1.

PROCESS DESCRIPTION AND CONTROL

1.1 Process Description
A mixture of oil, gas and water is produced through each well head by virtue of the well head
natural pressure and its flow rate is controlled via a choke valve which a multi-position is
throttling valve located on the surface. Choke valve is motor operated and its opening is
based on production targets defined for the well and on results of well testing. Pressure of this
fluid is monitored at upstream of choke valve by a pressure transmitter. Well head production
line is joined with a production and a test manifold. In test manifold, only one well head flow is
aligned in order to determine individual phase flow rates, pressure, temperature and density.
After that it is connected with manifold line and then with trunk line. HIPPS is provided on
each trunk line.
With the passage of time, natural pressure of well will be depleted. An electrical submersible
pump (ESP) will then be installed in place of the SSDV in the each well to make the required
pressure and pump the mixture out.
1.2 Integrated Control and Safety System
1.2.1 ICSS description
The Mishrif Central Processing Facility has process control system (PCS) and safety
instrumented system (SIS) combined for better communication between the two and termed
as Integrated Control and Safety System (ICSS). For this project, ICSS constitutes of the
following systems.

DCS

ESD

PLC

FGDS

MPFM

ESP

MMS

This integrated DCS, ESD, F&G, ESP, MMS and PLCs are connected through a control and
communication networks for ease of production control and maintenance.
Remote acquisition of well pad data and process variables are available in the central control
building located in the CPF. The ICSS is of distributed topology and the systems are
connected through redundant data communication network connecting several nodes
located in field in dedicated Satellite Instrument Houses (SIH) for each well pad.
The 05 no(s) of SIH for their respective Well Pad are given below in table 3.2.1.

1.2.2 Well Pad Control

Each well pad has its dedicated SIH for control and monitoring the key parameters and
production as stated in table 3.2.1. The SIH # 5,6,7,8 and 10 have similar architecture and
they communicate through a redundant fiber optic link to the telecom room in CPF control
room.
Table 3.2.1 SIH detail for each Well Pad

Sr. #

SIH #

Well Pad #

830-SIH-105

Well Pad 05

830-SIH-106

Well Pad 06

830-SIH-107

Well Pad 07

830-SIH-108

Well Pad 08

830-SIH-110

Well Pad 10

1.2.3 Satellite Instrument House

As stated above in table 3.2.1, every well pad has a dedicated SIH for monitoring and control.
It houses all the component of the ICSS as per requirement. A network cabinet is deployed
where fiber optic to Ethernet convertors are installed. Also, there are network switches which
are used to route the communication through redundant channels. This cabinet is used as the
point for communication between SIH and CPF control room.
Separate cabinets are present for each of the ICSS components. They are mainly PDP,
FGDS, DCS, ESD, MPMS and an engineering work station to facilitate configuration and
engineering in all the 05 no(s) SIH.

DCS

The DCS provides process control and monitoring for the plant such as basic regulatory and
sequential control, non-safety related interlocks, process monitoring, alarm management,
data archiving, trending, reporting etc. It is to be noted that the DCS controller hardware and
I/O are distributed geographically with the modularized plant philosophy. The DCS
architecture, being the backbone of the ICSS, is integrated with all other components of ICSS.

ESD

The ESD is a dedicated control system responsible for the safe and controlled shutdown in wake
of any emergency , process upset or planned shutdown. The ESD operation is separate from
the DCS and does not take part in the regulatory control of the process plant. The ESD
consoles are also present with hardwired push buttons for initiating shutdown. The logic of the
shutdown is derived from the cause and effect drawings of the process plant.

Fire and Gas Detection System

The FGDS is responsible for early warning of any leak or fire in the process facility. It is also a
dedicated system which is separate from any other control system of the ICSS. It
communicates with the main CPF through a dedicated optical fiber link. There a number of
detectors installed in the field and the buildings for the early warning of the same.

Multi Phase Metering System

The MPMS is used for multiphase flow metering of the process medium from the well and is a
packaged unit. The MPMS panel located in each SIH is used for flow computing and
communicates to the CPF control room to the dedicated engineering server for flow
computation.

Power Distribution Panel

The power distribution panel is located in each of the SIH for the ICSS components. Its equipped
with the redundant power supplies along with the circuit breakers.

Variable Speed Drive

There is also a variable speed drive panel which is used to vary the speed of any electrically
driven pumps operated from their respective SIH.
In SIH 07, other than the standard configuration, 02 no(s) of PLC are deployed, one for
instrument air and other for test water injection. They communicate to DCS via a redundant
fiber optic network from field. The ESD and DCS also communicate to the main MCC as part
of the system architecture hence the motor start / stop and status is available as per the
control philosophy.
A WHCP is present in field which is used to control 04 no(s) of wells of each well pad and is
communicated through hard wired signals to DCS and ESD both. The typical configuration of
the SIH is given in the figure below.

1.2.4 Field Control Panel

In Field, a dedicated control panel known as WHCP is provided for ease of operation. Each
WHCP is able to control 04 no(s) of well heads. The WHCP drives the hydraulically actuated
valves essential for well operation. The WHCP has indications and controls for the hydraulic
valves, pumps and their status. All Wellhead Control Panels have the following functionality
1. Pump discharge, CP header, Fusible loop, SSSDV, SSDV and EQV pressure
indication.
2. All pumps of the well head can be put on local/remote/off through a selector switch
located in the same WHCP.
3. Dedicated start and stop buttons are given for each pump of the wellhead.
Other than that the Wellhead Control Panel (WHCP) provides:

Individual well control (local control from the WHCP)

The hydraulic power for all three valves of each of the 4 well head i.e. SSSDV, SSDV
and Equalizing valve and their hydraulic pressure indicated through pressure gauges
located in the front of the WHCP

Information and command switches for each well and for the hydraulic supply unit. For
each well head, dedicated ESD push button along with the reset button is given with
ESD status lamp. The 03 no(s) of the valves i.e. SSSDV, SSDV and EQV can be
opened and closed through the push buttons located in the front of the WHCP. Their
opening and closing indication is shown through a dedicated lamp. The lamps turn
green for open indication and are turned off for closed indication.

The WHCP is equipped with the HP and LP header for the hydraulic oil along with the
accumulator. They are equipped with the pressure transmitters for monitoring the pressure.
The accumulator is also equipped with a level transmitter.
The following settings apply to the hydraulic supply pressure to surface and subsurface safety
valves.
SSSDV:

Max working pressure: 5500-7000 psi

Min working pressure: 600 psi

Design pressure: 10000 psi

SSDV:

Max working pressure: 3000 psi

Min working pressure: 1200 psi

Design pressure 6000 psi

1.3 EMERGENCY SHUTDOWN

1.3.1 Emergency Shutdown Description
Emergency Shutdown System (ESD) is designed to safely shut down all or part of the
Well pad as the situation demands.
The emergency shutdown of each well pad is fully detailed in documents:

Emergency Shutdown Diagram

Cause and Effect diagrams

The ESD functions at CPF and well pads are interconnected. The ESD can also be initiated
from the CPF control room ESD hardwired console or from the individual WHCP panel by
pressing the dedicated push button for each well head. The following paragraphs describe
the general well pad shutdown. Each system (production, test separation) is detailed in its
respective book in this manual.
The well pad ESD system is divided into three main ESD levels.
1.3.2 ESD Level 0
ESD Level 0 is a very high level of shutdown and causes complete shutdown of the all well pads.
Causes:

Main power supply down

Manual activation of switch 000-00-EHS-001-A

Effects:

All well pads shutdown (05, 06, 07, 08, 10)

All well heads shutdown

Corrosion inhibitor pumps shutdown

Scale inhibitor pumps shutdown

Asphaltene inhibitor pumps shutdown

1.3.3 ESD Level 1

ESD Level 1 is a high level of shutdown and causes complete shutdown of the single well pad.
Causes:

Manual activation of switch 000-00-EHS-004-A

Confirmed fire

Confirmed gas detection

Effects:

All the well heads on single well pad will be shutdown.

1.3.4 ESD Level 2

ESD Level 2 is a low level shutdown which will trip only one well head.
Causes:

Hand switch push button located on the WHCP

LP fusible plug

Well head pressure High High

Well head pressure Low Low

Effects:

Individual well head will be shutdown

Note:

It is important to remember that the SSSDV will not be closed on this shutdown level.