Instrumentation in general

1. Explain the following:

a) Zero error b) span error c) Repeatability
d) Proof pressure e) adjustable range f) model number
Zero error: The linear error throughout the scale or range of an instrument.
Span error: the non-linear error throughout the scale or range of an
instrument
Repeatability: Reproduction of the same reading on its upscale and down
scale measurement.
Proof pressure: 1. times the ma!imum wor"ing pressure the instrument
body can withstand.
1
Adustable range: The range between which and instrument can be
calibrated or set.
!odel number: # uni$ue instrument identification number pro%ided by the
manufacturer.
". #hat is $swit%h differential& on a pressure'temperature'le(el'flow
swit%h)
The &switch differential' is the difference between the switch &actuation' and
&reset' points (%alues).
*. +ow to sele%t a measuring instrument or a swit%h for a parti%ular
pro%ess)
)ollowing parameters are to be considered while selecting an instrument for a
process application.
- process chemical characteristic
- process normal operating pressure
- process ma!imum wor"ing pressure
- the re$uired measurement range or the re$uired set point
,. Explain the differen%e between $line brea- prote%tion& and a $line brea-
dete%tion& system)
.ine brea- prote%tion: it is to pre%ent the process line brea" due to e!tra
high pressure. )or e!ample: the high-pressure switch in the station oil
discharge line.
.ine brea- dete%tion: it is to detect the process line brea". )or e!ample: the
low-pressure switch in the gas lift manifold.
/. Explain the following with its appli%ation areas.
a0 !i%ro swit%h b0 limit swit%h %0 proximate
!i%ro swit%h: *mall changeo%ers switch ha%ing a common+ normally open
and normally closed terminal. ,ften used in -nstrument *witches.
.imit swit%h: changeo%er switch ha%ing a common+ normally-open and
normally-close terminal. ,ften used on .*/0 status detection and in the door
operation.
Proximeter: wor"s on the change in magnetic flu!. ,ften used on .*/0
status detection and in the door operation.
1. #hat is a $solenoid (al(e&) +ow does it wor-)
2
# solenoid is a coil wrapped around a piece of iron. 1hen power is applied to
the coil the iron piece becomes a temporary magnet and it pulls the plunger
up. The plunger in turn changes o%er the port connections on the %al%e.
2.+ow many types of solenoids are there)
There are basically two types of solenoids. They are:
1. 2ormally closed type and 3. 2ormally open type
3.+ow many port solenoid (al(es are there)
There are many different port configuration solenoids a%ailable. # few of the
commonly used solenoid %al%es are:
3port solenoid %al%e+ 4port solenoid %al%e+ port solenoid %al%e and 5 port
solenoid %al%e6etc.
4.what is a $relay&) 5raw a s-et%h of a simple relay.
3
#n electrical relay consists of a coil with an iron core at the centre (solenoid)
and a set of %oltage free contacts. 1hen power is applied to the coil the iron
core at the centre becomes a temporary magnet and pulls the plunger+
thereby all the %oltage free contacts simultaneously change their polarity from
closed to open and open to closed.
Relays are a%ailable with %arious operational %oltage such as 130 /7+ 30
/7+ 1180 #7+ 380 #7 6etc.
Relays are a%ailable with different %oltage free contact types+ such as single
pole double throw+ single pole single throw6etc.
Relay contact status is always shown in the relay's de-energi9ed (no power)
condition.
16. #hat is a (oltage free %onta%t)
These are the relay's contacts that wor" independent of the relay coil power
supply. )or e!ample: the relay coil may be operating on 3 0 /7 and its
contact may carry 380 #7 to operate another piece of e$uipment.
11. 5raw a simple start and stop %ir%uit.
1". #hat is memory lat%h'self holding %onta%t)
&:emory latch' is the function initiation that is held in the memory until it is
erased. -n the abo%e drawing:
*tart push button is a spring return wired for normally opens.
*top push button is a spring return wired for normally closed.
Relay R1 is energi9ed and its contact selection is normally open.
,nce the start push button is pressed and released the relay R1 energi9es
and its first pair of contacts change from normally open to closed and holds
the relay R1 energi9ed. The relay contact R1-1 remembers that the start was
initiated and "eeps in the memory. The memory gets erased once the button
is pressed.
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1*. #hat is an $interfa%e relay&) #here is it used)
-t is a relay e!clusi%ely used as an interface between two separate power
supply operations or between two different logic operations. )or e!ample+ 30
/7 logic starting an electrical hea%y duty motors6etc.
1,. #hat is a $timer&)
Timer is an electrical relay consisting of a coil with an iron at the centre
(solenoid) and a set of %oltage free contacts that change o%er after a preset
time+ depending on the type of the timer.
1/. +ow many types of timers are there)
There are basically two types of timers. They are:
7ime delay pi%-8up 9 75P:: 1hen power is applied to the timer coil
(energi9ed)+ its contacts change o%er after the present time. 1hen the power
is remo%ed from the coil (de-energi9ed)+ its contacts change o%er
instantaneously.
7ime delay drop8out 9 755;: 1hen power is applied to the timer coil
(energi9ed)+ its contacts change o%er instantaneously. 1hen the power is
remo%ed from the coil (de-energi9ed)+ its contacts change o%er after the
preset time.
# combination of &time delay pic"-up' and &time delay drop-out' timer is also
a%ailable.
11.#hat is an $ele%tri%al safety barrier)
.lectrical safety barrier is an instrument used to pro%ide a separation between
intrinsically safe and non-intrinsically safe part of the instrument loop.
2ormally this segregation is pro%ided between the control room and the field
instruments.
12.+ow many types of safety barriers are there)
)ollowing are the commonly used safety barriers:
7urrent limiter
0oltage limiter
-nterface %oltage free contact barrier
13. +ow does a safety barrier wor-)
;enerally e%ery barrier is protected by a fuse+ 9ener diode+ resistor and
earthing system.
)use protects the circuit against high current drawn.
Zener diode maintains the ma!imum %oltage le%el across the terminals
Resistor restricts dead short grounding.
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"6. #hat is an $and gate&) <i(e an example.
-n an &and gate' all the input conare
re$uired to close to energise a relay.
-n a digital input+ all the inputs should be &1' to get an out put of &1'.
-n the drawing+ the relay contact &R1-1' and R3-1 should close to energies the
relay R4.
A typical example of an and gate
"1.#hat is an $or gate&) <i(e an example.
-n an &or gate' any one input contact is re$uired to close to energies a relay.
-n a digital input+ any one input should be &1' to get an output of &1'.
-n the drawing+ either the relay contact &R1-1' or the &o%erride' "ey contact
should close to energies the relay R4.
6
"". #hat is a $nor gate&) <i(e an exam
A typical example of an nor gate
-n a & nor gate' all the contacts are re$uired to be open energise a relay.
-n a digital inputs+ all the inputs should be' 8' to get an output of &1'.
-n the abo%e drawing+ the relay contact &R1-1' and the relay contact R3-1 must
be open to energise the relay R.
"*.#hat is a $primary element& and $ final =end0 element&)
Primary element: -t is the sensor which senses the process to be measured
or monitored+ such as a pressure+ temperature+ le%el+ flow transmitters
thermocouple+ RT/6etc.
>inal element: -t is the end element used for controlling the process
parameters+ such as a control %al%e+ -;0+ go%ernor6etc.
",.#hat $air supply pressure& is re?uired for a pneumati% transmitter)
#ir supply to a pneumatic instrument is 18"pa or 38psi
"/.#hat is the output of a pneumati% transmitter in psi and -pa)
,utput of a pneumatic transmitter is 38-188"pa or 4-15psi.
"1.what is the fun%tion of a $relay& in a pneumati% transmitter)
# relay in a pneumatic instrument wor"s as a proportional booster to transmit
the transmitter signal a long distance. Pneumatic relay amplifies the flapper-
no99le bac" pressure.
"2.#hat is a $negati(e feed ba%-& =for%e balan%e0 prin%iple)
2egati%e feedbac" is to balance the process pressure caused on the force bar
by the sensor+ to achie%e a balanced (pre-ranged) output. -f there is no
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negati%e feedbac" the output will saturate to a minimum or ma!imum for a
small deflection by the sensor.
"3.#hat will be the output of transmitter if the no@@le is blo%-ed)
-f the transmitter no99le is bloc"ed+ the transmitter output will go to ma!imum.
"4.#hat is the fun%tion of a relay restri%tion in a pneumati% transmitter)
# relay restriction is pro%ided to minimi9e the no99le pressure on the flapper.
*6.#hat will be the relay&s outputA if a flapper8no@@le&s output is /6-pa)
The relay output will be 58"pa. # pneumatic relay proportionately boosts the
flapper-no99le output in an instrument.
*1.#hat supply (oltage re?uired for an ele%troni% transmitter)
*upply %oltage to an electronic transmitter is 3-3<0 /7.
*".#hat is the output of an ele%troni% transmitter)
,utput of an electronic transmitter is -38 m#.
**.#hat is a $sensor& in transmitter) +ow many types of sensors are
there)
# sensor is part in a primary element used for sensing the process
parameters. ;enerally sensors are a%ailable in &low'+ medium' and &high'
ranges.
*,.#hat is the fun%tion of range sele%tion umper on an ele%troni%
transmitter)
Range selection jumpers on the amplifier are used to arrange the transmitter
calibration range to &narrow'+ &medium' or &wide' range.
*/.#hat is the ad(antage of a lo%al re%order =example: !8,60)
=ocal recorders are used as a temporary recording facility near the process
measurement point. ;enerally it is used for obser%ation+ study or for a
troubleshooting purposes. )or e!ample: well head pressure recording+ %essel
le%el recording6etc.
*1.#hat is a $re%ei(er type& and a $sensor type& lo%al re%order)
Re%ei(er type: where the recorder element recei%es the process 38-188"pa
signal through a transmitter.
Sensor type: where the recorder element directly senses the process
pressure.
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*2.#hat has to be done to re8range a lo%al flow re%order =example: !8
,60)
The recorder's sensor & range spring' has to be replaced to suit the recorder's
new rang+ then re-calibrate the recorder.
*3.#hat pre%aution has to be ta-en while wor-ing on a transmitter used
in a %ontrol loop)
To wor" on a transmitter used in a control loop+ the controller has to be in
manual from auto mode. # continuos watch on the process parameter is
re$uired.
*4.#hat is a signal sele%tor relay) <i(e an example with the inputs and
outputs.
There are two types of signal selector relays: &low signal selector' and high
signal selector' relay.
=ow signal selector: it accepts two or more input signals and the output is the
lowest of the input signals.
>igh signal selector: it accepts two or more input signals and the output is the
highest of the input signals.
,6.#hy is a %omputing relay =Sortberg0 used in an $anti8surge %ontrol&
system) #rite its output formula.
7omputing relays are used for multiplying and di%iding the input signals.
The computing relay used in the solar anti-surge control panel is to measure
the &true' flow with respect to the design parameters. The flow measured
across the orifice plate is measured against the discharge pressure. The
following is the computing relays output formula:
,ut put ? @ (flowAt!Aoutput - 38) 6(dish.pressAt! A output- 38) B38
,1.#rite the expansion form of $I<B&) #hat does it do) <i(e some
examples of where it is used)
-;0 stands for & inlet guide %ane'.
-;0s are used to control an inlet flow (load) where the e$uipment speed is
constant.
)or e!ample: the blower -;0 controls the inlet gas flow
-;0 inside a gas turbine controls the inlet airflow
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Pro%ess in general
Separators
1.what is the separator ba%- pressure) #hat happens if a separator&s
ba%- pressure is in%reased or de%reased)
*eparator bac" pressure is the pressure maintained on the li$uid surface.
:aintaining the uniform bac" pressure is critical. Rising in the bac" pressure
may result in less production of oil and %ice %ersa.
".why is ba%- pressure maintained in a separator)
*eparator bac" pressure maintained to push the oil from the separator to the
surge tan" and also to pro%ide a steady suction pressure to the compressors
and blowers.
*.#hat is a separator) Explain the parameters measured during a well
test.
# %essel used in gathering station for conducting a 4 phase tast of
the process fluid+ such as oil+ gas and water.
4 phase test is to measure the $uantity of oil+ gas and water (C*1)
a well can produce for the "nown $uantity of gas injection (gaslift) and the
opening of the cho"e (bean)
.ach test separator is used for testing only one well at a time.
Though a well is normally tested for 3hrs. at times+ period tests are
also conducted.
,.#hat is the fun%tion of a $net oil %omputer& in a test separator&s
pro%ess measurement)
# process of computing the C*D1 (water) in the gross oil.
The loop in%ol%es a field capacitance chamber (Bcapacitance probe) in the oil
outlet line+ an oil turbine meter+ a capacitance di%iding unit in the control room.
The flow measured by the oil turbine meter is sent to the 2,7* unit where it
di%ides the oil flow measured by the turbine meter into net oil and C*D1.
/.#hy is separator&s gas output generally than the gas input =gas lift0)
;as from a test separator is appro!imately e$ual to the sum of gas injected
into the well through gaslift+ and the gas produced by the well.
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1.#hat happens to the well %onne%ted to a test separator when the test
separator shutsdown)
1hen a test separator shutsdown and its inlet .*/0 closes+ the oil is di%erted
to the bul" separator through a bypass %al%e.
2.5raw a s-et%h of a test separator and identify the instrument
%omponentsA %ontrol loop and ES5Bs.
A typical test separator P&I
3.#hy is a high pressure swit%h pro(ided on a separator) #hat is the
shutdown setting on it)
>igh pressure switch is pro%ided on the test separator to protect it against the
process high pressure. >igh pressure switch is set at 88"paE (Refer to the
station drawings for the exact setting parameters)
4.#hat may happen if the high le(el swit%h fails to dete%t a high le(el in
the separator)
-f the high li$uid le%el switch fails to detect a high le%el+ the process li$uid will
carry o%er into the gas discharge line to the compressors+ blowers and to the
flare.
16.#hat may happen if the low le(el swit%h fails to dete%t a low le(el in
the separator)
-f the low li$uid le%el switch fails to detector a low le%el+ the process gas
pressure may enter the surge tan" and may possibly rapture the surge tan"+
which is a low pressure %essel.
11.Explain the fun%tion of all the ES5Bs of a test separator.
11
-nlet pressuring .*/ is to balance the pressure across the inlet .*/.
-nlet main .*/ is to close in case of any emergency.
Cy-pass %al%e to di%ert the well flow to production separators in case
the inlet .*/ closes.
,il outlet .*/ to surge tan".
1ater outlet .*/ to surge tan".
)low line balance .*/ between the oil and water compartments.
1".#hy is a field reset push button pro(ided for opening'%losing an
ES5B)
The field reset push button in the field for each .*/0 is to ensure that the
area and the process around+ is healthy before opening the .*/0.

Surge tan-
1.#hat is the appli%ation =purpose0 of a surge tan- in an oil station)
# surge tan" is a storage tan"+ it recei%es oil from the production and test
separators. *urge tan"s pro%ide higher capacity and stability to the li$uid.
There are two surge tan"s in e%ery gathering station wor"ing in a parallel
mode. #lso the surge tan"s separates the #P (atmospheric) gas from the
crude oil. -t also pro%ides a buffer function to the transfer pumps.
".#hat are the ad(antage of two surge tan-s in an oil station)
Two surge tan"s pro%ide for higher capacity and stability to the li$uid.
.ach surge tan" can be ta"en for maintenance separately.
*.#hat is the height of a surge tan- in an oil station)
.ach tan" is F.15 :ts. (48 feet) in height+ ha%ing a capacity (%olume) of 1G<8
CC=H3GI :4 (refer to the station drawings for the e!act parameters)
,.#rite the formula for %al%ulating the surge tan- oil le(el in -pa)
=i$uid head in "pa ?pgh
p? /ensity of the li$uid
g? ;ra%ity
h?>eight of the li$uid column
/.#hat is $blan-eting gas) #hat does it do)
&Clan"eting gas' is a gas phase maintained abo%e the oils surface. The
blan"eting gas restricts atmospheric air entering inside the tan"+ pre%enting an
e!plosi%e gas mi!ture in the tan".
12
1.#hat is a normal surge ran- blan-eting gas pressure)
Clan"eting gas is maintained at 8.5 J 1.8 "pa pressure (refer to the station
drawings for the e!act parameters) through a regulator abo%e the li$uid
surface.
2.#hat is a Cdehydration tan-D) <i(e an example)
/ehydration tan" is a settling tan"+ specifically used for separating water from
the crude oil. )or e!ample: the big storage tan"s used in the main pumping
stations at )ahud+ Karn #lam+ Libal6etc.
3.#hat is $s-imming& in a 5ehydration 7an- operating pro%ess)
-t is a process for reco%ering oil from dehydration water.
4.#hy and what sort of instrumentation is pro(ided on s-imming line)
;enerally a capacitance probe is installed to detect the water in the oil line.
16.#hat is the differen%e between an atmospheri% flareA low pressure
flare and a high pressure flare) <i(e some examples.

Atmospheri% flare: the flare used to went %ery low pressure gas to
atmosphere. )or e!ample: the flare line from a surge tan" top.
.ow pressure flare: the medium pressure flare+ generally used for the
process line. )or e!ample: station bac" pressure to flare.
+igh pressure flare: the flare used for flaring the spill o%er gas from the >P
(high pressure) grid to flare.
Pump
1.#rite the manual operating se?uen%e of a pump =start and stop0.
*tart se$uence:
- open the suction %al%e full
- Cleed the pump casing to ensure that there is no trapped gasHair.
- ,pen the discharge %al%e partially.
- -nitiate a start to the electrical motor.
- ,pen the discharge %al%e fully.
*top se$uence:
- -nitiate a stop to the electrical motor.
- 7lose the discharge %al%e fully.
- 7lose the suction %al%e fully.
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1.#hat is a $line brea- prote%tion& system)
-n is to pre%ent a process line brea" due to e!tra high pressure.
)or e!ample: the high pressure switch on the station oil discharge line.
".5raw a small s-et%h of a pumpA showing the in8boardA out8board and
thrust bearing lo%ations.
*.#hat is $%a(itation& in pump operation) #hat are the symptoms of
%a(itation in a pump)
7a%itation is an abnormal operating situation where the pressure of the li$uid
is reduced below its %apour pressure+ gas will brea"out. -f the pressure is
reco%ered abo%e the %apour pressure+ the gas bubbles will implode again.
This process is called &ca%itation'. -t can cause serious damage to the pump. -f
a pump is ha%ing ca%itation problems the following abnormalities are noticed.
- low or no discharge pressure
- low or no discharge flow
- abnormal sound (gra%el flowing sound)
- high casing temperature
- 6.tc.
P.S:cavitation can also occur in control valves.
,.#hat may happen to a pump if it is operating at a high dis%harge
pressure)
-f a pump is operating on a high discharge pressure the following may
happen:
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- Pump seal may lea".
- *hutdown on high casing temperature.
- 6etc.
/.explain the te%hni?ues =methods0 of %ontrolling a tan- le(el through a
motor dri(en pump.
Tan" le%el can be controlled by the following two methods:
Eontrol loop with a le(el %ontrol (al(e:
# normal motor dri%en pump and a le%el control loop on the tan" with a la%el
control %al%e in the discharge line can control the tan" le%el. =e%el control loop
measured and controls the tan" le%el by closing or opening the pump
discharge line le%el control %al%e. >ere the pump rotates at a constant speed.
Eontrol loop with a turbine'motor speed %ontrol:
.ither with a gas turbine or a %ariable speed motor+ a pump can control the
tan" le%el. Tan" le%el controller output may be fed to the gas turbine or motor
to %ary its speed to maintain the tan" le%el. (2ote: in this loop there is no le%el
control %al%e).
1.list the shutdown prote%tion system generally installed on a pump.
;enerally+ the following alarm and shutdown protection are pro%ided on a
pump:
.ow su%tion pressure:
pressure switch is set at 4.5"pa M (Refer to the station drawings for the
e!act setting parameters)+continuously monitoring the pump suction pressure.
2ormal suction pressure to the pump is from the surge tan"'s static head of
around 4G"pa.
-n case the pump gets a low suction pressure below 4.5"pa+ the switch
initiates only:
- &=ow suction pressure' alarm on the control panel.
-f the alarm condition e!ists for 18sec. Then the logic initiates:
- &=ow suction pressure' alarm on the control panel.
- The pump shutsdown (18sec delayed shutdown).
- Pump shutdown status is sent to *7#/#.
Pump bearing high temperature:
NjO type (iron constantanHiron) thermo-couples on the pump inboard and
outboard bearing+ continuously record and monitor the bearing temperatures.
-n case the bearing temperature e!ceeds FG
8
c (Refer tot the drawings
for the e!act setting parameters)+then the logic initiates:
- &>igh pump bearing temperature' alarm on the control panel.
- The pump shuts down.
- Pump shutdown status is sent to *7#/#.
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Pump %asing high temperature:
NjO type (iron constantanHiron) thermocouple on the pump casing
continuously records and monitors the casing temperature.
-n case the casing temperature e!ceeds <8
8
c (Refer to the station
drawings for the station drawings for the e!act setting parameters)+ then the
logic initiates:
- &>igh pump casing temperature' alarm on the control panel.
- The pump shutsdown.
- Pump shutdown status is sent to *7#/#.
!e%hani%al seal lea-:
#n on-line mechanical seal pot (a float chamber) in the seal drain
continuously measures any lea" abo%e the set limit (through the drain
restriction). -n case of the lea"+ the switch initiates:
- &>igh seal lea"' alarm on the control panel.
- The pump shutsdown.
- Pump shutdown status is sent to *7#/#.
!otor bearing temperature:
NjO type (iron constantanHiron) thermocouples on the motor inboard and
outboard bearing+ continuously record and monitor the bearing temperatures.
-n case the bearing temperature e!ceeds F8
8
c (refer to the station
drawings for the e!act setting parameters)+ then the logic initiates:
- >igh motor bearing temperature' alarm on the control panel.
- The pump shutsdown.
- Pump shutdown status is sent to *7#/#.
2.At what F of the dis%harge !;B opening does the main motor start
and why)
The main motor starts at 18P opening of the discharge :,0 (refer to the
station drawings for the e!act setting parameter). This is to pre%ent the main
motor tripping on o%erload.
3.what is $series& and $parallel& pumps) 5raw a small s-et%h of the both
types of pump installations.
Series pumps: while both pumps are running+ one pump discharges goes to
the suction of the other pump.
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Parallel pumps: while both pumps are runing+ both pumps discharge the
li$uid to a common header.
4.Explain the ad(antages'purpose of series and parallel pumps.
Series pumps: pumps in series can discharge the li$uid at higher pressure.
Parallel pumps: pumps in parallel can discharge more %olume of li$uid.
16.#hat %are has to be ta-en while starting a series pump)
To a%oid seal failure due to high suction pressure+ first start the second pump
in series prior to starting the first pump.
11.#hat is the purpose of a pump dis%harge $high pressure swit%h&)
Pump discharge &high pressure switch' wor"s as a line brea" protection
switch. -t shutsdown the pump at a set high pressure+ thus pre%enting the line
brea".
<as lift
1.#hat is gaslift flow) #hat does it to)
17
-t is a process for lifting the oil from an oil-well by injecting a "nown
$uantity of high pressure gas.
The rate of gas lift flow (injection) is determined by the production
programmer based upon the well-test result.
".#hat is $line brea- dete%tion& system)
=ine brea" detection system is to detect a process line brea".
)or e!ample: the low pressure switch on the gas lift manifold.
*.#hat does indi(idual gas lift pressure represent)
-ndi%idual gas lift pressure represents the amount of pressure re$uired to lift
the li$uid column in the oil well.
,.#hy is there a pressure swit%h downstream of the %ontrol (al(e in gas
lift)
The pressure switch wor"s as a line brea" detector. -f the gas lift line brea"s
the process pressure drops downstream of the control %al%e and the pressure
switch shutsdowan (closes) the control %al%e. There is no alarm facility for this
detection system.
/.#ht will happen to the gas lift flowA when an oil will ?uits)
-f the oil well $uits+ the gas lift flow becomes 9ero.
1.#hat will happen to the gas lift pressureA when an oil well ?uits)
-f the oil well $uits+ the gas lift pressure saturates the upstream pressure.
2.#hy is the gas lift flow rate =flow set point0 different for e(ery oil well)
The gas lift flow setpoint is set to deri%e the ma!imum oil output to the
minimum gas out. #lso the gas lift flow set point depends on the oil well depth+
process line si9e and cho"e %al%e bac" pressure.
3.#hy is there no gas lift flow for some oil wells)
*elf flowing wells do not re$uire gas lift.
4.#hy are there so many gas lift sele%tor swit%hes on the sele%tor box)
.ach gas lift selector switch is meant for one particular gas lift. ;as lift
selector bo! will ha%e switches for as many number of gas lifts in the field.
16.#hat will happen to the gas lift %onne%ted to a parti%ular separator
when the separator inlet ES5B %loses)
18
1hen the separator inlet .*/0 closes+ all those gas lifts selected on the gas
lift selector bo! will shutdown (by closing the gas lift control %al%e through a
solenoid %al%e).
Station in general
1.+ow is the station ba%- pressure %ontrolled in se?uen%e through gas
turbinesA blower and station ba%- pressure (al(e) 5raw a simple s-et%h
and explain.
>un%tion
# method of controlling the =P and >P gas in an oil gathering
station.
-t also wor"s as part of the gas optimi9ation program+ by minimi9ing
the gas to flare.
This control system came into force after the installation of &)o!trot'
gas compression station and the blowers in fahud oil gathering stations.
The control system is incorporated in )ahud &b' &c' &d' and &e'
gathering stations.
;peration
# master suction pressure set point is deri%ed to the Clowers+ *olar gas
compressors and the station recycle %al%e by a reduction of 4"pa respecti%ely.
)or e!ample:
:aster suction pressure set point set at 158"pa+ goes to the following:
- blower suction pressure controller as 158"pa
- solar suction pressure controller as 1I"pa
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- station recycle controller as 14"pa
#hat happens in these %ondition is:
.ow su%tion header pressure
since the Clower's suction pressure set point is the highest+ the
blower effecti%ely closes the -;0 to bring up the suction pressure by
reducing the e!port to &f' station.
)urther if the suction bac" pressure goes down+ the solar turbine
whose suction pressure set point is ne!t in the order+ lowers its speed to
bring up the suction pressure.
#s a last control+ the station recycle %al%e opens to maintain 14"pa
in the suction header by deli%ering the gas compressor discharge to the
common suction header.
The condition may occur due to a separator shutdown+ low gas
proFduction+ oil wells $uitting+ gas lift failure.
+igh Glower dis%harge pressure
The Clower discharge pressure controller output o%errides its suction
pressure controller output and closes it s -;0 to bring down the high
discharge header pressure.
The condition resets automatically when the discharge pressure
becomes normal.
This control system is to pre%ent any Clower discharge line
brea"age.
The condition may occur due to any Ruston turbine shutdown or
turbine low speed in &f' station.
+igh solar %ompressor dis%harge pressure
The solar discharge pressure controller output o%errides its suction
pressure controller output and the turbine speed is brought down to a
ma!imum of its minimum discharge flow (just abo%e its indi%idual recycle
%al%e opening).
The condition resets automatically when the discharge pressure
becomes normal.
This control system is to pre%ent any gas compressor discharge line
brea"age.
The condition may accur due to a gas injection well $uitting+ many
gas lift injection has closed or >P grid header pressure going high.
.ow .ow su%tion header pressure at 1,*-pa
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The station recycle %al%e opens and puts the gas compressor
discharge into the suction header.
This is to pre%ent the *olar and Clower from a low suction shutdown.
,n a %ailability of the suction gas pressure+ the solar turbine will
speed-up and the /emag Clower's -;0 will open full.
The condition may occur due to two or more separators ha%ing
shutdown in the station.
*.#hy is there an $oil sa(er pit& at an oil station)
,il sa%er pit collects all the low pressure li$uid that drains from the separators+
scrubbers+ tan"s6etc.
,.7o whi%h point does the $sa(er pit& pump dis%harge the oil)
,il sa%e pit pump discharges the oil to the suction of the station transfer
pumps.
/.7o whi%h point are the %ompressor&s high pressure s%rubbers
drained)
;as compressor high pressure scrubber drains are connected to the
separator's inlet header.
1.#hat is a $%y%lone separator&) #hat is the differen%e between an
ordinary s%rubber and a %y%lone separator)
/uring its operation as the name says+ the &cyclone separator' ma"es a
cyclone noise. -n a cyclone separator+ the process gas enters the separator at
a tangential angle. -n other scrubbers the process gas enters at the center of
the center of the %essel.
2.#hat is an $oil manifold&) #hat is the ad(antage of an oil manifold)
# junction where all the oil wells join together to a specific main
header.
-t is used for di%erting a well to the re$uired separator.
# cho"e may be in line with the manifold to maintain the well bac"
pressure.
-t also helps in balancing the load among the separators.
A#AREHESS IH <EHERA.
1. #hat are the following gases:
a0 ri%h gas b0 lean gas %0 sour gas
Ri%h gas: # gas containing condensate or wet gas. # gas from a gas well or
an oil well.
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.ean gas: # dry gas produced through an 2;= or gas plant. # gas without
condensate.
Sour gas: # gas containingHcontaminated with >3*. *pecial care has to be
ta"en while handling this gas. -t is corrosi%e and health ha9ardous. *tations
handling sour gas are generally designated as >
3
* areas.
". #here are the following items:
a0 propane b0 gly%ol %0 shellsol d0 lube oil e0 %hemi%al ine%tion
Propane: propane is a hydrocarbon+ in the li$uid form it is used - a chillier
(heat e!changer) to cool a gas.
<ly%ol: -t is a hygroscopic chemical used for absorbing water from a
process fluid. ;lycol is regenerated (water is remo%ed) by heating in a heater
up to 188 /eg 7 and circulated bac" to the process operation.
Shellsol: # chemical used for cleaning rusty parts. >and glo%es ha%e to
be worn for the safe handling of shellsol.
.ube oil: #n oil e!clusi%ely used for lubricating and cooling a bearing+
shafts6etc. The grade and $uality of lube oil depends on the e$uipment
operation and speed.
Ehemi%al Ine%tion: # process of injecting and chemical into a process
to achie%e a certain process re$uirement.
*. #hat are the following:
a0 ;il well b0 gas well %0 gas ine%tion well d0 water well
e0 water ine%tion well
;il well: # well which produces crude oil and gas.
<as well:# well which produces only gas.
<as ine%tion well: #n abandoned or specifically drilled dry well+ used for
injecting the e!cess gas produced in an oil gathering station.
#ater well: # water supply well used for la feed to an R, plant or for
injecting into a water injection well.
#ater ine%tion well: #n abandoned oil well or a well specifically drilled
for injecting the water produced in an oil gathering station.
,. #hat is the fun%tion of the following:
a0 ;il rig b0 wor-8o(er rig %0 seismi% sur(ey d0 water rig
;il rig:#n unit used for drilling an oil or gas well.
#or- o(er rig: # rig used specifically for wor"ing on an e!isting oil or gas
well.
Seismi% sur(ey: # team searching and estimation of oil and gas reser%es.
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#ater rig: #n rig used for drilling a water supply well.
/.#hat are these stations:
a0 ;il station b0gas station %0booster station d0H<. e0R.;. plant
a0 !ain pumping station I0 fire water pumping station
;il station: a station for collecting (gathering) the crude oil from an oil field.
The process may in%ol%e the separation of oil and gas+ compression of the
gas+ re-injection of the gas to oil wells+ storage and e!port of the crude oil to
the main tan" form.
<as station: a station purely used for handling gas. The process may in%ol%e
the remo%al of sulfur+ water+ 2;=6etc. the inlet gas to the station is a rich gas
(wet gas) and the outlet is a lean gas (dry gas).
Gooster station: an intermediate station used to boost the flow rate when the
recei%ing station is far away from the main pumping location.
H<.: a process plant for li$uefying the natural gas by compressing and
cooling the gas. The plant recei%es rich gas for compression and cooling to
remo%e the =P; (li$uid petroleum gas). The gas discharge from the plant is a
lean gas (dry gas)
R.;.Plant: re%erse ,smosis Plant. # plant that pro%ides good $uality drin"ing
water with a balanced p> and free of micro-organism and salt.
#ater Ine%tion Plant: a plant e!clusi%ely used for pumping dehydrated water
into the water injection wells.
H;ES: crude oil stabili9ation plant. The plant process in remo%ing the
dissol%ed gas from crude oil before e!porting the oil for shipment.
!ain oil pumping station: a station where the oil gathered from all the
stations is pumped prior to being sent to :#).
>ire water8pumping station: a station e!clusi%ely used for pro%iding the
firewater to the fire hydration system using electrical and emergency bac"-up
diesel pumps.
1.Explain the meaning of the following words:
a0 >lash point b0 ignition point
)lash point: the temperature at which a petroleum product ignites momentarily
(without a separ")+ but does not burn continuously
-gnition point: the temperature at which a petroleum product ignites in
presence of air.
2.#hat is a double blo%- Ibleed system)
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# double bloc" and bleed %al%e is a safe practice for isolating and de-
pressuri9ing a process line. -n this process the upstream and downstream of
the process line is isolated to ensure total bloc"ing of the process+ and the
process is bled to where the wor" is to be carried out.
3.#hat are the ad(antages of 5ES o(er the SPEE8"66 %ontrol system)
/7* stands for distributed control system. There are many ad%antages of
/7* o%er the *P.7388 system+ which is almost outdated. The following are
some of the ad%antages of the /7* system.
2umber of instruments on the control panel is minimi9ed to a 0/Q
(%isual display unit).
# graphical interface of the station PD- on the 0/Q.
Time trend of the process parameter can be seen read and
recorded.
Remote control operation facility.
)ast operation and minimum.
7ontrol parameters settings can be easily changed.
7ontroller tuning can be easily adjusted.
The PD- loop can be easily modified.
=ong duration of history can be logged and recalled.
# ma!imum number of control loops can be operated.
Proportional J integral:
-n this case+ an e!tra bellows with %ariable restriction is added to the system.
*uppose input pressure shows a sundden increase. This dri%es the flapper
towards the no99le+ increasing output pressure until the prop. Cellows
balances the input as in the pre%ious case. The integral bellows is shill at the
original output pressure because the restriction pre%ents. pressure changes
from being transmitted immediately. #s the increased pressure on the output
bleeds through the restriction. the integral bellows slowly mo%es the flapper
closer to the no99le. There by colnsing a steady increase in output pressure
(as dictated by the integral mode)the %ariable restriction allows for %ariation of
the lea"age rate and hence the integration time.
Proportional J deri(ati(e:
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-n this case a %ariable restriction is placed on the line leading to the balance
bellows+ thus as the input pressure increases+ the flapper is mo%ed towards
the no99le with no impedance because the restrictions pre%ent an immediate
response of the balance bellows. Thus the output pressure rises %ery fast and
then+ as the increased pressure lea"s in to the balance bellows+ decreased as
the balances bellows mo%es the flapper bea" away from the no99le
adjustment of the %ariable restriction allows for changing the deri%ati%e time
constraint.

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