6830)

Refer the following PEFS:

1. SNG-249-PX-2365-68010-0002
68010-0003

6.SNG-249-PX-2365-

2. SNG-249-PX-2365-68020-0002
68020-0003

7.SNG-249-PX-2365-

3. SNG-249-PX-2365-68030-0002
68030-0003

8.SNG-249-PX-2365-

4. SNG-249-PX-2365-68003-0001
5. SNG-249-PX-2365-68004-0001
4.6.1 Process
Gas from the suction scrubber is routed to compressor. Between
start-of-run to end-of-run conditions for Phase SNDC-1, Booster
Compressor will receive from about 10.5 to 7 MMSCMD gas at
pressures ranging from 70 to 38 bara and compress it to a pressure

required at SNGP inlet for meeting its export gas target. The most
severe discharge temperature at the end-of-run is estimated to be
about 175C.
The compressor will be a single stage centrifugal type and will be
driven by a synchronous electrical motor
The suction pressure of the compressors will depend on the supply
pressure at the Plant Inlet Manifold, which will be controlled as
described in Section 4.1.1. During initial phase of operation, gas
inlet pressure will be high enough for two compressor operation,
with the third on standby, resulting in a marked improvement in
availability and production efficiency.
Compressor control will have an integrated capacity & antisurge
control. Each unit will have an independent antisurge control
integrated with overall capacity control for the entire trains. The
integration will ensure the turndown and stability.
Compressor will have a dry gas seal system, with process gas for
primary seal and instrument air as separation gas for secondary
seal. Primary seal vents will be routed to the existing SNGP AP Flare
system. Normally, seal gas for the compressor primary seal will be
provided from compressor discharge, with a cold start supply from
fuel gas line. Each compressor will have its own seal gas treatment
unit consisting of a heater, pressure letdown valves and a filter.
The control narrative for a Booster Compressor K-6810 is discussed
in this document and the same is applicable for the other booster
compressors (K-6820 and K-6830).
4.6.2 Controls
4.6.2.1

Control of Compressor Systems

Each compressor control consists of the following:

All 3 stages of Start-up, i.e. Startup of Auxiliaries,
Pressurizing, and Startup of compressor performed by
automatic start sequence, with each stage initiated
from FCS HMI process schematic.
PSD isolate compressor train and remain pressurized.
ESD isolate compressor train and, depressurize using
blow down valves.
Control of auxiliaries, viz. suction scrubber, coolers,
inlet and outlet ESD valves, lube oil, and seal gas
system.
Normal Shutdown Automatic shutdown sequence
initiated from FCS HMI process schematic in the CCR,
FARI and LCP.
4.6.2.2

Control of Compressor Machine

The Machine control consists of the following functions:

Speed (Capacity) control with manual override
Integrated Capacity & Anti-surge control system
Compressor
performance
machine
monitoring
(pressure, temperature, vibration and speed)
Start-up/Stop sequence
Control of Utilities
Lube oil control system
Seal gas control system with temperature controller.
Remote monitoring of compressor performance from
Qarn Alam/Saih Nihayda Conditioning Monitoring
Group.
4.6.2.3

Integrated Capacity and Anti-Surge Control

Two separate measures are provided to protect machine against

damage from surging due to insufficient loading: an anti-surge
control, and a capacity control. The capacity control scheme may be
interfaced from the FCS HMI process schematic.
Each machine has a dedicated integrated capacity & anti-surge
controller. Integrated Capacity and Anti-surge controller shall
perform as a minimum the following functions:

In normal operation, the speed of all three compressors will

be controlled from the pressure controller (68PICA-0007)
located in the common SNDC-1 discharge header, which will
receive its set point from the SNGP Master Flow Controller
located in the export gas line.

In case the throughput demand of the SNGP Master Flow

Controller exceeds gas supply from the wells and the suction
pressure falls below its set point, the low suction pressure
constraint controller (68PICA-1108) will control compressor
speed. It will reduce the speed to maintain the suction
pressure.

In case the compressor discharge pressure increases beyond

the design limit of discharge system, then the discharge
pressure constraint controller
(68PICA-1203) will
control compressor speed. It will reduce the speed to
maintain the discharge pressure.

Incase the compressor motor power increases on demand, a

high power constrain controller (68XIC-1209) will control the
compressor speed. It will reduce the speed to maintain
compressor motor power within the limit.

In case the compressor discharge temperature increases

beyond the design limit of discharge system, then the
discharge temperature constraint controller (68TICA-1202)

will control compressor speed. It will reduce the speed to

maintain the discharge temperature.

The anti-surge controller (also included in the integrated

capacity & anti-surge control block 68UIC-1001) is intended
to prevent the compressors operating point to move towards
the surge line.

During normal compressor operation, the capacity controller will

adjust the compressor speed attempting to meet the process flow
demand; however if the compressor operating point moves towards
the compressor surge line based on the operating conditions, the
capacity control will demand the opening of the capacity control
valve 68UCV-1215 first and then the anti-surge control will demand
the opening of the anti-surge valve
68UCV-1210.
The integrated capacity & anti-surge controller block 68UIC-1001
receives the process measurements from the three pressure
transmitters (68PICA-1108, 68PICA-0007 & 68PICA-1203) and the
compressor suction flow transmitter 68FT-1103. These process
measurements are used to calculate the compressor operating point
which is used as the process measurement for the capacity
controller.
The integrated capacity & anti-surge controller block 68UIC-1001
also receives the process measurements from the two pressure
transmitters (68PI-1107 &, 68PI-1201), temperature transmitters
(68TT-1105 & 68TT1201) and the compressor suction flow
transmitter 68FT-1103. These process measurements are used to
calculate the compressor operating point which is used as the
process measurement for the antisurge controller.
All the transmitters involved in the anti-surge control shall be fast
response (< 100 msec) type transmitters.
The antisurge controller block will give a surge alarm in case the
operating point has reached the surge point and an indication signal
when the operating point is closed to surge and the antisurge valve
start to open.
For the detailed description of the Control of Compressor (e.g.
anti surge / capacity control, start- up sequence, shut down
sequence,etc) refer Compressor Vendor Document.
4.7

Compressor After Coolers (E-6812, E-6822 & E-6832)

Refer the following PEFS:

1. SNG-249-PX-2365-68010-0003
2. SNG-249-PX-2365-68020-0003
3. SNG-249-PX-2365-68030-0003

The control narrative for an after cooler E-6812 is discussed in this

document and the same is applicable for the other after coolers (E6822 and E-6832).
4.7.1 Process
Depending on the suction pressure, the temperature of the
compressed gas on Booster Compressors discharge will be about 90
to 165C and requires cooling before it enters the existing inlet
cooler of SNGP. This is accomplished in an air cooled compressor
heat exchanger installed on each compressor train downstream of
the compressor. The cooler consists of 2 bays, each housing 2
bundles and cooled by 2 fans, both on variable speed drives. In order
to match original design conditions of the existing SNGP, it is the
design intent to control the gas exit at 100C.

4.7.2 After Cooler Outlet Temperature Control Logic

68TICA-1203-After Cooler Outlet temperature
4.7.2.1

Objective

To control the discharge cooler fans in order to achieve the required

temperature of the gas at the outlet of the discharge cooler.
4.7.2.2

Functional Description

The only parameter requiring control is the outlet temperature.

When outlet temperature of the gas is at 90C, both the cooler fans
shall be running at the minimum possible speed. If the cooler outlet
temperature reduces further to a temperature 85C, 68TICA-1203
will stop one of the running fan and at the temperature 80C, it will
also stop the other fan.
The outlet temperature starts rising due to stopping of both fans.
When outlet temperature of the gas is at 85C, 68TICA-1203 will
start first stopped fan and at the temperature 90C, it will also start
the other fan. To maximize the cooling, both fans will run at
controlled speed to maintain temperature at 100C.
4.7.2.3
I.

Operational and Implementation Aspects

Start-up
During start-up the low low temperature trip (68TZA-1204)
shall be overridden. The temperature controller 68TICA-1203
implemented in the DCS is configured with a default setting
with 0.0 % output and will "only" transfer to AUTO mode and
local set point on having received a request to start the fin
fans from the start-up sequence.

II.

Normal Steady-State
Temperature transmitter will control the variable speed
drives of the cooler fans in order to keep the outlet
temperature of the gas at 100 deg C.

III.

Crippled mode operation

Temperature transmitter will be put in manual mode. Start /
stop of the cooler fans will be done manually.

IV.

Shut down
No special provisions are required.

V.

Operator interface
DCS graphic displays will show all real time process data.

VI.

Calculation
No calculations are required.

VII.

Special consideration
None.

VIII.

History
None.

4.8

Condensate Separator (V-6803)

Refer the following PEFS No. 1) SNG-249-PX-2365-68005-0001

4.8.1 Process
The Condensate Separator V-6803 collects hydrocarbon and water
separated from Compressor Suction Scrubbers V-6811/6821/6831
and separates condensate and water. Some flashing occurs due to a
pressure differential between the source and destination vessels.
Therefore, the Condensate Separator will be designed and operated
as a horizontal 3-phase separator.
Separated liquids will proceed on their own pressure head to their
respective destinations existing in the SNGP Facility. Condensate
will be sent to E-6213 Condensate Cooler and produced water to V6214 Produced water degassing vessel. Flashed off-gas will be
disposed of into Off-Gas Pipeline.
The separator is designed in accordance with DEP to achieve liquids
removal better than 99% of the inlet liquid volume, and is equipped
with a Schoepentoter, Single weir, Mismat, vortex breaker and plate
pack.
4.8.2 Condensate Level Control Logic
68LICSA-0302-Condensate level controller
68FICQ-0302-Condensate flow controller
4.8.2.1

Objective

To control condensate level in the condensate separator.

4.8.2.2

Functional Description

The V-6803 condensate level control is performed by 68LICSA-0302

(master controller). To achieve better control, level control is
cascaded to slave flow controller 68FICQ-0302 which regulates the
control valve 68FCV-0302 located on condensate outlet line.
Opening & closing of 68FCV-0302 is linked to the opening/closing of
PSD valve 68UZV-0303 which is located upstream of 68FCV-0302.
On condensate high level, the controller 68LICSA-0302 also initiates
bypass operation. For high level, it opens condensate separator
bypass PSD valve 68UZV-0311 and closes inlet PSD valve 68UZV0310. When level reaches below high level set point, condensate
separator will be taken to normal mode by closing bypass PSD valve
(68UZV-0311) and opening inlet PSD valve (68UZV-0310).
4.8.2.3
I.

Operational and Implementation Aspects

Start-up
During start-up the controller shall be in manual mode.
However, opening of 68UZV-0303 will drive 68FCV-0302 in
auto mode.

II.

Normal Steady-State
Level transmitter is tracking the actual value.

III.

Crippled mode operation

In case of input signal failure the level controller will be put
in manual mode. Valve opening and closing will be done
manually.

IV.

Shut down
During the PSD or ESD of the condensate separator ,
upstream PSD valve (68UZV-0303) will close and activates
68XS-0301 which will close 68FCV-0302.

V.

Operator interface
DCS graphic displays will show all real time process data.

VI.

Calculation
No calculations are required.

VII.

Special consideration
None.

VIII.

History
None.

4.8.3 Produced Water Level Control Logic

68LICA-0301- Produced water level controller
4.8.3.1

Objective

To control the produced water (interface) level in the condensate

separator.
4.8.3.2

Functional Description

Condensate separator (V-6803) produced water level control is

performed by
68LICA-0301 which regulates the control valve
68LCV-0301 located on produced water outlet line.
Opening and closing of 68LCV-0301 is linked to the opening/closing
of PSD valve (68UZV-0304) located upstream of 68LCV-0301.
4.8.3.3
I.

Operational and Implementation Aspects

Start-up
During start-up the controller shall be in manual mode.
However , opening of 68UZV-0303 will drive 68LCV-0301 in
auto mode.

II.

Normal Steady-State
Level transmitter is tracking the actual value.

III.

Crippled mode operation

In case of input signal failure the level cotroller will be put in
manual mode. Valve opening and closing will be done
manually.

IV.

Shut down
During the PSD or ESD of the condensate separator ,
upstream PSD valve (68UZV-0304) will close and activates
68XS-0302 which will close 68LCV-0301.

V.

Operator interface
DCS graphic displays will show all real time process data.

VI.

Calculation
No calculations are required.

VII.

Special consideration
None.

VIII.

History
None.

4.8.4 Pressure Control Logic

68PICA-0303A- and 68PICA-0303B- Condensate separator pressure

controllers.
4.8.4.1

Objective

To control the pressure of the condensate separator.

4.8.4.2

Functional Description

The Condensate Separator (V-6803) pressure control is performed by

two independent pressure controllers 68PICA-0303A and 68PICA0303B. The pressure of the condensate separator is transmitted to
both pressure controllers by 68PT-0303 installed on condensate
separator gas outlet line. The compressor common suction header
pressure shall be given to calculation block 68PYC-0302. The
pressure controllers (68PICA-0303 A/B) receive signal from pressure
control calculation block 68PYC-0302 and from the pressure
transmitter 68PT-0303. The pressure controller 68PICA-0303A
maintains the condensate separator pressure 4 bar lower than the
common suction header pressure by regulating control valve 68PCV0303A which is located on vessel off-gas outlet line.
Another control valve (68PCV-0303B) is provided on the flare line
from vessel. This control valve is regulated by controller 68PICA0303B which also receives the set point from calculation block
68PYC-0302 and from the pressure transmitter 68PT-0303. The
control valve shall have set point approximately 1 bar more than
68PCV-0303A set point. In case of any upset of 68PCV-0303A, the
vessel pressure will increase and then vessel pressure will be
reduced by opening control valve (68PCV-0303B) and excess gas will
be sent to flare system. When vessel pressure reduces, then 68PCV0303B will close and again control will be handed over to another
valve 68PCV-0303A.
4.8.4.3
I.

Operational and Implementation Aspects

Start-up
During start-up both the controllers shall be in manual mode
until the pressure will reach to normal value, then it will be
put in the auto mode.

II.

Normal Steady-State
Pressure transmitter is tracking the actual value.

III.

Crippled mode operation

In case of input signal failure the both cotrollers will be put in
manual mode. Valves opening and closing will be done
manually.

IV.

Shut down

No special provisions are required as controller will become

disabled for direct pressure control and switch to manual
mode.
V.

Operator interface
DCS graphic displays will show all real time process data. All
control modes and parameters, except the calculation
functions of pressure controllers, will be available in standard
graphic displays and accessible to the operator.

VI.

Calculation
Calculations block is required.

VII.

Special consideration
None.

VIII.

History
None.

4.8.5 Differential Pressure Switch Logic

68PDSA 0305- Condensate separator pressure differential switch.
4.8.5.1

Objective

To prevent high level in compressor suction scrubbers.

4.8.5.2

Functional Description

The Condensate Separator (V-6803) pressure control is performed by

two independent pressure controllers 68PICA-0303A and 68PICA0303B. Failure of this pressure controllers leads to increase the level
in the compressor suction scrubbers which further leads to
compressors PSD.
To prevent Compressors PSD, due to the above reason, a pressure
differential switch
68PDSA-0305 is provided.
The differential pressure switch receives the signals from a pressure
transmitter 68PT-0301 installed on condensate separator and
compressor suction common header pressure controller 68PICA0006. When the differential pressure is less than 2 bar (at low
differential pressure), the pressure differential switch opens
condensate separator by pass valve 68UZV-0311 and closes
condensate separator inlet valve 68UZV-0310 to allow condensate
separator to work in bypass mode.
When the pressure differential is more than 2 bar (low differential
pressure set point, it opens condensate separator inlet PSD valve
(68UZV-0310) and closes the bypass PSD valve (68UZV-0311) to
allow condensate separator to work in normal mode.
4.8.5.3

Operational and Implementation Aspects

I. Start-up
During start-up pressure differential switch shall be in
manual mode and inlet valve shall be kept open. When the
pressure in the condesate separator reaches to normal value,
then it will be put in the auto mode.
II. Normal Steady-State
Pressure transmitter is tracking the actual value.
III. Crippled mode operation
In case of input signal failure, the pressure differentail switch
will be put in manual mode. Valves opening and closing will
be done manually.
IV. Shut down
No special provisions are required.
V. Operator interface
DCS graphic displays will show all real time process data.
The switch mode and other parameters, except the
calculation functions of pressure switch, will be available in
standard graphic displays and accessible to the operator.
VI. Calculation
Calculations block is required.
VII. Special consideration
None.
VIII. History
None.

5.0 REFERENCE

Saih Nihayda Depletion Compression Phase- I, Basis for

Design Doc no VEC4552/RPT/101, Rev-B.
Saih Nihayda Depletion Compression Phase- I, Process
Description
and
Control
Philosophy,
Doc
noVEC4552/RPT/102, Rev-B

6.0 ATTACHMENTS

Process Control Schematic Diagram

Process Engineering Flow Schemes

Appendix-I
Process Control Schematic Diagram

Appendix-II
Process Engineering Flow Schemes