InstrEng Instrumentation Engineering

OIL IN WATER ANALYZER

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In the offshore production facilities, the Oil in Water Analyzer plays an important rule to continuously analyze the oil content of the produced water from the separation process. In typical application, the Oil in Water Analyzer is placed in the outlet of produced water treatment package to see whether the treated water has been as per requirement or not. In typical application (in particular application it shall refer to applicable local regulation) the maximum oil in water content should not exceed 30 mg/L (or 30 ppm) per 24 hr average.<span id="more-665"></span></div>
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See below typical P&ID showing the Oil in Water Analyzer that control the flow of treated produced water. In this P&ID the Oil in Water Analyzer will continuously monitor the oil content of the water, if the oil content is higher than the requirement (30 mg/L or 30 ppm) then the on-off valve to overboard will close and the on-off valve to off-spec produced water tank will open and vice versa. The daily total oil in water content is also calculated by using an output from the flow transmitter.</div>
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In the input of the produced water treatment package, there is also oil in water analyzer put in 2oo3 configuration to monitor the produced water input. If the oil content of the produced water input it self is already higher than the produced water treatment package capacity, then the input to produced water treatment is closed and by passed to off-spec produced water tank.</div>
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OIL IN WATER ANALYZER

In the offshore production facilities, the Oil in Water Analyzer plays an important rule to continuously analyze the oil content of the pr...

Oil in water analyzer technology

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In general, there is no particular standard and codes that oblige the user to use certain oil in water sensor technology such as Infrared, solid state sensor, UV fluorescent, etc, . But so far, the most popular oil in water analyzer technology for offshore application is UV fluorescent sensor technology. UV fluorescent technology becomes most popular due to its long life time of its UV source and easiness of operability and maintainability of the equipment. Another consideration is that the UV fluorescent sensor technology has a high sensitivity and low measurement limit compare with other technology.<span id="more-673"></span></div>
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The operating principle of this oil in water UV fluorescence analyzer is utilizing a light emitting source to excite the oil molecule to a certain energy level. This excited oil molecule will emit back the light in lower wave length due to a relaxation state before. This emitting light is then called fluorescence light. Each oil molecule has a specific fluorescence wave length light. In this way the oil presence can be accurately detected by a fluorescence sensor.</div>
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See below picture showing an illustration of the fluorescence process.</div>
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Oil in water analyzer technology

In general, there is no particular standard and codes that oblige the user to use certain oil in water sensor technology such as Infrared,...

INTRODUCTION TO GAS METERING SYSTEM

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In the gas producing plant (onshore or offshore), the gas metering system is the final stage of the production step before it send to the end user of the gas product. It plays a very important role as a custody transfer meter. Every measurement is required as practical as possible to have a very accurate measurement or a very minimum error. This issue (measurement accuracy or error) is very important since it will determine the quantity of the gas product that will be paid by the customer. Larger the error means less money that will be paid by the customer in correlation with the amount that they received. Since it plays very important role and almost appear in every gas producing plant, it will be good for us to know the basic principle regarding this gas metering system. So what is the basic principle to measure the gas that will be exported?<span id="more-445"></span></div>
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First of all, there will always be a contract between the plant business units with the customer. This contract stated the quantity and quality of the gas that they will buy. The quantity of the gas will be measured by an ultrasonic flow meter. The used of the ultrasonic flow meter is the most used flow measurement device right now, but for alternative we can also use an orifice with differential pressure transmitter as a measurement device. Usually, it requires a 2 x 100% flow meter stream with active and standby stream.. This ultrasonic flow meter installation & configuration shall conform to AGA 9 standard & codes.</div>
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Since the flow of a gas is very affected by pressure and temperature, the pressure and temperature transmitter will also install in the downstream of the ultrasonic flow meter to compensate the flow reading. All row measurement data will fed to flow computer to determine the actual gas flow in relation with pressure and temperature variation.</div>
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The quality of the gas is related to composition and characteristic of the gas. The composition of the gas will be measured by gas chromatograph and presented in form of % composition. For example for particular measurement, CH4 (methane) composition is 98%, C2 (ethane) composition is 0.05%, etc. This composition data will be fed to the flow computer to calculate the Gross Heating Value (GHV). The use of this gas chromatograph and also the calculation of GHV shall conform to GPA-2172 and GPA-2261 standard & codes.</div>
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The characteristic of the gas will be measured by a moisture and dew point analyzer. The need of measuring moisture is related with the water content in the gas. The water vapor in the natural gas mixture doesn’t burn. Thus the excess of the water content in the gas will reduce the value of the gas. That’s why there was some gas dehydration treatment in the gas processing plant to reduce the water content as low as possible. The quality of this gas dehydration treatment will be measured again by moisture analyzer before the gas is being exported.</div>
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The need of dew point analyzer is related with the condensation of the gas product. The dew point analyzer will determine at what temperature the gas will start to condense at given operating pressure. This parameter is very important such as for gas turbine fuel. There were no allowable liquid hydrocarbons forming inside the burner. If the liquid hydrocarbon forming inside the burner, there will be a less efficient turbine, high NOx emission, and can caused several damage. The dew point analyzer will inform the end user so that they can establish a pre-heat stage before they use the gas to prevent the condensation forming. The installation and consideration of sampling system of this analyzer (dew point and moisture) shall refer to API RP 555.</div>
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All the data regarding the measured quantity and quality of the gas being exported can be monitored in the Human Machine Interface (HMI) called metering station computer. This computer is the interface between all instrument equipment and the operator. The operator can check the history, print the report, diagnose the flowmeter etc. It also the interface between the gas metering system with other control system available at the plant such as PCS (Process Control System), ESD (Emergency Shutdown) system etc.</div>
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As a conclusion, we can conclude that the gas metering system assembly consists of the following sub-skid:</div>
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<li style="margin: 0px 0px 0px 20px; padding: 0px;">Metering skid, consist of ultrasonic flow meter, pressure transmitter, temperature transmitter, pressure gauge, temperature gauge etc.</li>
<li style="margin: 0px 0px 0px 20px; padding: 0px;">Analyzer shelter, consist of gas chromatograph, dew point analyzer, and moisture analyzer.</li>
<li style="margin: 0px 0px 0px 20px; padding: 0px;">Gas metering panel, consist of flow computer and station computer (usually gas metering panel are located inside the control room).</li>
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Please take note that the mentioned sub-skid is only for simplify our understanding. For detail arrangement, we should refer to any particular project requirement. But in typical, the system will be more or less similar to the arrangement above. See below picture to get more clear understanding.</div>
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INTRODUCTION TO GAS METERING SYSTEM

In the gas producing plant (onshore or offshore), the gas metering system is the final stage of the production step before it send to the ...

Gas turbine generator control system

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Gas Turbine Generator Overview</div>
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The gas turbine generator is a combination system of a compressor, turbine, and generator. First of all, the air intake is compressed by the compressor . This compressed air will be heated by a fuel combustion process. This hot and high pressure air will be expanded in the turbine so that the turbine is rotating and producing a thrust force. This thrust force is used by the compressor itself and also to drive the electrical generator. The electrical generator then producing some electricity or electrical power for further use.<span id="more-1102"></span></div>
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There are three subsystem of the gas turbine generator system, the lube oil system, the fuel gas system, and fire & gas detection & suppression system. The lube oil system purpose is to lubricate all the bearing in the turbine. This lube oil system is using a lube oil cooler to dissipate the heat of the lube oil that coming back from the turbine bearing. The temperature and pressure of the lube oil is controlled by the temperature regulator and pressure regulator valve.</div>
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The fuel system purpose is to regulate the fuel supply so that the efficient combustion will be reached in the combustion process. The fuel supply is filtered and controlled before further use in the combustion process.</div>
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The fire & gas detection and suppression system is designed to detect any flame or gas accumulation in the turbine skid enclosure. This system will flood the enclosure with CO2 if fire is developed in the skid enclosure.</div>
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Gas Turbine Generator (GTG) Control & Safety System</div>
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In general, the gas turbine vendor is supplying a complete package of their gas turbine generator including all field instrument, fire & gas detector, and a dedicated PLC for the GTG control & safety system.  There are several process variable that need to be monitored and controlled by its dedicated PLC such as turbine temperature, exhaust temperature, lube oil temperature, fuel gas pressure, air intake pressure, fuel gas flow, enclosure flame detection, enclosure gas detection, etc. There are also several control function that need to be done by its dedicated PLC such as start-up and shutdown control etc.  See below picture to get a better understanding regarding the general gas turbine generator control system.</div>
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Gas turbine generator control system

Gas Turbine Generator Overview The gas turbine generator is a combination system of a compressor, turbine, and generator. First of all, ...

Marshalling Cabinet or Marshalling Panel

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<span style="font-family: Calibri;">As discussed in the </span><a href="http://instreng.blogspot.com/2013/03/typical-architecture-of-instrumentation.html"><span style="color: blue; font-family: Calibri;">Typical Architecture of Instrumentation and Automation System</span></a><span style="font-family: Calibri;">, the automation architecture of the plant is 
having a marshalling cabinet in between the junction box and the system 
cabinet.  This marshalling cabinet 
function is to interface the incoming field cable (which is normally a multipair 
cable) and the I/O (Input/Output) card connection. Without marshalling cabinet, 
we can sure (for large number of I/O) that there will be a trouble for operation 
personnel to maintain and operate the cabling.</span></div>
<span style="font-family: Calibri;"></span><span style="font-family: Calibri;">One of the important interface function of the 
marshalling cabinet is the cross wiring function. Cross wiring is always 
necessary since the incoming field signal and the channel quantity of the I/O 
card is always different. For example let’s say we have a 24 pair incoming field 
cable that carry 20 field analogue signal. This field signal will be split at 
least into two analogues 16 channel I/O card. The First 16 I/O will be in the 
first 16 channel I/O card and the other 4 will be in the next 16 channel I/O 
card. To have this split wiring (cross wiring) in the system cabinet is not a 
good practice from the operation and maintenance point of view. Thus the 
marshalling cabinet is needed.</span><br />
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<span style="font-family: Calibri;">Another cause of the cross wiring is the mixed of 
I/O signals that coming from the field. The incoming multipair cable can have 
mixed AI (Analaogue Input) and AO (Analogue Output) signal in the same multipair 
cable. This mixed signal will be split in the marshalling cabinet so that the AI 
signal will be terminated in the dedicated AI termination board and so do the AO 
signal.<o:p></o:p></span></div>
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<span style="font-family: Calibri;">In some application such as voting application for 
safety system (i.e. 2oo3 voting) there is a requirement to have the I/O signal 
allocated in the different I/O card so that the common fault cause can be 
avoided. This application ofcourse once again need a cross wiring in the 
marshalling cabinet.<o:p></o:p></span></div>
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<span style="font-family: Calibri;">In typical application, the marshalling cabinet is 
having the following cable routing.<o:p></o:p></span></div>
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<span style="font-family: Calibri;">1.</span><span style="font-family: 'Times New Roman'; font-size: 7pt;">       
</span><span dir="ltr"></span><span style="font-family: Calibri;">The 
multipair field cables enter the marshalling cabinet through the bottom part of 
the cabinet.<o:p></o:p></span></div>
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<span style="font-family: Calibri;">2.</span><span style="font-family: 'Times New Roman'; font-size: 7pt;">       
</span><span dir="ltr"></span><span style="font-family: Calibri;">Then each wire of the incoming multipair field 
cable is terminated in the surge protection devices or surge arrester. If there 
is no requirement of such surge protection devices, each wire is terminated in 
the terminal block.<o:p></o:p></span></div>
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<span style="font-family: Calibri;">3.</span><span style="font-family: 'Times New Roman'; font-size: 7pt;">       
</span><span dir="ltr"></span><span style="font-family: Calibri;">From the surge protection devices, in Non IS 
application, there will be a cross wiring that match the field signal and the 
I/O address assignment in the termination board. If the system is IS, then 
before cross wiring, each wire connection is routed first to the IS 
Barrier.<o:p></o:p></span></div>
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<span style="font-family: Calibri;">4.</span><span style="font-family: 'Times New Roman'; font-size: 7pt;">       
</span><span dir="ltr"></span><span style="font-family: Calibri;">The 
dedicated system cable that has a ‘plug and play’ connection is then routed from 
the termination board to the I/O card in the system 
cabinet.<o:p></o:p></span></div>
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<div class="MsoListParagraphCxSpLast" style="margin: 0cm 0cm 10pt 36pt; mso-list: l0 level1 lfo1; text-indent: -18pt;">
<span style="font-family: Calibri;">5.</span><span style="font-family: 'Times New Roman'; font-size: 7pt;">       
</span><span dir="ltr"></span><span style="font-family: Calibri;">Some termination board may require a dedicated DC 
power supply that can be taken from the DC power supply in the marshalling 
cabinet.<o:p></o:p></span></div>
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Marshalling Cabinet or Marshalling Panel

As discussed in the Typical Architecture of Instrumentation and Automation System , the automation architecture of the plant is having a ...

Motor Operated Valves

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<span style="font-family: Calibri;">Motor operated valve (MOV) is an ordinary ball 
valve or any other valve that operated by an electric actuator. In general, the 
MOV is used as isolation valves for equipment which requires regular access. The 
MOV is also used on any valve that the total energy required to open or close 
the valve manually is large. No specific reason regarding why MOV is used except 
from ease of operation point of view.</span></div>
<span style="font-family: Calibri;">The typical MOV construction consist of electric 
motor actuator, gear box, and the valve it self. First of all, the motor is 
rotated by applied an AC voltage to it. The motor rotation then transferred 
through a gear mechanism to the output thrust part. The output thrust is then 
transferred to the gear mechanism in the gear box to rotate the valve 
stem.</span><br />
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Motor Operated Valves

Motor operated valve (MOV) is an ordinary ball valve or any other valve that operated by an electric actuator. In general, the MOV is us...

Typical Architecture of Instrumentation & Automation System

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<span style="font-family: Calibri;">In general application, the instrumentation and 
automation architecture is consist of field instruments, individual & 
multicore cable, junction boxes, marshalling cabinet, and system cabinet. Each 
of them is combined together so that the control loop application can be 
performed correctly.</span></div>
<span style="font-family: Calibri;"><a href="" name="more"></a><o:p></o:p></span><br /><br />
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<span style="font-family: Calibri;">The field instruments are any of the instrument 
equipment used to measure and control the process variables. Such type of 
instruments is pressure transmitter, temperature transmitter, flow transmitter, 
level transmitter, control valves, solenoid valves etc. This device is act as a 
front liner in the instrumentation control loop.<o:p></o:p></span></div>
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<span style="font-family: Calibri;">The cables, both individual and multicore, are used 
to connect the field instruments with the controller. This cables is used as a 
signal or power transmission. First of all, the individual field instruments are 
connected by and individual cables to a junction box. This junction box is used 
to re-connect the individual cables with the respective multicore cables. So, 
instead of laid up the individual cables for each instruments to the control 
room, we laid up the multicore cables (usually comes in big size) to the control 
room.<o:p></o:p></span></div>
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<span style="font-family: Calibri;">The marshalling cabinet is used as a place to do a 
cross wiring of the multicore cables with the respective terminal block 
allocations. The arrangements of the multicore cables that come from field 
usually didn’t come in the control loop point of view. And usually, the ICS 
vendors have their own arrangement regarding their I/O module and the respective 
controller. So they do a cross wiring in this marshalling and the incoming 
multicore cables adapt the arrangement of the I/O and controller make by ICS 
vendors.<o:p></o:p></span></div>
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<span style="font-family: Calibri;">The system cabinet is used to place all the I/O 
card/module and also the controller it self. All the wire that has already 
arranged in the marshalling goes to this cabinet directly without any more 
difficult arrangement. The incoming cables comes to this cabinet has already 
tidy and match with their respective I/O channels. In this controller, the 
signal comes in and comes out from and to the field to establish a complete 
control loops. Below is the typical instrumentation architecture illustration 
that widely used in the any oil & gas projects.</span></div>
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Typical Architecture of Instrumentation & Automation System

In general application, the instrumentation and automation architecture is consist of field instruments, individual & multicore cabl...