Sie sind auf Seite 1von 7

APPENDIX III

Electrostatic separator
FJORDS Power Unit
instructions

1. Preamble

The Power-Units for electrostatic separator are built by AGECELEC for the account of FJORDS and
under an exclusivity agreement contract.

For all information request or problems about the FJORDS Power-Unit, including spare parts, please
contact:

Fjords Processing
9-11, Av. du Val de Fontenay
94120 Fontenay sous Bois Cedex
Telephone +33 1 41 93 82 20
Fax +33 1 41 93 82 21

Warning: The high voltage side of the FJORDS Power-Unit being connected to electrode grids
located inside the electrostatic separator, there are risks of electrocution for human being
while works are performed on electrical parts and electrostatic separator internals as well as risks
of arcing and explosions.
Due do these risks the applicable local safety instructions completed with special FJORDS safety
instructions mentioned in FJORDS electrostatic separator instructions manual, have to be carefully
followed before and during all operations on the FJORDS Power-Unit (s) and/or the electrostatic
separator.

Under no circumstance (except the electrical test as described in paragraph 6) should the FJORDS
Power-Unit be energised if the electrostatic separator is not completely full of liquid.

Before any maintenance work be performed on FJORDS Power-Unit, the bushings and/or in
electrostatic separator internals the electrical departure in substation will be locked in safe open
position. In case of multi FJORDS Power-Unit installation on the same electrostatic separator , the
electrical departure of all the FJORDS Power-Units will be locked in safe position even is only one
FJORDS Power-Unit is concerned by the works.

The FJORDS Power-Unit is integrally filled with oil, do not attempt to open or to dismantle the valves,
the safety valves, the cover, the visiting plates and the plugs (and the pressure detecting device if
any) as no air and moisture have to enter the FJORDS Power-Unit tank.

The HV chamber is designed and manufactured to resist, in case of electrostatic separator bushing
failure, to a pressure equal to the electrostatic separator one and for a maximum of 40 bar. Before to
open the HV chamber and or to attempt to dismantle the bushing the electrostatic separator has to
be depressurised and blanketed. Using the filling plug connection, the lack of pressure in the HV
chamber will be checked.

2. Lifting

- The FJORDS Power-Unit will be lifted exclusively by the use of the lifting lugs located on the
top of the FJORDS Power-Unit cover.
Electrostatic separator
FJORDS Power Unit
instructions

3. Before installation

- The FJORDS Power-Unit will be externally checked to detect any deterioration or loss during
transportation, lifting and eventual oil leakage. If damage is found the question of
responsibility for repair cost has to be discussed with FJORDS.
- The data indicated on the FJORDS Power-Unit plate (voltage, frequency and so on) will be
checked against those of the local electrical supply.
- The degree of mechanical protection IP 56 as well as the Cenelec protection level for
hazardous area Eex "eo" IIB T4 as indicated on the plate will be checked to be acceptable for
the zone where the FJORDS Power-Unit is installed.
- The electrical protecting device of the FJORDS Power-Unit cable in electrical sub-station will
be checked to be correct and in accordance with the FJORDS Power-Unit maximum current.

4. FJORDS Power-Unit Installation

- For safety reasons the electrical departure in substation will be locked in safety open
position. In case of multi FJORDS Power-Unit installation, the electrical departure of all
the FJORDS Power-Units will be locked in safe position even is only one FJORDS
Power-Unit is concerned by the work.
- The FJORDS Power-Unit will be installed on the specially dedicated supports on the top of the
electrostatic separator. It will be carefully levelled and fixed with bolts, nuts and double nuts.
- The HV Separator bushing will be installed and connected in accordance with the FJORDS
instructions and drawings.
- The HV chamber of the FJORDS Power-Unit will be closed with his blind flange and gasket.
The plugs of the HV chamber will be tightened. The HV chamber will be filled with mineral oil
ESSO Univolt 52 or equal up to the mark indicated on the level gauge. It is of the first
importance to respect the oil level in the HV chamber.
- The electrostatic separator, the FJORDS Power-Unit and the separator bushing earthing lugs
will be connected to the local earthing network. This earthing connection will be checked by
the local electrical responsible and evidence of this control will be provided before put the
FJORDS Power-Unit into service.
- The FJORDS Power-Unit will be connected to the power cable according to the electrical
diagram. In case of multi FJORDS Power-Units installation, the phase's rotation as
indicated in electrical diagram will be imperatively respected.
- The power cable glands will be installed in accordance with supplier instructions.
- The FJORDS Power-Unit's control devices (current and voltage transformers, level switch as
well as the optional apparatus if any) will be connected in accordance with the project
electrical diagram. The control cable glands will be installed in accordance with supplier
instructions.
- The FJORDS Power-Unit connecting box will be closed and the 4 screws will be tight
according to supplier instructions.
- The action of the FJORDS Power-Unit safety devices (FJORDS Power-Unit low level switch)
as well as the Oil/Gas low level safety device that switch off the power on FJORDS Power-
Unit has to be checked.
Electrostatic separator
FJORDS Power Unit
instructions

5. Before putting the FJORDS Power-Unit into service.

- Check line voltage and frequency against FJORDS Power-Unit plate indications.
- Check that the FJORDS Power-Unit's power cable protecting device is suitable and operative.
- Check that the FJORDS Power-Unit is correctly installed, levelled and fixed on his supports.
- Check that the LV terminals (power and control) are correctly connected and tight.
- Check that the HV connection is correct and according to instructions.
- Check that the HV chamber is filled with oil up to the mark.
- Check that the earthing connections of the PU and the bushing are correct and certified.

Warning: Under no circumstance (except the electrical test as described in paragraph 6)


should the FJORDS Power-Unit be energised if the electrostatic separator is not completely
full of liquid.

6. First operation and electrical tests

Warning: We remind that during the tests the electrode grids located inside the electrostatic
separator vessel will be energised with high voltage. Before to energise the FJORDS Power-Unit,
please report to the local safety instruction as well as to FJORDS electrostatic separator
instructions and particularly:
- Fire permit (risk of arcing inside the electrostatic separator) to check the absence of
explosive mixture in the electrostatic separator.
- Before to enter the electrostatic separator check that the power supply departure is locked
in open and safe position.
- Access Permit to check that there is no risk for human health to enter the electrostatic
separator.
- Verification of electrostatic separator internals,
- Verification that nobody is staying or can have access in the electrostatic separator during
the tests, before closing and locking of all the electrostatic separator accesses.
- To avoid the risk of damage on the current transformer, this device has to be connected to
the ammeter (or shunted) before the FJORDS Power-Unit be energised.

We recommend that the electrical tests will be done under the supervision of an Fjords
Processing serviceman.

To perform these tests the action of the Oil/Gas low level safety device that switch off the power
on FJORDS Power-Unit when the electrostatic separator is not full of liquid has to be by-passed.

6A) Short circuit test (a shunt link is installed between the energised grid and the vessel
shell).
The goal of this test is to check the following:
- Correct connection of the HV parts.
- The full load data indicated in the FJORDS Power-Unit plate.
- The current transformer.
- No excessive vibrations.

6B) No load test (The shunt link used for load test is removed).
Electrostatic separator
FJORDS Power Unit
instructions

The goal of this test is to check the following:


- The insulation of the HV parts.
- The no load data indicated in the FJORDS Power-Unit plate.
- The voltage transformer.

After the tests the power supply departure will be locked in open and safe position and the by-
pass installed on the Oil/Gas low level safety device will be removed. The action of this device
that switch off the power on FJORDS Power-Unit when the electrostatic separator is not full of
liquid has to be checked before the electrostatic separator is put into service.
The shunt link used for test to be removed before closing the electrostatic separator.

7. FJORDS Power-Unit into service

No intervention except painting repair works will be done onto the Power-Unit while energised.
The checking of the correctness of the FJORDS Power-Unit operations will done by the voltage
and current indication (local or remote). For memory, the voltage value during operation is
normally comprised between 50 and 100% of the line voltage and the current is lower than 30%
of the short circuit current (except for heavy and/or high conductive crudes).
For information about process, please refer to the FJORDS instruction manual.

8. Maintenance

For any maintenance work to be performed during warranty period, please contact FJORDS
office.

Before to perform maintenance works on the FJORDS Power-Unit

- the HV chamber, and the bushing or electrostatic separator internals the FJORDS
Power-Unit will be de-energised and the electrical departure will be locked open. If the
electrostatic separator is equipped with several FJORDS Power-Units all the FJORDS
- Power-Units will be de-energised and locked in open position even if the maintenance
work has to be done on one FJORDS Power-Unit only.
- Check that the FJORDS Power-Unit (or all the FJORDS Power-Units) is de-energised on the
local panel or in control room.
- Before to open the FJORDS Power-Unit tank or the visiting plate, the FJORDS Power-Unit will
be depressurised using the top mounted filling connection, (use clean hose and can to
recover the oil in excess).
- Before to open the HV chamber and or to attempt to dismantle the bushing the
electrostatic separator has to be depressurised and blanketed. Using the filling plug
connection, the lack of pressure in the HV chamber will be checked.
- The dielectric rigidity of the mineral oil will be checked. Complementary oil filling will be done
using new or regenerated oil. The quality of this oil will be checked before filling.

8.1 Maintenance works.


Electrostatic separator
FJORDS Power Unit
instructions

Thanks to their heavy duty fabrication no maintenance on FJORDS Power-Units (except external
painting if necessary) has to be done during the first five years of operation.
At the end of each five years period the following maintenance works have to be done :
- One oil sample (0,3L) has to be taken using the bottom drain valve and a dielectric test of the
oil will be performed (according to IEC 296 §7.12). Breakdown voltage will not be less than
30kV. For new oil, breakdown voltage will be more than 50kV. Refer to IEC 296 "Rules for
transformer and switchgear oils" for information about oils. Warning : No air must enter the
transformer tank during this operation.
- The FJORDS Power-Unit bushing located in the HV chamber will be carefully checked to
detect any trace of burning or electrical path at the surface of the Teflon.
- Check the proper operation of the level switch.
- Check and adjust the set pressure of the safety valve at 0,2 Bar.
- Check the external protection and the absence of rust and corrosion and repair if necessary.

8.2 Special instructions for FJORDS Power-Unit bushing change.

To change the FJORDS Power-Unit bushing use the following instructions:


- In case of rain and or high humidity the FJORDS Power-Unit will be protected in order to avoid
water entering the FJORDS Power-Unit.
- De-energise the FJORDS Power-Unit (all the Power-Units of the same electrostatic separator
in case of multi Power-Units installation) and locked in open position.
- Check the absence of voltage on the FJORDS Power-Unit.
- Depressurised the electrostatic separator.
- Check the lack of pressure in the HV chamber using the filling plug.
- Check the lack of pressure in the transformer tank using the top mounted connection (use
clean hose and can).
- Drain fully the HV chamber and check the oil (black oil can be the indication that crude is
entered the HV chamber and that electrostatic separator bushing must to be replaced (Refer
to FJORDS instructions).
- Drain the FJORDS Power-Unit tank up to the bushing level.
- Remove the blind flange of the HV chamber
- Disconnect the HV connection and protect the HV cable
- Open the visiting trap on the FJORDS Power-Unit cover
- Disconnect the FJORDS Power-Unit bushing (terminal N° b)
- remove the FJORDS Power-Unit bushing by using the bushing wrench supplied with the
electrostatic separator.
- Use only new FJORDS Power-Unit bushing for replacement.
- Cut the correct length of cable and install a connecting eyelet.
- Put tightness paste on the conical threading of the new FJORDS Power-Unit bushing.
- Clean the HV chamber and threading,
- Install the new FJORDS Power-Unit bushing and tight it firmely.
- Reconnect the bushing cable in the FJORDS Power-Unit tank.
- Reconnect the HV connection and check the tighting.
- Close the blind flange of the HV chamber with new gasket.
- Close the visiting plate
- Fill the HV chamber up to the mark indicated on the level gauge
Electrostatic separator
FJORDS Power Unit
instructions

- Fill the FJORDS Power-Unit tank by the bottom valve completely and purge the air by the top
mounted valve.
- Remove from the bottom the oil in excess by the bottom valve and check that the thickness of
the cooling waves are in accordance with the drawing

8.3 After the maintenance work performed on the FJORDS Power-Unit,


- Check and eventually complete the oil filling of the FJORDS Power-Unit tank. The FJORDS
Power-Unit tank has to be completely purge of air. After filling the thickness of the cooling
waves has to be checked according to drawing and adjusted by draining the oil from
the bottom drain valve.
- Check and eventually complete the oil filling of the HV chamber. The level of oil at ambient
temperature has to be comprised between the marks of the level gauge.
- After completion of the maintenance works, perform the electrical tests as explained
paragraph 5.

9. Spare parts

For spare parts please contact FJORDS representative and specify the Power-Unit serial number
indicated in the Power-Unit plate and FJORDS reference number.
Electrostatic separator
FJORDS Power Unit
instructions

10. Trouble shooting

Too high current (Higher than A1a Check line voltage


A1 short circuit current indicated in Internal defect in Power-Unit
Excessive A1b
A plate) (Contact FJORDS representative)
temperature
Ambient temperature too high Protect the Power-Unit from direct
A2 A2a
(>50°C) effect of sun.
Low oil level in B1 Oil leakage B1a Refer to point E
B
Power-Unit B2 Level switch fault B2a Check and change the level switch
C1 Temperature too high C1a Refer to point A
Power-Unit tank Let cool down the Power-Unit and
C
Overpressure C2 Over filling with oil C2a check the thickness of the cooling
waves. Correct the filling
Check the electrostatic separator
Oil leakage on D1a
D D1 Gasket failure bushing
the HV chamber
D1b Check and change the gasket
Oil leakage on E1 Gasket failure E1a Check and change the gasket
E the Power-Unit E2 Valve or plug leakage E2a Repair and tight
tank E3 Corrosion of the tank E3a Repair
Check process conditions (refer to
F1 Process short circuit F1a
FJORDS operating manual)
Electrostatic separator bushing Check and replace electrostatic
F2 F2a
failure separator bushing
High current and
F F3 Power-Unit bushing failure F3a Check and replace Power-Unit bushing
Low voltage
Check and replace electrostatic
F4 Insulator failure F4a
separator insulator
Electrostatic separator Check and reajust electrostatic
F5 F5a
Electrode grids distortion separator electrodes grids
Loose connection between
G1 Power-Unit and electrostatic G1a Check and repair
Low current and
separator bushing
Line voltage (but
Loose connection in the Power-
G the electrostatic G2 G2a Check and repair
Unit
separator is not
Loose connection between
performing)
G3 electrostatic separator bushing G3a Check and repair
and electrode grids
Check equipment and connections and
H1 Voltage transformer fuses H1a
replace the fuses
H2a Check ammeter and repair
H2 Instrument failure
Low current and H2b Check voltmeter and repair
H
low voltage Loose connection on the control
H3 H3a Check and repair
circuit
H4 Current transformer failure H4a Check and repair
H5 Voltage transformer failure H5a Check and repair