OPERATING INSTRUCTIONS

CPE Job# - 13019

8 Vertical Well Test Separators

Custom Process Equipment, LLC 4727 NW Evangeline Thwy Carencro, LA 70520 Tel: 337-896-3815

Fax: 337-896-3816

www.cpe-llc.com

OPERATING INSTRUCTIONS

TEST SEPARATOR UNITSPEMEX EXPLORATION

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WARNING - DANGER

EXPLOSIVE/HAZARDOUS GASES AND LIQUID***************************************************************************************

Work being performed on this equipment may expose you to conditions which can be hazardous and dangerous, as this equipment or area may contain explosive, flammable or toxic gasses or liquids. Keep all open flames at least 30 meters away.

This equipment must be serviced and operated by properly trained and qualified personnel only.

Do not clean, service, repair, or attempt to perform any work without relieving pressure and purging combustibles.

Check for unsafe conditions and follow your company's safety practices any time work is performed on this equipment.

If you have any questions, contact Custom Process Equipment, llc. prior to performing any work on these units.

TABLE OF CONTENTS

Equipment Description

1

Design Basis

2

Basic Operation

3

Pre Start Up

4

Start Up

5

PLC Operation

6

Maintenance

7

Troubleshooting

81.0EQUIPMENT DESCRIPTION

Each test separator package consists of the following items: One (1) three-phase vertical test separator vessel provided with high efficiency internals.

One (1) lot integrated control system to include valves, instruments and controls adequately sized for the design flow conditions. System accurately measures gas, oil and water flow throughout the specified flow range. One (1) Data Acquisition Control System complete with integrated DELL computer console, software, emergency battery back-up system for 8 hours, and an Allen Bradley MicroLogix PLC.

2.0DESIGN BASIS2.1TEST SEPARATOR This manual is intended to cover test separator packages for several well locations. Below is a summary of the process conditions for each location.Tag Number10001000100010002100100021002100

FieldOGARRIO (5)OGARRIO (2)SAN RAMONCERRO NANCHITALRABASACINCO PRESIDENTES 1GIRALDASSUNUAPA

Max Liquid Flow 409478421610159895080008000BPD

Min Liquid Flow 25252525501005050BPD

Max Gas Flow 55555555MMSCFD

Min Gas Flow 0000000.50.75MMSCFD

MAX Water Cut100100100100100100100100%

Min Water Cut00000000%

MAX Pressure 76751078.57Kg/cm2

Min Pressure 0.50.50.50.50.5155Kg/cm2

Max Temp 5050505050505050C

Min Temp 1010101010101010C

OIL Density 31.530.531.528.529.5324637API

Vessel Diameter 3636363654365454in. (OD)

Vessel Length 120120120120180120180180in. (S/S)

LSHH5858585882588282inches

LSH5656565680568080inches

NLL5050505074507474inches

LSL4444444468446868inches

LSLL4242424266426666inches

3.0BASIC OPERATION

3.1The test separator unit is used to evaluate gas, oil and produced water flow from individual wells. The three-phase separator vessel is used to separate the well stream into three components, gas, oil, and produced water. The gas flow rate and liquid flow rates are measured along with the operating pressure and temperature. The flow data is sent to the local PLC for data processing and analysis.

The three-phase separator vessel is equipped with the following internals. Please refer to the Custom Process Equipment separator vessel drawing no. CPE-13019-DW-2200 (36 OD Test Separator Package) or CPE-13019-DW-2201 (54 OD Test Separator Package) for reference.

A)One (1) removable plate type inlet diverter which absorbs the momentum of the inlet stream and results in initial liquid/gas separation.

B)One (1) high efficiency 316 stainless steel mesh type mist eliminator. The mist eliminator is constructed of individual pieces which are removable through the vessel manway. The support bracket can be partially disassembled in order to allow vane section removal.

C)One (1) oil bucket to collect produced oil.

C)One (1) 18 manway intended to provide access to the inside of vessel.

3.2The separator is designed to remove 99% of liquid particles 10 microns and larger from the gas stream. The carryover of liquid should not exceed 0.1 gal / MMSCF if the separator is operated within its design parameters. The quality of the product leaving the vessel depends on many factors such as temperatures, specific gravities and viscosities of oil and water, solid content, pH, process chemicals used, and most importantly flow rate. To achieve maximum performance, the volumes should be maintained within the vessel's rated capacity. 3.3As the produced gas and liquid enter the separator vessel, liquids collect in the lower section of the vessel. The gas flows through the mist eliminator and out of the gas outlet nozzle at the top of the vessel. The liquid residence time allows the oil to separate from the water. As the oil separates, it forms an oil pad which spills over into the oil bucket and forms an oil level. The oil level can be observed through level gauge LG-1102 (36 OD) or LG-2102 (54 OD). The overall level in the oil bucket is determined by the height of level control set point, See Section 2.1 for level settings. Level Indicating Transmitter, LIT-1102 (36 OD) or LIT-2102 (54 OD), senses the oil level in the bucket and controls level control valve, LCV-1102 (36 OD) or LCV-2102 (54 OD) which maintains the normal oil level of the oil bucket. 3.4As the oil leaves the test separator vessel, it travels through an inline Y-type basket strainer, which removes any large solids prior to entering the liquid measurement devices. 3.5Oil leaves the basket strainer and flows through a Micro Motion coriolis type liquid flow meter, FM-1102 (36 OD) or FM-2102 (54 OD). The coriolis liquid flow meter determines the total amount of oil flow and transmits this measurement to the PLC.

Once the liquid is measured, it is recombined with the produced water and sent off skid.

See Section 2.1 for all control set points and process flow details. Also refer to the Instrument Data Sheets and vendor data for reference.

3.6During normal operation, an oil/water interface level is established below the top of the bucket.

3.7The oil/water interface level can be observed through level gauge LG-1101 (36 OD) or LG-2101 (54 OD). The oil/water interface level determined by the height of level control set point, See Section 2.1 for level settings.

3.8 Level Indicating Transmitter, LIT-1101 (36 OD) or LIT-2101 (54 OD), senses the oil/water interface level and controls level control valve, LCV-1101 (36 OD) or LCV-2101 (54 OD) which maintains the normal interface level in the separator vessel.

3.9As the produced water leaves the test separator vessel, it travels through an inline Y-type basket strainer, which removes any large solids prior to entering the liquid measurement devices. 3.10Produced water leaves the basket strainer and flows through a Micro Motion coriolis type liquid flow meter, FM-1101 (36 OD) or FM-2101 (54 OD). The coriolis liquid flow meter determines the total amount of produced water flow and transmits this measurement to the PLC.

Once the liquid is measured, it is recombined with the oil and sent off skid.

See Section 2.1 for all control set points and process flow details. Also refer to the Instrument Data Sheets and vendor data for reference.

3.11As the well stream begins to separate in the vessel, the produced gas flows through a high efficiency mesh type mist eliminator. Any residual liquid droplets which are still in the gas stream will separate and fall into the liquid space. 99% of liquid particles 10 microns and larger are removed from the gas stream.3.12Internal pressure of the test separator unit is measured and reported to the PLC by pressure indicating transmitter PIT-1100 (36 OD) or PIT-2100 (54 OD).

3.13As the gas leaves the test separator vessel, it travels through a McCrometer v-cone type gas measurement device, FE-1100 (36 OD) or FE-2100 (54 OD). This instrument determines the total gas flow and transmits this information to the PLC. 3.14Temperature indicating transmitter, TIT-1100 (36 OD) or TIT-2100 (54OD), measures and reports to the internal temperature of the test separator to the PLC. 3.15Two levels of safety systems have been provided on the test separator unit.

The first level of the safety system is alarms. An alarm is initiated when an event causes the operating conditions of the separator to deviate from the normal process variables. The event could be an abnormal flow condition or a mechanical malfunction. An alarm can be initiated by the following instruments:

PIT-1100: monitors internal pressure of the test separator MBD-1100. TIT-1100: monitors the internal temperature of the test separator MBD-1100. Level transmitters: monitors the oil liquid level and interface level in the test separator. The alarm signal is sent to the PLC which informs the operator of a possible abnormal process condition or system malfunction. 3.16The second level of the safety system is pressure relief valve PSV-1100 (36 OD) / PSV-2100 (54 OD). The relief valves will relieve the internal pressure of the either separator in the event it reaches the design pressure of 10.5 kg/cm2 (150 psig). Warning: The PSV-0110 relieves directly to atmosphere. 4.0PRE-START UP

The test separator unit is mounted on a structural steel skid. The unit should be located on flat level surface. Leveling may be required to ensure that the unit is not listing excessively which will interfere with the proper operation of the unit.

4.1PRE-START-UP INSTRUCTIONS

4.1.1Ensure that separator unit is located on firm level foundation. Remove all shipping braces, temporary flange covers, and protective guards. Inventory all parts.

4.1.2Visually check the vessels couplings, nozzles, vessel shell, and accessory items, to see that none have been damaged during transportation.

4.1.3Verify that all ladders are properly installed if it was removed for transportation.

4.1.4Check and tighten as needed all pipe support bolting.

4.1.5Install vessel accessories, ship loose items and all necessary field piping that may have been shipped loose during transportation. (PI's, TI's, Level Gauges, etc.).

4.1.6Check that all vessel accessories such as pressure gauges, gauge glasses, relief valves, etc. are installed in proper location. Refer to the drawings for nozzle locations, dimensions and general description. In addition, you may refer to vendor literature.

4.1.7Check all instrument tubing for damaged areas or kinks. Repair or replace before startup. Check all electrical connections for damage. Repair as required.

4.1.8Verify the position of the following valves:

Gas Outlet Piping 6 A2R ball valve upstream of FE-1100 (36 OD) or FE-2100 (54 OD) is in the open position. 1 A2R ball valve in blowdown line is in the closed position.

Oil Outlet Piping

2 A2R ball valve directly downstream of LCV-1102 (36 OD) or LCV-2102 (54 OD) are in the closed position.

All A2R ball valves upstream of LCV-1102 (36 OD) or LCV-2102 (54 OD) are in the open position.

2 A4R globe valve in by-pass line are in the closed position. isolation valve for pressure indicator is in the open position.

Water Outlet Piping

2 A2R ball valve directly downstream of LCV-1101 (36 OD) or LCV-1102 (54 OD) are in the closed position.

All A2R ball valves upstream of LCV-1101 (36 OD) or LCV-1102 (54 OD) are in the open position.

2 A4R globe valve in by-pass line are in the closed position.

isolation valve for pressure indicator is in the open position.

Level Transmitters 2 A2R isolation valves on are in the open position.

vent and drain valves are in the closed position.

Pressure Vessel

isolation valve for pressure indicator and pressure transmitter is in the open position.

3 A2RF (LO) ball valve under relief valves are in the open position.

2 A2R ball valve on vessel drain line is in the closed position.

Instrument Air Line isolation valves are in the open position.

Off skid instrument air supply is connected to on skid instrument air line.

4.1.9Check all flanged connections and tighten any loose nuts. Remove any temporary flange covers on PSV outlet.

4.1.10Ensure that PLC data cable is securely connected to both the on-skid control panel and the data cable junction box located in the control room. The PLC cable should be protected at all times to avoid damage.

4.1.11Ensure that the appropriate flow lines, hoses, unions, etc. which connect the test separator unit to the well head are connected securely.

4.1.12Strainer screens are to be inspected and cleaned prior to unit start-up.

4.1.13Verify proper electrical grounding of all equipment.

5.0START-UP

Start-up of this equipment should be performed only by qualified personnel. Prior to unit start-up, the user should initialize the PLC control system. See Section 6 for PLC information.5.1When starting up the unit, the pressure should be slowly brought up to line pressure. During this time, the pressure indicators should be checked to ensure that all pieces of equipment are operating within the design parameters. In addition, check all flanges and screwed connections for possible leaks. A thorough review of the Vendor Data Manual to familiarize the operator with the equipment supplied is recommended.

5.2Procedure

5.2.1Make sure all manual valves are in the proper start-up position. See section 4.1.8 above for proper valve position. Ensure that instrument air supply is available and provided to on skid instrument air supply line.

5.2.2Verify that all instruments have been calibrated to desired ranges.

5.2.3Slowly begin filling the vessel. As the vessel pressure gradually increases, check all piping connections for leaks. Do not fully open the inlet valve until the separator pressure and liquid level reaches the desired operating pressure and normal liquid level. The liquid level can be visually determined by level gauges. Internal pressure is indicated by pressure indicator and pressure transmitter.

5.2.4Once the liquid level reaches the normal operating level, slowly open the 2 A2R manual ball valves downstream of all level control valves. Check the level control valves to determine if it is operating correctly. Make adjustments as required.

5.2.5Once the separator is operating, check all measurement instruments to ensure they are operating correctly.

6.0PLC Local HMI and Remote HMI

Operation Manual

6.1This manual is for the operation of the local HMI and remote PC based HMI. The local PanelView 100 plus touch screen is built on the Rockwell Factory Talk platform ver.7.0. The interface to the operator is via touch. The control philosophy is straight forward and user friendly. The initial start-up screen is the heart of the control scheme all information needed is easily accessed from this screen. See graphic 1.0.

1.0

The main screen above is dynamic meaning all the data is live readings via the Allen Bradley MicroLogix PLC. All indications visible on the main screen that have alarming or control attributes have associated screens accessible by touching that indicator. Example level indication LT-1101 is pressed to access its associated alarm set points screen. See graphic 1.1.

SETPOINT

1.1

ALARMING

6.2When any alarm parameter falls outside of its normal set range an alarm is initiated and the alarm popup screen becomes visible. See graphic 1.2. The active alarm will be indicated in the text field of the popup and the operator will be able to clear and or close the alarm screen. If this alarm is associated with a facility shutdown procedure via the facility control system, the operator will also need to reset the alarm form the main screen to reset the ESD output from the PLC.

1.2

ALARM HISTORY

6.3Alarm history allows the operator to access historical alarming events from the touch screen. Pressing the alarm history button from the main screen allows access to this screen. See graphic 1.3. Acknowledgement, clearing and sorting is available from this screen. The alarm history screen is a very powerful and useful screen in managing the alarming of this unit.

1.3

CONTROL

6.4Valve control and tuning parameters are also accessed in this same manner by touching each valve to access its associated control parameter screen. Example valve LY-1101 is touched to access its associated control screen. See graphic 1.4. From this screen the operator may change the control set point, Manual/Auto control of valve position, and adjust the PID loop parameters. The ability to monitor the CV, PV, and SP in a trending format gives the operator complete loop tuning capability locally. (EXPERIENCED MAINTAINANCE PERSONEL ONLY IS RECOMENEDED CPE IS NOT RESPONSIBLE FOR OPERATIONS OUTSIDE DESIGNED PARAMETERS)

1.4

MONITORING

6.5Monitoring of most all indication is done from the main screen but precise instantaneous Separator flow information is monitored by specific flow instruments. The instantaneous flow data is accessible from the PanelView main screen by touching the associated flow instrument. Example Gas Flow FT-1100 is touched to access its associated rate screen. See Graphic 1.5. Example Oil Flow FT-1102 is touched to access its associated rate screen. See Graphic 1.6.

1.5

1.6

LIQUID METER DIAGNOSTICS

6.6Liquid flow measurement is accomplished via an Emerson Micromotion Coriolis Meter. This meter has a diagnostics screen to allow an operator to view specific meter attributes to aid in troubleshooting meter problems and incorrect readings. The diagnostics screen is accessible by touching the METER DIAG button from each associated meter rate screen. See graphic 1.7.

1.7

6.7The units are supplied with remote PC functionality. The same menu, navigation and functionality are present with the PC based HMI. (CPE IS NOT RESPONSIBLE FOR OPERATING ANY EQUIPMENT OUTSIDE ITS DESIGNED PARAMETRS). Please see attached ABB TotalFlow manual.7.0MAINTENANCE7.1Refer to manufacturers literature and manuals for detailed information on maintenance of valves and instrumentation supplied with the unit.

7.2Cleaning and Inspection: Vessels should be cleaned and inspected at the end of the first 6 months on heavy oil service and at the end of one year on lighter oil service. Where heavy sand is suspected, cleaning every 60-90 days may be necessary. Frequency of future cleanings should be constantly re-evaluated as production operations continue and based on results of past inspections and cleanings.

7.3Valves and Controls: All valves and controls should be properly lubricated at selected intervals to assure best performance. Maintenance and repair of valves and controls depends upon severity of service, e.g. mud, sand, etc. Refer to manufacturers literature provided.

7.4Safety Valve: A safety valve requires periodic inspection to assure the operator that the valve is not sticking and will provide "safety relief". Pressure testing is the approved method.

7.5Routine Maintenance Recommendation

Daily:

1)Check the pressure gauge readings

2)Check the gauge glass levels

(Clean as required)

3)Note any irregularities

4)Check for leaks and repair as required

5)Check for liquid levels in gas filter vessel MAJ-5000. Drain as required.

Weekly:1)Inspect controls and valves for proper operation

Monthly:1)Clean and inspect strainer screens per company procedure

Semi-

Annually:1)Check all pressure relief valves

Annually:1)Inspect vessel internals for scale and sludge accumulation and corrosion (especially pits) and clean as required.

2)Inspect, clean and repair valves and controls, replace damaged trim

8.0TROUBLE SHOOTING (As Applicable)

The following is a trouble-shooting guide for the test separator vessel. For trouble shooting of the PLC control system and power generator, see applicable vendor documentation.

PROBLEMPOSSIBLE CAUSESOLUTIONS

Vessel Low pressureBreak in production inlet flow line or other inlet components.Check inlet connections, flow lines and component upstream of separator unit for damage or leaks. Repair as required.

PSV in fixed open positionCheck PSV Repair or replacement required

Level control valve in fixed open positionCheck pneumatic control signal from LCV-0110

Check Level transmitters for proper operation and setting. Adjust or repair as required

Check LCV actuators and valve for proper operation. Repair or replace as required

Manual drain valve on vessel leaking.Check valve. Repair or replace as required.

Gas or liquid discharge piping leaking.Inspect discharge piping. Repair as required.

Vessel High PressureGas outlet piping plugged or valve in gas outlet line closedInspect piping for obstructions. Check that all in-line valves are in correct position.

PSV in fixed closed position and/or will not relieve pressureCheck PSV for proper operation. Repair or replace as required

Block valve below PSV is closed. Open valve.

Vessel High Liquid LevelLiquid outlet piping plugged or valve in liquid outlet line closedInspect piping for obstructions. Check that all in-line valves are in correct position

Level transmitter not calibrated or malfunctionCheck level transmitters for proper operation. Adjust or repair as required

Level control valve malfunctionCheck LCVs for proper operation. Adjust or repair as required

Check pneumatic control signal to LCVs.

Vessel Low Liquid LevelLevel transmitter not calibrated or malfunctionCheck level transmitters for proper operation. Adjust or repair as required

Level control valve malfunctionCheck LCVs for proper operation. Adjust or repair as required

Check pneumatic control signal to LCV-0110.

Level control valve bypass openCheck by-pass valve position.