Petroleum Development Oman L.L.C.
Document Title: Chemical Injection
Document ID
Document Type
Security
Discipline
Owner
Issue Date
Revision
PR-1103
Procedure
Unrestricted
Operations and Engineering
Functional Operations Manager - UOP
January 2012
3.0
Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor
any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.
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PR-1103 – Chemical Injection
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i
Revision: 3.0
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Document Authorisation
Authorised For Issue – January 2012
Page 3
PR-1103 – Chemical Injection
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ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details
of all revisions prior to these are held on file by the issuing department.
Revision No.
Date
Author
Scope / Remarks
3.0
Jan-12
Robin Norman UOP6
Full Review and Update to new format
2.0
Oct-07
UOP6
Reformatted and revised as required
Sep-01
UOP1
Reviewed and Revalidated
iii Related Business Processes
Code
Business Process (EPBM 4.0)
EP.71.02
Operate Wells and Facilities
iv Related Corporate Management Frame Work (CMF)
Documents
The related CMF Documents can be retrieved from the CMF Business Control Portal.
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PR-1103 – Chemical Injection
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TABLE OF CONTENTS
i
Document Authorisation ......................................................................................................... 3
ii
Revision History ..................................................................................................................... 4
iii
Related Business Processes ................................................................................................. 4
iv
Related Corporate Management Frame Work (CMF) Documents ........................................ 4
1
Introduction ............................................................................................................................ 6
1.1
Background ...................................................................................................................... 6
1.2
Purpose ............................................................................................................................ 6
1.3
Distribution / Target Audience .......................................................................................... 6
1.4
Changes to the Document................................................................................................ 6
1.5
Step-out Approval ............................................................................................................. 7
2
Roles and Responsibilities ..................................................................................................... 8
3
Chemical Injection Procedure ................................................................................................ 9
3.1
Scope ............................................................................................................................... 9
3.2
Safety Considerations ...................................................................................................... 9
3.3
Chemical Injection .......................................................................................................... 10
3.3.1
Starting Chemical Injection System ......................................................................... 10
3.3.2
Shutdown of Chemical InjectionSystem .................................................................. 12
3.3.3
Operator Checks during Operation of the Chemical Injection System .................... 12
Appendix 1 – Abbreviations ......................................................................................................... 13
Appendix 2 - User Feedback Page ............................................................................................. 14
…
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PR-1103 – Chemical Injection
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1
Introduction
1.1
Background
Revision: 3.0
Effective Jan-12
Chemicals are used in the production processes to:

Inhibit corrosion within vessels and pipelines;

Prevent the formation of scale;

Break down emulsions in the process fluids;

Inhibit foam generations in vessels;

Reduce or prevent bacteria formation / build-up;

Reduce or prevent the risk of hydrate formation (gas wells);
Types of chemical and injection rates shall be decided by the Production Chemists and /
or Corrosion Engineers. The chemical injection programme will be implemented by
Production Operations or contract companies.
NOTE: UEOC are the Technical Authority for all chemicals used for the Material Integrity
e.g. corrosion and UIK are the Technical Authority for all the chemicals used Flow
Assurance.
1.2
Purpose
The purpose of the procedure is to ensure a consistent approach throughout PDO for
the handling of chemicals during preparation and the use of injection equipment.
1.3
Distribution / Target Audience
This procedure is intended to be referenced and used by:
1.4

Production Supervisors

Production Operators

Contract Personnel
Changes to the Document
Responsibility for the upkeep of the Document shall be with the Functional Production
Manager UOP, the Owner. Changes to this document shall only be authorised and
approved by the Owner.
Users of the Document who identify inaccuracy or ambiguity can notify the Custodian or
his/her delegate and request changes be initiated. The Requests shall be forwarded to
the Custodian using the “User Feedback Page” provided in this Document.
The Document Owner and the Document Custodian should ensure review and reverification of this procedure every 3 years.
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PR-1103 – Chemical Injection
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1.5
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Step-out Approval
This procedure is mandatory and shall be complied with at all times. Should compliance
with the procedure be considered inappropriate or the intended activity cannot be
effectively completed or safely performed, then step out approval must be obtained from
the Asset Manager - using the PR-1001e – Operations Procedure Temporary Variance,
prior to any changes or activities associated with the procedure being carried out.
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PR-1103 – Chemical Injection
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2
Roles and Responsibilities
Production Coordinator

Responsible for conducting periodic compliance
checks on chemical injection operations
Production Supervisor

Ensures compliance to safe handling of chemicals
Production Chemist

Provides the Technical Authority for the use of
chemicals for Flow Assurance

Details chemicals to be used, injection points and
injection rates

Provides the Technical Authority for the use of
chemicals for Flow Assurance

Advices Production Chemist
concerning corrosion control
Petroleum Engineering

Advices Production Chemist of properties of the well /
process fluids to ensure effectiveness of chemical
injection.
Production Operator

Check that the Chemical Injection program as
detailed by Production Chemistry and Corrosion
Engineering is being carried out by the Contract
Company.
Contractor

Adhere to the terms of the contract.

Report any defects or anomalies through the defined
reporting channels.

Inform the Contract Holder if compliance to the
contract cannot be achieved.

Follow this procedure for operation of chemical
injection and adapt it to meet the requirements of the
individual installation
Corrosion Engineering
Page 8
PR-1103 – Chemical Injection
on
all
matters
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3
Chemical Injection Procedure
3.1
Scope
Revision: 3.0
Effective Jan-12
The scope of this procedure shall be generic. Generally all chemical injection pumps are
piston type direct displacement units, which allows them to overcome line pressure on
the pumping stroke to inject the chemical. The chemical injection points are normally
fitted with ‘quills’ which penetrate into the line so that the chemical is injected into the
main flow providing good mixing and dispersion.
A contract to manage the chemical injection equipment and the chemical inventories is
currently in place and is overseen by Production Chemistry. The chemical injection
procedure shall be adapted by the contractor to suit the actual chemical injection system
and equipment installed at the site.
Operations personnel shall reference this procedure and adapt it if required and
undertake onsite monitoring of the injection systems and equipment between the visits
of the Contract Company.
3.2
Safety Considerations
WARNING: Some chemicals used in production chemistry are extremely toxic and
must have a Permit to Work in force before they can be handled. This includes
replenishing and setting strokes. Before handling any such chemicals personnel
involved should be briefed and ensure that the SHOC card is available for
reference in cases of emergency or spillage. Appropriate safety equipment i.e.
showers and eye baths must be available in the immediate vicinity of the
operations.
The following safety considerations shall be adhered to where applicable:

Chemicals shall only be used on site if a SHOC card is available for that
chemical;

Chemicals shall not be used if the container is open or has been damaged;

Chemicals that are ‘out of date’ shall not be used;

Chemicals shall only be stored and mixed in designated areas Mixing
chemicals shall be carried out as detailed on the SHOC card or by the
Production Chemist;

When handling chemicals PPE and full safety wear as advised on the SHOC
card shall be worn;

Chemical spills shall be addressed promptly and in accordance with the SHOC
card;

Any damage to chemical injection equipment shall be reported and the
equipment taken out of service until repairs and / or replacements have been
made;

Positive displacement chemical injection pumps should not be run with
discharge valve closed;

Positive displacement chemical injection pumps should have the stroke set to
minimum when not in use1;
1
For some chemicals such as scale inhibitor, if the pump will not be used for long period then it
should be flushed with potable water in order to prevent damage to pump internal parts
(equipment safety).
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3.3
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
Chemical injection shall only be made through the correct injection points only;

All chemicals shall be stored under the shade not under direct sun heat;

Emergency eye wash facilities shall be made available near the chemical skid
and with clean potable water which can be used at the time of emergency. If
emergency eye wash is not available, portable eye wash bottles must be made
available instead;
Chemical Injection
The Procedure for preparing, starting and stopping chemical injection is generic and
should be adapted to suit different system configurations that may be installed in PDO.
The Procedure assumes that the chemical injection pump(s) are of the positive
displacement type and are powered from an electrical or pneumatic source.
Chemicals for injection shall be supplied in ‘drums’ or in ‘bulk’ depending on the type
and use of the chemical. Whichever method of supply is used handling of the chemical
shall be in accordance with SP-1194 – Chemical Management.
CAUTION: Personnel operating chemical injection equipment or handling
chemicals in bulk shall have the necessary competencies.
3.3.1
Starting Chemical Injection System
The following procedure will be required when initially preparing the chemical injection
system for use.
1.
The operator shall ensure that there are no PTW covering the system or any
other associated system / equipment.
PTW’s that prevent chemical injection being undertaken shall be closed out
before the startup of the system and equipment is permitted.
2.
Check the chemical injection pump(s) are isolated from the energy source
(pneumatic or electrical) before undertaking pre-startup checks.
3.
Check the chemical injection pump(s) suction and discharge valves status
and ensure that they are CLOSED
4.
Check the inventory of chemical.
5.

If the chemical is fed from a bulk tank isolate and replenish the tank in
accordance with the SHOC card.

If the chemical is supplied from a drum ensure that sufficient drums
are available to complete the required chemical injection program.
Inspect the chemical injection pump(s) for mechanical damage and loose
fittings.
Check the coupling between the pump and power source is secure and
undamaged.
Check the injection pipework and injection points.
Page 10
6.
De-isolate the energy source.
7.
Check all instrumentation root valves are OPEN.
8.
Ensure chemical injection pump(s) suction and discharge valves are OPEN.
9.
Set chemical injection pump(s) stroke to ‘minimum’.
10.
OPEN isolation valves on injection manifold (if applicable).
PR-1103 – Chemical Injection
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11.
Start chemical injection pump(s).
12.
Set the chemical injection pump(s) stroke to the required setting as specified
by the Production Chemistry or Corrosion Engineering focal point.
Chemical Injection
Required
Resolve Permit To
Work Conflict
YES
Is Conflicting Permit
To Work in Force?
NO
Check all Instrumentation
Lines are De-Isolated
Check Chemical Injection
Pump(s) Motive Power Source is
Isolated
OPEN Chemical Injection
Pump(s) Suction / Discharge
Valves
Check Chemical Injection
Pump(s) Suction /Discharge
Valves are CLOSED
Set Chemical Injection Pump(s)
Stroke to Minimum
Replenish Stock
As Required
NO
Is Sufficient Stock
of Chemical Available?
YES
Inspect Chemical Injection
Pump Mechanical End for
Damage
De-Isolate Chemical Injection
Pump(s) Motive Power
Page 11
PR-1103 – Chemical Injection
OPEN Isolation Valves on
Injection Manifold if required
Start Chemical Injection Pump(s)
Set Required Injection Stroke
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3.3.2
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Shutdown of Chemical InjectionSystem
The following procedure will be required when shutting down the chemical injection
system.
Chemical Injection
Completed
Set Chemical Injection Pump(s)
Stroke to Minimum
CLOSE Chemical Injection
Pump(s) Suction / Discharge
Valves
Stop Chemical Injection Pump(s)
Isolate Chemical Injection
Pump(s) Motive Power Source
CLOSE Isolation Valves on
Injection Manifold if required
Drain Chemical Injection
Pump(s) Discharge Line
1.
On completion of chemical injection operations reduce the chemical injection
pump(s) stroke to ‘minimum’.
2.
Stop chemical injection pump(s).
3.
CLOSE isolation valves on injection manifold (if applicable).
4.
CLOSE chemical injection pump(s) suction and discharge valves.
5.
Isolate the energy source.
6.
Drain chemical injection pump(s) discharge line (if required)
Isolate at chemical drum or bulk tank if the shutdown is to be prolonged.
3.3.3
Operator Checks during Operation of the Chemical Injection System
Page 12

Inspect the chemical injection pumps for leaks, noisy or abnormal operation.
Report any defects through the corrective maintenance notification process.
Refer to

Ensure all spills are cleaned up and waste materials disposed of in the correct
manner.

Inspect injection points and report any leaks.
PR-1103 – Chemical Injection
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Appendix 1 – Abbreviations
The following abbreviations are used in this Procedure.
Page 13
PTW
Permit to Work
SHOC
Safe Handling of Chemicals
PR-1103 – Chemical Injection
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Appendix 2 - User Feedback Page
PR-1103 – Chemical Injection User Feedback Page
Any user who identifies an inaccuracy, error or ambiguity is requested to notify
the custodian so that appropriate action can be taken. The user is requested
to return this page fully completed, indicating precisely the amendment(s)
recommended.
Name:
Ref ID
Page Ref:
To:
Date:
Brief Description of Change Required and Reasons
UOP7
Custodian of Document
Page 14
PR-1103 – Chemical Injection
Date:
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