OPERATION AND MAINTENANCE

MANUAL FOR
1
st
& 2
nd
STAGE 3 PHASE SEPARATOR
Petrodar Order No. 11!"#$311!!132$M%!1$!2!
E&'()*ent Ta+ No. 1,- 2,- 3,- .,$/3!1
LEPS Do0 No. LEPS$2!!#1!!"$O&M
H(+1e(+ Do0 No. PDOC$2322!#$,D$MEC$!#"
Issue and Revision Record
0
16-03-
09
Submitted for Approval LEPS LEPS
Re
3
No.
Date Des0r()t(on
Pre)ared
45
S'))1(er
Re3(e6ed
45
S'))1(er
A))ro3ed
45 HDC
O6ner
Petrodar peratin! "ompan#
Limited
EPCC Contra0tor
$i!lei! Petroleum Services
% Inv& "o& Ltd&
S'))1(er 7 S'4$Contra0tor
LA'SEL EPS (ec)nolo!ies Pte
Ltd
INDE8
1.! SAFET9
Do0'*ent No LEPS$2!!#1!!"$O&M
Petrodar Operating Company
Moleeta FPF Oil Development
Project
1&1 Safet# *)en Enterin! t)e separator
1&+ Safet# *)en fillin! t)e vessel *it) il
1&3 Safet# *)en Empt#in! t)e ,essel
2.! E%UIPMENT DESCRIPTION
+&1 Internals
+&+ -eir plates
+&3 .affle
+&/ ,orte0 .rea1er
+&2 3e-sandin! Line and 4o55les
+&6 $eatin! "oil
3.! START$UP PREPARATION
3&1 ,essel and Internals
3&+ Pipe -or1s
3&3 Instruments
3&/ Electricit#
..! START$UP PROCEDURE
/&1 6illin! *it) "rude
/&+ Ad7ustment of Interface Level
/&3 il Level
".! NORMAL OPERATION
2&1 4ormal peratin! and 8aintenance Instructions
2.! S9MPTOMS OF FAULT9 SEPARATOR OPERATION
#.! SHUT DO:N PROCEDURE;Nor*a1 and E*er+en05<
9&1 S)ut do*n
9&+ Empt#in! t)e Plant
/.! ELECTRICAL MAINTENANCE
:&1 $i!) ,olta!e Electrical 6ailure
=.! DESIGN AND PERFORMANCE DATA
9&1 3esi!n
9&+ 3escription
Do0'*ent No LEPS$2!!#1!!"$O&M
9&3 Performance
9&/ $a5ards
9&2 Information Sources
1!.! STORAGE AND HANDLING
11.! OPERATION
11&1 .asic Principles of peration
11&+ Slu!!in! "onditions
11&3 Emer!enc# Levels
11&/ 6ault "onditions
12.! MAINTENANCE
1+&1 Recommended sc)edule of 8aintenance
1+&+ 8aintenance Re;uirements
1+&3 ,essel
13.! ANNE8URES
13&1 Process and Instrumentation dia!ram
13&+ <eneral Arran!ement Plan
13&3 Instrument Sc)edule
13&/ "orrection for .uo#anc# t#pe Level <au!e
Do0'*ent No LEPS$2!!#1!!"$O&M
PRE START-UP CHECS OF FOR THREE PHASE SEPARATOR
NOTE > Read t?(s (nstr'0t(on 0o*)1ete15 )r(or to (ntrod'0(n+
Cr'de O(1 (n t?e Se)arator. Conta0t 5o'r La@se1 Re)resentat(3e Aor
start$') ass(stan0e.
:ARNING PerAor* a11 oA t?e Ao11o6(n+ ste)s (n order to ens're
)ersonne1 saAet5 and e&'()*ent )rote0t(on.
Pre1(*(nar5 Ins)e0t(on
Perform t)e follo*in! preliminar# inspection before puttin! t)e Separator online
Isolate all po*er sources to t)e Instruments and "ontrols to be certain t)at no s)ort circuit ta1es
place
.#pass all interloc1s to t)e Separator
Rec)ec1=correct t)e Separator and pipin! installation
Ensure t)at all t)e e0ternal=internal bolts are full# ti!)tened as per t)e re;uired tor;ue ran!e&
8a1e sure all t)e .affle plate> -eir plate> ,orte0 brea1er are in order and in place& Looseness
and misali!nment durin! transportation s)ould corrected durin! inspection
8a1e certain t)at all pipin! are securel# connected and properl# supported
Inspect all Separator control components ?control valves> flo* meterin! devices> c)ec1 valves>
strainers> !au!es> etc&@ to ma1e certain t)at t)ese components are correctl# oriented in t)e pipin!
sc)eme in order to ac)ieve t)e proper direction of flo* and functional operation
Inspect t)e Separator inlet to ma1e certain t)at t)e inlet screen and clean-out connections )ave
been properl# made and are free of tools> e;uipment and debris
6ull# open t)e inlet and disc)ar!e line manual valves of t)e Separators
pen t)e ,alves in t)e drain lines
All t)e instruments and t)e valves *)ic) are dama!ed durin! t)e transportation are replaced *it)
t)e ne* items are rectified *it) t)e spares
All t)e pipe lines are cleaned and flus)ed *it) t)e *ater to remove all t)e loose items > dust and
ot)er matters
Do0'*ent No LEPS$2!!#1!!"$O&M
1.! SAFET9
SAFET9 RULES AND RECOMMENDATIONS APPLICABLE ON SITE :ILL
BE APPLIED DURING ERECTION- NORMAL OPERATION AND
MAINTENANCE :ORCS ON UNITS.
All procedures indicated in t)is manual t)at could be in contradiction *it) applicable safet#
rules on site> *ill be modified to meet site re;uirements
In an# case> if several safet# rules !overn t)e same application> t)e most constrainin! ones
*ill be applied
1.1 SaAet5 6?en enter(n+ t?e se)arator
-)en enterin! t)e separator t)e safet# rules applicable to process vessel s)ould be
follo*ed& As e0ample some of t)ese rules are listed )ere underA
Aut)ori5ation permit to enter t)e vessel s)ould be delivered b# t)e relevant
aut)orit#
All vessel flan!es connected *it) process lines s)ould be blinded
,essel must be free of oil> *ater !as or dirt
An e0plosivit# test must be carried out in all accessible parts of t)e vessel internal
Internal temperature must be acceptable
4atural or mec)anical ventilation s)ould be sufficient to permit *or1 inside t)e
vessel *it)out ris1
Etc
1.2 SaAet5 6?en enter(n+ t?e 3esse1 6(t? o(1
In order to avoid t)e information of e0plosive mi0ture> t)e vessel s)ould be totall#
pur!ed from air before c)ar!in! *it) )#drocarbons
()is pur!in! can be done usin! nitro!en or ot)er inert !as *)ic) is not )armful if
released to atmosp)ere
1.3 SaAet5 6?en e*)t5(n+ t?e 3esse1
In order to avoid formation of e0plosive atmosp)ere *)en empt#in! t)e vessel > it is
absolutel# imperative to replace pumped put product b# inert !as?e0& 4itro!en@ or
*ater under lo* pressure?B12psi!@
Do0'*ent No LEPS$2!!#1!!"$O&M
Special care *ill be ta1en also to avoid an# vacuum in eac) vessel compartment
durin! pumpin! out&
2.! E%UIPMENT DESCRIPTION
2.1 Interna1s
Separators are )ori5ontall# mounted on a s1id& ()e separator is divided in to t*o
compartments be a *eir plate& i&e t)e *ater side and t)e oil side& Internals consist of
*eir plate> baffles> vorte0 brea1er and diverter& Internals are of SS316 and are bolted
to t)e vessel *it) fittin!s *)ic) are SA216<r&90
2.2 :e(r P1ate
"rude and *ater mi0ture enters to t)e left side of *eir& ()e interface is controlled and
not allo*ed to rise above t)e )ei!)t of t)e *eir& ()is *eir 1eeps t)e separated *ater
in left compartment& 3urin! lo* production rates t)e oil *ill overflo* to t)e oil
compartment over t)e *eir& 3urin! )i!) production rates t)e oil level *ill be above
t)e *eir and bot) compartments *ill be flooded *it) oil
()e )ei!)t of *eir plate is ad7ustable& 6or t)e first sta!e> 3 levels ?12:2>
1902%+102mm@ of ad7ustabilit# is possible and for second sta!e> + levels ?0000@& -eir
s)ould be fi0ed to t)e flat bars on vessel s)ell t)rou!) neoprene rubber& 4eoprene
rubber is also used to seal t)e bolt )oles
2.3 BaAA1e
.affle plates are fitted on t)e *ater side to en)ance separation& Inlet crude oil mi0ture
enters t)e separator on t)e left side of t)e baffle and )as to pass t)rou!) t)e baffles
to !et transferred to t)e ri!)t side of t)e baffle& All t)e baffle t)rou!) t)e baffle plates
e0cept t)e bottom plate can be unbolted and removed t)rou!) t)e man)oles for t)e
1st sta!e and second sta!e
2.. ,orteD Brea@er
,orte0 brea1er is placed at t)e outlet of bot) crude oil and produced *ater& It )elps to
brea1 t)e vorte0 formation on t)e outflo*
Do0'*ent No LEPS$2!!#1!!"$O&M
2." Desand(n+ L(ne and noEE1es
Inlet crude mi0 brin!s *it) it sand particles> *)ic) !et settles in t)e vessel& 3esandin!
needs to be done to remove t)e accumulated sand in t)e vessel& 6re;uenc# of
desandin! operation depends on t)e sand content in a !iven crude mi0& 3e-sandin!
*ater is circulated t)rou!) t)e desandin! line and it is spra#ed on t)e accumulated
sand at t)e bottom of t)e vessel t)rou!) t)e spra# no55les> *)ic) are fitted to t)e
desandin! pipes& 3esandin! line is of SS316 8aterial
2.2 Heat(n+ Co(1
In order to maintain a temperature of 20 de!rees " in t)e separator at all times> even
*)ile it is not in operation> )ot oil is circulated t)rou!) t)e )eatin! coils& Inlet )ot oil
temperature is +20C"
3.! START > UP PREPARATION

D IMPORTANT NOTE BEFORE STARTING AN9 OPERATION- PLEASE
REFER TO CHAPTER 1.!. FSAFET9G.
3.1 ,esse1 and Interna1s
Ensure t)e condition of t)e pressure vessel and t)e internals&
")ec1 t)e ma0imum allo*able *or1in! pressure and t)e operatin! temperature>
*)ic) are mar1ed on t)e name plate of t)e vessel&
3.2 P()e :or@s
Ensure all pipe *or1 is correctl# installed
3.3 Instr'*ents
")ec1 all instruments for correct function
")ec1 all relief=safet# s#stem for correct operation
")ec1 all control valves and associate s#stem for correct function includin!
EfailureF modes&
3.. E1e0tr(0(t5

All electrical part s)ould be carefull# c)ec1ed G *irin! of all elements s)ould be c)ec1ed
as *ell as t)eir satisfactor# connection> Eart)lin! circuit s)ould be c)ec1ed
Do0'*ent No LEPS$2!!#1!!"$O&M
..! START UP PROCEDURE
(See chapter 1.0 SAFETY)
..1 C?ar+(n+ 6(t? H5dro0ar4on
HIMPORTANT NOTE
BeAore 0?ar+(n+ 6(t? ?5dro0ar4on- t?e 3esse1 s?o'1d 4e 0o*)1ete15 Aree oA a(r. T?(s
)'r+e s?o'1d 4e done 6(t? n(tro+en or an5 ot?er (nsert +as not ?ar*A'1 to t?e
at*os)?ere. C?e0@ t?at a11 3a13es. Dra(ns 3ents sa*)1e are 01osed and t?e(r 0a)s are
(nsta11ed. :?en t?e 1e3e1 oA o(1 (s 4et6een t?e 1o6 1e3e1 and ?(+? 1e3e1- t?en reset t?e
1o6 and ?(+? a1ar* oA t?e (nterAa0e 45 )ress(n+ t?e reset )'s? 4'tton on t?e 0ontro1
)ane1.
..2 AdI'st*ent oA InterAa0e Le3e1
6ollo* t)e development of t)e interface level b# usin! t)e level !au!e on t)e
standpipe& -)en t)e set supper level is reac)ed> t)e control valves opens in
accordance *it) t)e controller si!nal and allo*s produce *ater to flo* out of vessel&
()e preferred settin!s at desi!n production rates for 6irst Sta!e Separator are as
follo*sA
Interface Li;uid LevelA IL$$
IL$
ILL
ILLL
Do0'*ent No LEPS$2!!#1!!"$O&M
Preferred settin! for Second Sta!e Separator isA
Interface Li;uid LevelA IL$$
IL$
ILL
ILLL
"ontrol valves operation ta1en place suc) t)at t)e interface la#er sta#s bet*een IL$ and ILL
additional lo* level and )i!) level cut offs are provided bet*een IL$ and ILL&
")ec1 alarm and trip circuit for )i!) and lo* levels b# stimulatin! abnormal level conditions&
..3 O(1 Le3e1
il levels are maintained on t)e basis of follo*in! oil level settin!s&
()e preferred settin!s at desi!ned production rates are as follo*sA
Li;uid Level in SeparatorA L$$
L$
LL
LLL
Preferred settin!s for +nd sta!e are
Li;uid Level in SeparatorA L$$
L$
LL
LLL
Levels are controlled bet*een L$ and LL& Additional cut offs are provided at L$$ and
LLL&
")ec1 alarm and trip circuits for )i!) and lo* level b# stimulatin! abnormal level
condition&
".! NORMAL OPERATION
".1 Nor*a1 O)erat(on and Ma(ntenan0es Instr'0t(ons
?See ")apter 1&0 SA6E(HF@
Do0'*ent No LEPS$2!!#1!!"$O&M
".1.1 O)erat(on Data S?eet
If re;uired a dail# operatin! data s)eet *ill be issued& ()is data s)eet
allo*s all essential parameters t)at allo* operation and control of t)e
plant&
".1.2 Pre)arat(on Aor t?e Ins)e0t(on oA t?e ,esse1
-)en a vessel inspection is foreseen> t)e follo*in! recommendation
s)ould be applied
Stop t)e plant
")ec1 t)at t)ere is no volta!e on t)e Po*er unit
3rain t)e vessel accordin! to ")apter 9&+
Isolate t)e vessel b# placin! blind flan!es on all t)e inlet and outlet
no55les&
pen bot) man)oles and top vent of vessel&
,ent t)e vessel *it) lo* pressure steam if available ?Lo*er t)an 3
bar@ for +9/ )ours&
"onnect a stripped cable to an eart)lin! pad or to vessel *all> t)en
connect it to t)e electrode& 4o spar1 or presence of current s)ould be
detected&
"lean t)e internal *alls of vessel *it) pressuri5ed *ater> )ot if
available&
.efore enterin! t)e vessel ensure t)at t)e temperature )as dropped
sufficientl# to allo* entr# and t)at an# )armful or flammable !as )as
been pur!ed&
".1.3 Ma(ntenan0e and tro'41e > s?oot(n+
()e separator until offers )i!) operatin! reliabilit# because all parts of t)e unitsA
vessel and internal ?baffles> *eir> etc @ pipin! etcIstatic elements &It trouble on t)e
treatin! operations occurs> t)en refer to c)apter :&0
All items of e;uipments ?Instruments> vessels> po*er units> pipin! etc@ s)ould be 1ept
in !ood condition and clean ?free of rust@ t)e# s)ould be c)ec1ed re!ularl# for !ood
operation and sealin!&
If a part or e;uipment appears to be fault# or out of order> t)en refer to t)e trouble G
s)ootin! !uide in t)e manufacturerJs manuals
Do0'*ent No LEPS$2!!#1!!"$O&M
It is recommended t)at *)en t)e vessel is opened or maintenances internal
distribution and collection pipe *or1 to!et)er *it) t)e electrode s !rids and t)e vessel
s)ell are inspected for si!ns of erosion and=or corrosion&
".1.. Po6er and 0ontro1 Pane1
E;uipment on t)e control panel suc) as rela#s> contactors> voltmeter> ammeter and
pus) buttons *ill be c)ec1ed and maintained re!ularl#&
2.! S9MPTOMS OF FAULT9 SEPARATOR OPERATION
HNOTEA .efore ad7ustment in t)e plant> c)ec1 t)at operatin! conditions are in
conformit# *it) re;uired specifications&
FAULT PRIMAR9 CAUSE SECONDAR9 CAUSE REMED9
1 $i!) oil ppm in
produce *ater
outlet
A Ineffective separation
B Level settin! of
interface level not
effective
a. "ontrol valve defective
4. "onnection fault at L(
0. 6ault in 3"S si!nals
Lea1a!e t)rou!) .affle
Plated
$i!)er production rates
over t)e desi!n rates
Reduce production
to desi!n limits
Lo* operatin!
temperature
$i!) viscosit#
2 $i!) *ater ppm in
oil outlet
A Lea1a!e t)rou!) *eir
plates
a. .olts on *eir
loose=!as1et not
defective
")ec1 and ti!)ten
B Level settin! of
interface level not
effective
a. "ontrol valve defective
4. "onnection fault at L(
0. 6ault in 3"S si!nals
Lea1a!e t)rou!) .affle
plates
$i!)er production over
t)e desi!n rates
Reduce production
to desi!n limits
Lo* operatin!
temperature
$i!) viscosit#
3 Sand content )i!) A Sand accumulation too a. "arr# out
Do0'*ent No LEPS$2!!#1!!"$O&M
in outlet *ater )i!) desandin!
operation
B a.
. 4o outflo* in
outflo* lines
4o !as content 4. Kse inert !as
0.
" Improper
functionin! of
vorte0 meter
C a.
4.
2 Improper
functionin! of P3
meter
A
B
#.! SHUT DO:N PROCEDURE ;NORMAL AND EMERGENC9<
;BeAore an5 o)erat(on- )1ease reAer to 0?a)ter 1.!. FSaAet5G<
#.1 S?'t Do6n
()e follo*in! procedure s)ould be follo*ed
"lose all manual valves
Stop t)e oil pumps
"lose isolation valves of unit
Stop electrical feed of )eat tracin! lines
* REMARCS
-)en t)e vessels are to be ta1en out of service t)e drain lines and an# compartments
s)ould be blo*n do*n to remove all t)e material t)at )as been collected&
,essels to be full# vented before man *a#s are released and pur!ed *it) nitro!en&
<as mas1s to be *orn *)en enterin! t)e vessel until it is certain t)at all )appens and
compartment are clear of !as and free of )a5ardous contaminates&
#.2 E*)t5(n+ t?e P1ant
-)en it is necessar# to completel# empt# t)e vessel> appl# t)e follo*in! procedure
"lose t)e inlet valves of "rude
3rain t)e oil and t)e *ater
As soon as t)e drainin! is complete "arr# out 3esandin! operation and flus)
out sand
pen bot) man)oles
Place blind flan!es or spectacles on at eac) no55le connected to pipe *or1&
Do0'*ent No LEPS$2!!#1!!"$O&M
#.2.1 IMPORTANT NOTES
3urin! t)e operation it is absolutel# imperative to replace t)e pumped-out product b#
inset !as ?e&!& 4itro!en@ or *ater under lo* pressure
Air must never enter t)e empt#in! vessel in order to avoid an e0plosive mi0ture
/.! ELECTRICAL MAINTENANCE
=.! DESIGN AND PERFORMANCE DATA
=.1 DESIGN 1st STAGE SEPARATOR
MANUFACTURER
PROCESS DATA ;DESIGN BASIS FOR EACH SEPARATOR IS #"J OF GROSS TRAIN
THROUGHOUT
I4LE( "43I(I4 ( 1
S(
S(A<E SEPARA(R (A< 4A 1,=+,=3,=/,-:301 ARE AS 6L-S ?EA"$@
3ES"RIP(I4 K4I( 3ESI<4 K(LE( 6L-
6IRS( HEAR ?8AL IL@
LA(ER HEARS
?8AL <ross Li;uid@
((AL 6L- '!=)r 161+00&9 163339
IL ?RE6ER PR3K"( SPE"&@ '!=)r 969:0 309:0
-A(ER '!=)r :32+0 13+300
<AS '!=)r 900&9 +29
(E8PERA(KRE C 20 20
PRESSKRE 1pa! :00 :00
3E4SI(H 6 IL E8KLSI4 '!=m3 9/3&9 9/3&2
3E4SI(H -A(ER '!=m3 9::&/ 9::&2
,IS"SI(H 6 IL E8KLSI4 cP 16:9 1909
,IS"SI(H 6 -A(ER cP 0&2/19 0&2/31
PRODUCT SPECIFICATION
1. L(&'(d )art(01es oA s(Ees 1"!)* and a4o3e s?a11 4e re*o3ed Aro* o't1et +as;1!!J REMO,AL<
2. O(1 Retent(on t(*e s?a11 4e 1! *(n'tes ;*(n(*'*<
3. 6ater retent(on t(*e s?a11 4e 1! *(n'tes ;*(n(*'*<
.. 6ater 0't (n o't1et o(1 strea* s?a11 4e 1ess t?an 3!J 3737
3esi!n "odes ASME ,III DI, 1 U$STAMP
FLUID O(1- 6ater & Gas
S:EET SER,ICE
Do0'*ent No LEPS$2!!#1!!"$O&M
PERA(I4< (E8PERA(KRE A43 PRESSKRE
I4(ER4AL /"! 1Pa! M "! "
EL(ER4AL - 1Pa! M - "
3ESI<4 (E8PERA(KRE A43 PRESSKRE
I4(ER4AL 13/! & FULL ,a0''* 1Pa! M 12" "
EL(ER4AL - 1Pa! M - "
8A-P 1.2".#" 1Pa! M "
8I4I8K8 3ESI<4 8E(AL (E8PERA(KRE
P-$( REAS4 IF RE%D.- AS PER CODE
RA3I<RAP$H NI4( E66A S$ELL 1!!J $EA3 1!!J
$H3R(ES( 1#=. 1Pa! $ori5ontal position
-I43 ,EL"I(H 13" 1m=) EAR($OKA'E P4E UBC1- KL!.!#"
"APA"I(H =1./2 m
3
I4SKLA(I4 3/** THICC Hot- As )er PDOC$SP$MEC$!1.
RE8AR'S APPLICABLE PDOC SPECIFICATION PDOC$SP$MEC$!2!
Do0'*ent No LEPS$2!!#1!!"$O&M
MATERIALS
SHELL
(HPE "#lindrical S)ell
AS8E 8A(ERIAL SA "12 Gr #!
3ESI<4 ($I"' 8m 1/.".
"RRSI4 ALL& 8m 3
8ILL (LERA4"E 8m !.3
((AL ($I"' 8m 1/.".
48I4AL ($I"' 8m 1=.!2
HEAD
(HPE 2.1 SE
AS8E 8A(ERIAL SA "12 Gr #!
3ESI<4 ($I"' 8m 1/.#"
"RRSI4 ALL& 8m 3
8ILL (LERA4"E 8m !.3
((AL ($I"' 8m 1/.#"
48I4AL ($I"' 8m 22.23
SA33LE PLA(ES =
-RAPPER PLA(E
SA 32 7 SA"12 GR #!
(RAHS NO
SKPPR( I4( SA "12 GR #! EL( SA "12 GR #! 7 SA 32
.L(S I4( SA 1=3 GR B#M EL( SA 1=3 GR B#
4K(S I4( SA 1=. GR2HM EL( SA 1=. GR 2H
6LA4<ES SA 1!" N
4PPLE -4E"'S SA 1!2 GR B
<AS'E(S SPIRAL :OUND SS 3!.
,ESSEL (RI8
$EA(I4< "IL SS 312L
I4(ER4ALS SS 312 L
DESIGN 2ND STAGE SEPARATOR
MANUFACTURER
PROCESS DATA ;DESIGN BASIS FOR EACH SEPARATOR IS #"J OF GROSS TRAIN
THROUGHOUT
I4LE( "43I(I4 ( +
43
S(A<E SEPARA(R (A< 4A 1,=+,=3,=/,-:30+ ARE AS 6L-S ?EA"$@
3ES"RIP(I4 K4I( 3ESI<4 K(LE( 6L-
6IRS( HEAR ?8AL IL@
LA(ER HEAR
?8AL <ross Li;uid@
((AL 6L- '!=)r 11+:16 /2111&1
IL ?RE6ER PR3K"( SPE"&@ '!=)r 96630 30620
-A(ER '!=)r 329+0 1/+90
<AS '!=)r /66 191&1
(E8PERA(KRE C 102 102
PRESSKRE 1pa! /00 /00
Do0'*ent No LEPS$2!!#1!!"$O&M
3E4SI(H 6 IL E8KLSI4 '!=m3 ::9&/ :99&+
3E4SI(H -A(ER '!=m3 9// 9//
,IS"SI(H 6 IL E8KLSI4 cP 93&9 93&39
,IS"SI(H 6 -A(ER cP 0&+623 0&+62+
PRODUCT SPECIFICATION
1. L(&'(d )art(01es oA s(Ees 1"!)* and a4o3e s?a11 4e re*o3ed Aro* o't1et +as;1!!J REMO,AL<
2. O(1 Retent(on t(*e s?a11 4e 1! *(n'tes ;*(n(*'*<
3. 6ater retent(on t(*e s?a11 4e 1! *(n'tes ;*(n(*'*<
.. 6ater 0't (n o't1et o(1 strea* s?a11 4e 1ess t?an 3!J 3737
3esi!n "odes ASME ,III DI, 1 U$STAMP
FLUID O(1- 6ater & Gas
S:EET SER,ICE
PERA(A(I4< (E8PERA(KRE A43 PRESSKRE
I4(ER4AL 3!! 1Pa! M 1!" "
EL(ER4AL - 1Pa! M - "
3ESI<4 (E8PERA(KRE A43 PRESSKRE
I4(ER4AL 13/! & FULL ,a0''* 1Pa! M 12" "
EL(ER4AL - 1Pa! M - "
8A-P 1.2".#" 1Pa! M "
P-$( REAS4 IF RE%D.- AS PER CODE
RA3I<RAP$H NI4( E66A S$ELL 1!!J $EA3 1!!J
$H3R(ES( 1#=. 1Pa! $ori5ontal position
-I43 ,EL"I(H 13" 1m=) EAR($OKA'E P4E UBC1- KL!.!#"
"APA"I(H ## m
3
I4SKLA(I4 3/** Hot- As )er PDOC$SP$MEC$!1.
RE8AR'S APPLICABLE PDOC SPECIFICATION PDOC$SP$MEC$!2!
MATERIALS
SHELL
Do0'*ent No LEPS$2!!#1!!"$O&M
(HPE "#lindrical S)ell
AS8E 8A(ERIAL SA "12 Gr #!
3ESI<4 ($I"' 8m 1/."2
"RRSI4 ALL& 8m 3
8ILL (LERA4"E 8m !.3
((AL ($I"' 8m 1/."2
48I4AL ($I"' 8m 1=.!"
HEAD
(HPE 2.1 SE
AS8E 8A(ERIAL SA "12 Gr #!
3ESI<4 ($I"' 8m 1/..3
"RRSI4 ALL& 8m 3
8ILL (LERA4"E 8m !.3
((AL ($I"' 8m 1/..3
48I4AL ($I"' 8m 22.23
SA33LE PLA(ES =
-RAPPER PLA(E
SA 32 7 SA"12 GR #!
(RAHS NO
SKPPR( I4( SA "12 GR #! EL( SA "12 GR #! 7 SA 32
.L(S I4( SA 1=3 GR B#M EL( SA 1=3 GR B#
4K(S I4( SA 1=. GR2HM EL( SA 1=. GR 2H
6LA4<ES SA 1!" N
4PPLE -4E"'S SA 1!2 GR B
<AS'E(S SPIRAL :OUND SS 3!.
,ESSEL (RI8
$EA(I4< "IL SS 312L
I4(ER4ALS SS 312 L
=.2 Des0r()t(on
See <eneral arran!ement plan
=.3 PerAor*an0e
()e PP8 of oil in *ater at t)e outlet meet s)all be less t)an +000 ppm
Li;uid particles of si5e 120 microns and above s)all be removed from t)e outlet
!as ?100Q removal@&&
il retention time s)all be minimum of 10 minutes
-ater retention time s)all be minimum of 10 minutes
-ater cut in oil stream s)all be less t)an 10Q v=v
=.. HaEards
()is separator contains )ot> )i!)-pressure $=" fluids& bserve statuar# re!ulations
for operatin! vessel& 3o not enter vessel until it )as been pur!ed and spaded-off& 3o
not operate vessel outside of desi!n conditions& 3o not sub7ect to sur!es=slu!s
outside of desi!n conditions&
=." InAor*at(on So'r0es
Do0'*ent No LEPS$2!!#1!!"$O&M
Address ;ueries on separator performance ?not vessel@ to A
$up Sen! offs)ore and En!ineerin! Pte Ltd
12+ <ul "ircle> Nuron!> Sin!apore
(el R62 6:61///9
1!.! STORAGE AND HANDLING
11.! OPERATION
()e separators are in t)e form of )ori5ontal pressure vessels fitted *it) internals to effect
separation of oil> *ater and !as&
11.1 Bas(0 Pr(n0()1es oA O)erat(on
()ree p)ase crude oil consistin! of oil> associated !as and *ater enters t)e separator
at t)e inlet no55le&
It first encounters a diverter> *)ere t)e bul1 separation of li;uid and !as ta1es place&
()e mi0ture t)en passes t)rou!) t)e perforated baffle plate *)ic) causes it to calm
do*n and aid oil *ater separation& After t)e baffle plate ma7or separation of oil and
*ater ta1es place and t*o separate la#ers of oil and !as are establis)ed& ()e
re;uired residence time is available to t)e mi0ture *)ic) causes t)e oil particles to
rise up*ards from t)e *ater p)ase and *ater particles to move do*n*ards from t)e
oil p)ase&
After separation t)e *ater flo*s out t)rou!) t)e produce *ater outlet line& ()e control
valve on t)is line is re!ulated so as to maintain a level of interface lo*er t)an t)e *eir
level& As t)e level of oil e0ceeds t)e *eir level> t)e e0cess oil flo*s over t)e *eir to
t)e ri!)t side in t)e oil 5one& At normal production rates t)e oil level *ould be above
t)e *eir )ei!)t& ()e separated oil t)en flo*s out t)rou!) t)e oil outlet&
n t)e left side of *eir> t)e interface level is controlled bet*een t*o preset alarm
levels ie I$L and ILL& A standpipe is fitted in parallel *it) t)e separator> capable of
reflectin! levels in t)e separator& n t)is standpipe> t)ere are t*o float t#pe level
transmitters> *)ic) transfer t)e si!nal to 3"S control& 3"S controls t)e interface level
b# re!ulatin! t)e control valve on t)e produce *ater outlet line& Alarms are also
si!naled at 3"S at t)ese levels&
In addition to t)ese> for levels above I$L and belo* ILL> a level transmitter is fitted to
initiate si!nal at I$$ and ILL *)ic) cuts off of t)e inlet and outlet valves& 6loat t#pe
level !au!e is fitted on t)e standpipe to indicate t)e interface levels&
n t)e oil side of *eir> t)e oil level is controlled bet*een t)e t*o alarm levels ie $L
and LL& ()is control is ac)ieved b# re!ulatin! t)e control valve on t)e oil outlet and
on t)e oil inlet& 6or levels be#ond t)is ran!e> a level transmitters is provided to initiate
si!nal at $$L and LLL *)ic) *ill valve cut off inlet and outlet valves& 8a!netic level
!au!e is provided to indicate oil levels&
All transmitters for interface detection are buo#anc# t#ope and t)ose for oil level
detection are diap)ra!m t#pe&
Do0'*ent No LEPS$2!!#1!!"$O&M
11.2 Meas'r(n+ and Contro1 (nstr'*ents
6lo* indicatorA 3ifferential pressure t#pe indicator is provided in t)e incomin!
crude oil line> *)ic) measures flo* *it) t)e )elp of orifice plates&
,orte0 6lo* 8eterA Provided on t)e produce *ater outlet line
3ifferential Pressure IndicatorA 3ifferential pressure transmitter and indicator are
provided to measure t)e pressure drop across t)e strainer on crude oil outlet line&
(emperature IndicatorA + nos> provided on t)e vessel
Pressure indicatorA (o indicate t)e pressure
Level IndicatorsA 6itted on t)e vessel to measure interface level and il level&
11.3 Contro1 ,a13es
P, ,alve on t)e <as line
ES3, A n crude inlet
Level "ontrol ,alvesS
1 on "ustod# oil outlet
1 on produce *ater outlet
11.. Fa'1t 0ond(t(ons
Provided t)e separators are operated *it)in t)e desi!n criteria specified in section
1&3> no faults s)ould occur& ()e main *a#s to identif# failure areA
- E0cessive oil carr#out in produce *ater do*nstream
- Increase in normal operatin! pressure drop across t)e separators&
.ecause of t)e nature of t)e separators it *ould be impractical to mention all t)e
possibilities *)ic) could cause t)e above> but in t)e event of an# of t)e above
occurrin!> t)is is to be reported immediatel# to $SEPL *it) t)e process flo*
particulars as specified in section 1&3&
Tro'41e S?oot(n+ G'(de
FAULT PROBABLE CAUSE
1 E0cessive pressure drop across
separator
.loc1a!e in separator=internals dama!ed&
pen separator and investi!ate&
+ Separator operatin! at incorrect levels Instrument=control valve fault A
consult suppliers product data
3 Incorrect separation efficiencies ")ec1 1 % + and also c)ec1 process
conditions are as stated in t)is manual
12.! MAINTENANCE
Do0'*ent No LEPS$2!!#1!!"$O&M
12.1 Re0o**ended S0?ed'1e oA *a(ntenan0e
All internals s)ould be visuall# inspected ever# : *ee1s> unless in operation t)e
separator fails to meet t)e re;uired dut# and process specification for t)e !as and
li;uid streams&
12.2 Ma(ntenan0e Re&'(re*ents
Interna1s- Ro't(ne Ma(ntenan0e
()e )ori5ontal separators comprise internal baffles t)at )ave to be re!ularl#
maintained durin! t)e life of t)e vessels& ()e internals are listed in t)e description
section of t)is manual and t)e follo*in! activities s)ould be carried out as per
recommended sc)eduleA
1@ Internals s)ould be visuall# inspected for si!ns of crac1in!> erosion>
dama!e etc&> and repaired as necessar#&
+@ ")ec1 all internals are free of dirt> debris> bloc1a!es etc&> ensure t)e# are
free of tar build-up etc&
3@ ")ec1 all items s)o* no si!ns of dama!e from erosion> sur!es etc&>
c)ec1 *eirs and sound&
/@ ")ec1 all boltin! is ti!)t and fitted *it) second nut ?loc1 nut@&
2@ "arr# out re-certification inspection of pressure vessels in accordance
*it) manufacturerJs instructions=statuar# re;uirements&
If it is necessar# to remove t)e internals from t)e vessels follo* t)e reversed
procedures outlined in section 3&3&
12.2.1 ,esse1
As re;uired b# pressure vessel code> carr# out periodic re-certification
re;uirements&
")ec1 forA
"rac1in! of attac)ment *elds to s)ells
Erosion of vessel s)ells at areas around inlet=outlet no55les
"orrosion around drain connections and instrumentation connections
"lo!!in!> plu!!in! of instrumentation connections
Pittin! or scuffin! of an# !as1eted faces
Al*a#s use !as1ets *)en re-ma1in! no55le=man*a# flan!e connections&
Do0'*ent No LEPS$2!!#1!!"$O&M