Functional Specifications FOR Test Separation Module: Onshore Engg Services, N Delhi Document No.: OESG/ARP/TSP/M002 REV

FUNCTIONAL SPECIFICATIONS
FOR
TEST SEPARATION MODULE
0 06.12.2007
REV. DATE PREPARED BY CHECKED BY APPROVED BY
ONSHORE ENGG SERVICES, DOCUMENT NO. : REV

N DELHI TEST OESG/ARP/TSP/M002
SEPARATION
PROJ.: ASSAM RENEWAL PROJECT PAGE NO. : 1 OF 18 0
MODULE
JOB NO.: OESG- AA-07-001
TABLE OF CONTENTS
1.0 INTRODUCTION
1.1 Scope
1.2 Definitions and Abbreviations
1.2.1 Definitions
1.2.2 Abbreviations
1.3 Units of Measurements & Language

2.0 SCOPE OF SUPPLY
2.1 Engineering Design
2.2 Equipment Supply
2.3 Options
2.4 Exclusions
3.0 REFERENCED DOCUMENTS & ATTACHMENTS
3.1 Acts, Codes, Standards and Regulations
3.1.1 Codes and Standards
3.2 Requirements of Statutory Authorities
4.0 OPERATING CONDITIONS
5.0 PROCESS
5.1 Process Description
5.2 Process Design Data
5.3 Product Specification
5.4 Measurement and control Philosophy
5.5 Process Guarantee
5.5.1 Guarantee
5.5.2 Guarantee Period
6.0 MODULE
7.0 EQUIPMENT
7.1 Pressure Vessels
7.1.1 General
7.1.2 Design
7.1.3 Assembly
7.2 Piping & Valves
ONSHORE ENGG SERVICES, DOCUMENT NO. : REV

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PROJ.: ASSAM RENEWAL PROJECT PAGE NO. : 2 OF 18 0
MODULE
7.2.1 Design
7.2.2 Installation
8.0 OPERATION AND CONTROL
9.0 ELECTRICAL DESIGN
10.0 MAINTENANCE
11.0 PAINTING & PRESERVATION
12.0 QUALITY ASSURANCE, INSPECTION AND TESTING
13.0 CONTRACTOR DATA REQUIREMENTS
14.0 SPARE PARTS AND SPECIAL TOOLS
ONSHORE ENGG SERVICES DOCUMENT NO. : REV

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PROJ.:ASSAM RENEWAL PROJECT PAGE NO. : 3 OF 18 0
MODULE
1.0 INTRODUCTION
1.1 Scope
This Functional Specification covers the design, materials, fabrication, testing,

painting, inspection and supply of Test Separation Modules for onshore applications.
This Specification is based on a two -phase vertical separator vessel and describes
modules where all necessary equipment is completely confined within the boundaries
of a single structural module and mounted on it.
The Modules shall be equipped with Test Separation Vessel, baffles, internals
including Mist Extractor, internal / external piping, control devices and all necessary
accessories to make a complete and functional unit. The test separation should
include gas & total fluids metering at their respective outlets.
This Functional Specification will cover suitable module size to have appropriately
sized modules for all installations. Detailed below are the type of module size based
on liquid sm3/d required:
M3/d
• Module 1: 100
• Module2 250
TOTAL - 2 modules
No.s of units as per GGS scope of work
This Specification should be regarded as the Company’s minimum requirements for
this equipment. Wherever stringent requirements for design, safety and testing are to
be met as per code and standards at 3.1below , the same may be notified to the
company. Under no circumstances the requirements shall be relaxed to meet this
specification without prior written approval / agreement from the company.
The test separation module shall be designed in accordance with the process design
criteria stipulated in Section 5.0. In addition to the above, contractor shall investigate
the proven state of art technology to improve the separation process. Outcome of the
study highlighting the process / cost or any tangible / intangible benefits will be
provided to the company. In particular, the following should be examined for this
application:
• two-phase test separators for emulsified crude.
• Three-phase metering for crude oil, water & gas .

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1.2 Definitions and Abbreviations
1.2.1 Definitions
Company Oil and Natural Gas Corporation Limited (ONGC).
Contractor The party responsible for the design and supply of goods and/or
services, for a complete project or installation.
Inspector The person appointed by the Contractor to carry out engineering

inspection in the Supplier’s works.
Project Assam Renewal Project
Supplier The organisation, company or agency that is contracted to provide

goods or services to the Contractor.
Third Party An impartial body, possessing the necessary competence to verify

Inspector that designs and/ or manufacture satisfy the specification
and purchase order requirements.
1.2.2 Abbreviations
BRH Borholla (oil and gas field)
CMG Changmaigaon (oil and gas field)
CTF Central Tank Farm
DGMS Directorate General of Mines Safety
DML Demulgaon (oil and gas field)
ETP Effluent Treatment Plant
GLK Geleki (oil and gas field)
GCP Gas Compressor Plant
GCS Gas Collecting Station (in gas fields mainly)
GGS Group Gathering Station (for oil)
LKW Lakwa (oil and gas field)
LPN Laiplingaon (oil and gas field)
ONGC Oil and Natural Gas Corporation Limited

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OISD Oil Industry Safety Directorate
PFD Process Flow Diagram
P&ID Piping and Instrumentation Diagram
RDS Rudrasagar (oil and gas field)
TPL Trunk/Feeder/Collector Pipe Line
WIP Water Injection Plant
WHI/EPS Well Head Installation / Early Production System
1.3 Units of Measurements & Language
All values will be in SI Units (according to ISO 1000).
Standard conditions at 101.325 kPa and 15.56°C.
All documents and correspondence shall be in English language.
2.0 SCOPE OF SUPPLY
The Test Separation Module (“the Module”) shall include all the equipments identified
within this Functional Specification.
The Module shall be completely packaged with the related components and
accessories and delivered ready for operation.
No fabrication shall commence till the Company, or their designated representative,

has approved the approval drawings for construction / fabrication. Approval of
construction drawings does not relieve the Contractor of his responsibility for
compliance with process performance and following of relevant codes, standards,
specifications, safety design and meeting the requirements of governmental agencies
and boards.
The final sizing and design of the Module, including all internal and external
components, shall be the responsibility of the Contractor.
New technology options and developments are acceptable provided they give
equivalent or better process performance. The alternative options must be proven
and tested at a commercial level and submitted with relevant justification. Contractor
to list techno-economic advantages of new technology proposed.

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2.1 Engineering Design
The Module shall be designed in accordance with the process design criteria
stipulated in Section 5.0.
The Contractor shall be responsible for the detailed design of two phase test
separation Modules as detailed in Section 5.0. Each module should include the
following;
Item Qty Notes
Test Separation Vessel 1 2 Phase. Including internals

Intermediate Transfer Vessel 1 Working volume = 2 m3
Gas Metering 1 After test separator
Total oil & water Metering 1each After test separator
Base Assembly Module only
Piping Module only
Electrical & Instrumentation Module only
Controls Module only
The Module, and internal equipment, shall be constructed of materials appropriate for
the installation (operating and design conditions) and long term operation in the area
with ambient conditions as identified in Section 4.0. Materials and components for
this unit shall be new and unused.
The Modules design shall be based on the process information provided in design
basis of GGS and this document.
The Modules shall be supplied based on a 25 year design life.
2.2 Equipment Supply
The equipment supply shall include design, fabrication and supply of the following
main items:
Item Qty Notes
Test Separation Vessel Including internal piping, baffles ,

1 internals including Mist extractor, relief
valves, drains and external insulation
Intermediate Transfer Vessel Including relief valves, drains and
1
external insulation

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MODULE
Gas Metering 1 After test separator
oil and water Metering 1each After test separator
Base Assembly Module only
Piping Module only
Electrical Module only
Control valves &
Instrumentation including PSV, Module only
PCV etc.
Controls Module only
Insulation Vessels, pipes and structures. To
conform with process and safety
standards.
Heat Tracing As required to meet process
requirements.
Measurement Systems for Module only.
emulsion and produced gas • For Liquid Metering: Coriolis Mass
quantity and emulsion BS&W. Flow Meters/Ultrasonic Meters.
• For Gas Measurement – Senior
Orifice Metering
2.3 Options
The Contractor may provide options to the scope detailed in this Specification.
2.4 Exclusions
Supply and installation of equipment, piping, electrical, instrumentation, structural and

civil installations outside the module boundaries.
Supply of feed or discharge pumps.
Fire & Gas detection and suppression systems.
3.0 REFERENCED DOCUMENTS & ATTACHMENTS
Equipment, materials, design, construction and testing shall be in accordance with

this Specification and with the applicable parts of the documentation listed below.
Latest editions of standards, codes etc. as on Purchase Order date shall apply unless
otherwise specified.

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3.1 Acts, Codes, Standards and Regulations
As a minimum, all equipment supplied should be designed, manufactured and

delivered in accordance with the requirements of the latest editions of the following
Codes, Standards and Regulations:
3.1.1 Codes and Standards
3.1.1.1 Indian
OISD-STD-106 Process Design and Operating Philosophies on

Pressure Relief and Disposal System
OISD-STD-110 Recommended Practices on Static Electricity
OISD-STD-118 Layouts For Oil & Gas Installations
OISD-RP-149 Design Aspects for Safety in Electrical Systems
OISD-STD-152 Safety Instrumentation for Process System in

Hydrocarbon Industry
Inspection of Unfired Pressure Vessels.
OISD-STD-128
Inspection of Pressure relieving Devices

OISD-STD-132
OISD-STD-164 Fire Proofing in Oil & Gas Industry
OISD-STD-173 Fire Protection System for Electrical Installations
OISD-STD-180 Lightning Protection
OISD-GDN-192 Safety Practices during Construction

Recommended Practices for Environmental
OISD-GDN-201
Protection in upstream Petroleum Sector.
Guidelines on Safety Management System in

OISD-GDN-206
Petroleum Industry.
3.1.1.2 ANSI/API/NACE Standards
API RP 520 Sizing, Selection and Installation of Pressure-

Relieving Devices in Refineries
API RP 521 Guide for Pressure-Relieving and Depressurizing

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Systems
API RP 550 Manual on Installation of Refinery Instruments and

Control Systems
API Spec 12J Oil and Gas Separators
ASME VIII Div 1 Boiler & Pressure Vessel Code
ANSI / ASME B31.3 Chemical Plant and Petroleum Refinery Piping
ANSI / ASME B16.5 Pipe Flanges and Flanged Fittings
ANSI / AWS D1.1 Structural Welding Code-Steel
NACE-RP-0472 Methods and Controls to Prevent In-Service

Environmental Cracking of Carbon Steel Weldments
in Corrosive Petroleum Refining Environments
3.2 Requirements of Statutory Authorities
The Assam onshore facilities operate within the legal domain of India. The
Contractor, and sub-Contractors, must comply with the Regulations including
environmental protection Act of India. These include, but are not limited to;
• Equipment and Materials in accordance with Directorate General of Mines

Safety – India
• DGMS, Oil Mines Regulations, 1984
• Central Pollution Control Board(CPCB) & Assam Pollution Control

Board(APCB)
4.0 OPERATING CONDITIONS
The Modules will be designed, fabricated and installed to accommodate the local
environmental conditions of Assam district in India.
4.1 Local and Environmental Conditions are given in Appendix C
4.2 Utilities available are given in Appendix C.
5.0 PROCESS
The Modules serve the purpose of testing individual wells to monitor well / reservoir
performance. All installations will have well-fluids preheated in a bath-heater to
promote separation. The test separator will need to have the capability of testing

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MODULE
both oil and gas wells. This Functional Specification will cover three different module
sizes that will cater to ONGC’s Thirteen (13) installations.
Design case summary as follows:
• Number of installations: as per GGs scope of work
• Biggest producing oil-well: 220-250 m3/day
• Biggest producing gas-well: 0.1 MMSCMD
5.1 Process Description
The test separator’s main function is to test individual wells. The well that is to be
tested will be diverted to the test header from where it will be routed to a bath heater
for preheating. Heated well fluids will then be separated in a two -phase separator
with the liquids being routed to the intermediate transfer vessel or sampling vessel.
Water cuts for well-testing can vary from 5 to 95%.
While testing in LP mode, oil from the three-phase separator will continuously flow
into the intermediate transfer vessel, from where it would be pumped into the heater-
treater. While test separator is in HP/MP mode, fluid will go to the next separation
stage. Gas from the three-phase test separator is routed to the GCP while gas from
the inter-transfer vessel is sent to the LP compressor. Oil , water and gas will be
metered on the test separator outlet lines .
5.2 Process Design Data
Two -phase HP /LP Test Separator

• Operating Pressure: 2.5 – 60 kg/cm2g (refer design basis of GGS for
individual Test Separators)
• Temperature: 60 °C
• Design Flow: 4 – 220 m3/day and 4-100 m3/d of liquids(Note 1)
• Gas Flow: 0.001 – 0.10 MMSCMD
• Residence time: 3 minutes min. for liquids in two phase separator
• Surge and Swell factor Surge factor of 25% on maximum well fluid flow
rates and swell factor of 15% on maximum oil flow
rates
Note 1: Please refer design basis of GGS 4 m3/day represent the smallest producing
oil well while 220 m3/day represents the biggest producing well from the installations.
Module1 :
• Operating Pressure: 2.5 – 60 kg/cm2g
• Design Flow: 250 m3/day

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Module2
• Operating Pressure: 2.5 – 60 kg/cm2g
• Design Flow: 100 m3/day
• Residence time: 3 minutes minimum for liquids in two phase

separator
The total number of modules provided above are preliminary and may change
subject to finalisation and validation of process data.

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MODULE
Although a range of fluid parameters and composition has been provided in the
design basis, the module design should be developed on the worst case scenario
(i.e most conservative design).
5.3 Product Specification
Vessels should be sized as per the above design data to ensure wells are accurately
tested. As stated Section in 2.0, contractor to suggest on emerging and state of the
art technology that may differ from the system stated in this Section 5.2 and which
can aid in separation or reduce operation costs.
5.4 Measurement and Control Philosophy
The test separator level will be controlled via a control valve on the liquid outlet of the
vessel. The primary aim is the level control of the separator. A cascade system is
proposed where the level output from the separator vessel cascades to the flow
control loop on the liquid outlet from the separator.
Within the central level zone for the separator, the control loop will be in flow control
and the level may fluctuate within the present bands, say 25% L-N and 75% N-H.
When the level approaches the high and low levels more closely, the level controller
will adjust the set-point of the “flow control valve” to open or close the valve till
separator level returns to normal.
An alarm will be provided for high level in the separator.
When the level rises above high-level, the inlet valve closes and this decreases the
liquid influx into the inlet separator thereby decreasing the level.
The inlet shut-down valve will close when the level rises to HH level.
An alarm will be provided for low-level in the Inlet Separator.
The outlet shut-down valve will close if LL level is reached.
For pressure control split range PCVs will be fitted to the gas outlet lines from the
inlet separator which is controlled by PIT. The PIT is also present to allow
depressurisation of the vessel to the flare system, in the event of high pressure with
dedicated PCV for gas manifold and Flare lines.
Gas will be metered on the gas outlet using conventional methods such as orifice
plate. Coriolis and water-cut meters will be used for measurement of oil and water
lines respectively.

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MODULE
The contractor has the option of complying with the above control philosophy or
proposing an alternative design provided the control system offers advantages in
terms of process performance and cost savings.
5.5 Process Guarantee
5.5.1 Guarantee
The subcontractor guarantees and warrants for the duration of the Guarantee Period
described below that the Process System will be:
a) manufactured and commissioned in accordance with and will meet or exceed the
Specifications; and
b) free from all defect in design and workmanship; and
c) operable in accordance with, and based on the design data contained in the
Specifications; and
d) suitable for its intended purpose as per the Specifications.
5.5.2 Guarantee Period
The Guarantee Period will be for a period of twenty four (24) months from the date of
Delivery, or twelve (12) months from the date of completion of installation and
commissioning of the Process System at the Company’s Production Site, whichever
is less. During the Guarantee Period, Subcontractor at its cost, risk and expense, will
repair, redo or replace any part of the Process System which fails to meet the above
warranty or guarantee which manifests itself during the Guarantee Period.
The Guarantee Period for any executed repairs and replacement shall be eighteen
(18) months from the completed repair or replacement.
Any repairs should be carried out on-site if at all possible, and so as to minimise any
disruption to the working of the Process System and any other parts of the
Installation/Plant to the greatest possible extent.

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MODULE
6.0 MODULE
Refer Appendix C “ Module “.
7.0 EQUIPMENT
Adequate sampling connections and future connections for chemical additives shall
be provided and appropriately located.
7.1 Pressure Vessels
7.1.1 General
All vessels shall be code stamped to ASME VIII unless noted otherwise. All vessels
shall be registered with a suitable third party verification body (e.g. Lloyd’s, DNV).
7.1.2 Design
All pressure vessels shall be of welded construction in accordance with ASME Boiler
and Pressure Vessel Code, Section VIII Division 1.
Vessels shall be designed to withstand the loading exerted by internal or external

pressure, weight of vessel, wind, seismic, reaction of supports, impact and
temperature. Detailed vessel design including internals shall be the responsibility of
the Contractor.
vessel shall have adequate shell thickness not to be overstressed at mid-span and
near saddle supports with design loads under the following conditions:
• Full of water at atmospheric pressure.
• Full of water at hydrostatic test pressure.
• At operating liquid level and specific gravity at maximum allowable working

pressure (MAWP) with shell corroded.
Unless noted otherwise an internal corrosion allowance of 3mm is to be used in the

vessel design.
7.1.3 Assembly
All bolts in manholes, hand holes and nozzles shall straddle the normal vessel
centrelines.
All pressure bearing flanges shall comply with ASME B16.5 unless stated otherwise.

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MODULE
The Contractor shall design, furnish and install all internal support rings, downcomer
supports, bars, grating supports, wire mesh, seat angles, special breakers, baffles,
impingement and wear plates etc.
Reinforcing pads or doubler plates shall be provided beneath all attachments where
loading creates stress concentration or where attachment welds for external
appurtenances may cause locked thermal stresses.
All structural members, attached by welding to the outside of the vessel, shall be seal
welded continuously to the vessel.
Lifting lugs shall be installed to facilitate the handling of the vessel.
Vessel testing and inspections shall be in accordance with ASME VIII and to
Company approved standards.
7.2 Piping & Valves
7.2.1 Design
All piping shall be designed in accordance with ANSI / ASME B31.3 and this
Specification unless otherwise noted.
Process liquid lines shall be sized for fluid velocities in accordance with industry
standards.
The minimum required pipe wall thickness for any service shall be calculated in
accordance with ANSI / ASME B31.3.
Unless otherwise specified, all pressure piping shall have a minimum corrosion
allowance of 1.6mm. This is in addition to mechanical allowances.
7.2.2 Installation
“Stub-in” branch connections shall not be permitted.
A sufficient number of flanges or unions shall be provided in all piping to allow

disconnection of valves and equipment for maintenance.
Piping shall be arranged in a neat and simple manner. Piping, including supports,
valves and controls, shall be located so as not to present obstructions or stumbling
hazards nor interfere with equipment operation and maintenance. At least 600 mm
clear space shall be provided for access to equipment.
The minimum overhead clearance for piping or walkways shall be 2 metres. Piping
installed in pipe racks shall be grouped to have common bottom pipe elevations.

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Piping headers shall generally be terminated with flanges and shall be installed to
allow for future expansion of the header.
Pipe systems shall have block valves, by-passes and cleanouts to provide
convenient access and repair.
Piping shall be designed to minimise pockets and low points.
Drain and vent connections as required for testing, maintenance and operation shall
be provided on piping. As a minimum, lines shall have ½ “ vent connections at high
points and shall have ½ “ drain connections at low points. Connections only for
hydrotest do not require valves.
Valve drains shall be installed on equipment that is not self-draining.
Pipe elbows shall be long radius bends unless approved otherwise.
Where threaded pipe or fittings are used in hydrocarbon service, the piping between
any vessel or bridle and the first valve shall be a minimum of schedule 160.
Piping at equipment shall be supported in such a manner that the equipment may be
removed without effecting the piping and shall be supported to prevent transmission
of excessive moments and forces to equipments.
Adequate provisions shall be made in piping systems for thermal expansion and
contraction in accordance with ANSI / ASME B31.3.
Eccentric reducers with flat side up shall be used in pump suction connections.
8.0 OPERATION AND CONTROL
Refer to Appendix A, “Instrumentation and Control Guidelines”.
9.0 ELECTRICAL DESIGN
Refer to Appendix B, “Electrical Guidelines”.
10.0 MAINTENANCE
Refer to Appendix C, “Maintenance”.
11.0 PAINTING & PRESERVATION
Refer to Appendix C, “Painting & Preservation”.
12.0 QUALITY ASSURANCE, INSPECTION AND TESTING
Refer to Appendix C, “Quality assurance, inspection and testing”.

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13.0 CONTRACTOR DATA REQUIREMENTS
Refer to Appendix C, “Contractor data requirements”.
14.0 SPARE PARTS AND SPECIAL TOOLS
Refer to Appendix C, “Spare parts and special tools”.

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MODULE

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FUNCTIONAL SPECIFICATIONS

REV. DATE PREPARED BY CHECKED BY APPROVED BY

ONSHORE ENGG SERVICES, DOCUMENT NO. : REV

1.3 Units of Measurements & Language

ONSHORE ENGG SERVICES, DOCUMENT NO. : REV

ONSHORE ENGG SERVICES DOCUMENT NO. : REV

This Functional Specification covers the design, materials, fabrication, testing,

• two-phase test separators for emulsified crude.

• Three-phase metering for crude oil, water & gas .

ONSHORE ENGG SERVICES DOCUMENT NO. : REV

Company Oil and Natural Gas Corporation Limited (ONGC).

Inspector The person appointed by the Contractor to carry out engineering

Project Assam Renewal Project

Supplier The organisation, company or agency that is contracted to provide

Third Party An impartial body, possessing the necessary competence to verify

BRH Borholla (oil and gas field)

CMG Changmaigaon (oil and gas field)

CTF Central Tank Farm

DGMS Directorate General of Mines Safety

DML Demulgaon (oil and gas field)

ETP Effluent Treatment Plant

GLK Geleki (oil and gas field)

GCP Gas Compressor Plant

GCS Gas Collecting Station (in gas fields mainly)

GGS Group Gathering Station (for oil)

LKW Lakwa (oil and gas field)

LPN Laiplingaon (oil and gas field)

ONGC Oil and Natural Gas Corporation Limited

ONSHORE ENGG SERVICES DOCUMENT NO. : REV

PFD Process Flow Diagram

P&ID Piping and Instrumentation Diagram

RDS Rudrasagar (oil and gas field)

TPL Trunk/Feeder/Collector Pipe Line

WIP Water Injection Plant

WHI/EPS Well Head Installation / Early Production System

1.3 Units of Measurements & Language

All values will be in SI Units (according to ISO 1000).

Standard conditions at 101.325 kPa and 15.56°C.

All documents and correspondence shall be in English language.

2.0 SCOPE OF SUPPLY

No fabrication shall commence till the Company, or their designated representative,

ONSHORE ENGG SERVICES DOCUMENT NO. : REV

Item Qty Notes

Test Separation Vessel 1 2 Phase. Including internals

The Modules shall be supplied based on a 25 year design life.

2.2 Equipment Supply

Item Qty Notes

Test Separation Vessel Including internal piping, baffles ,

ONSHORE ENGG SERVICES DOCUMENT NO. : REV

Supply and installation of equipment, piping, electrical, instrumentation, structural and

Supply of feed or discharge pumps.

Fire & Gas detection and suppression systems.

3.0 REFERENCED DOCUMENTS & ATTACHMENTS

Equipment, materials, design, construction and testing shall be in accordance with

ONSHORE ENGG SERVICES DOCUMENT NO. : REV

As a minimum, all equipment supplied should be designed, manufactured and

3.1.1 Codes and Standards

OISD-STD-106 Process Design and Operating Philosophies on

OISD-STD-110 Recommended Practices on Static Electricity

OISD-STD-118 Layouts For Oil & Gas Installations

OISD-RP-149 Design Aspects for Safety in Electrical Systems

OISD-STD-152 Safety Instrumentation for Process System in

Inspection of Pressure relieving Devices