3TECHNICAL SPECIFICATIONS AND SCOPE OF WORK

FOR SKID MOUNTED HIGH PRESSURE (HP) GAS SEPARATOR (STANDARD SERVICE)
(With ASME ' U ' stamp)
1.0 SCOPE OF SUPPLY: -

Design, engineering, fabrication, testing, supply, pressure & functional testing of skid mounted horizontal three-
phase (oil, gas, and water) separators along with associated piping, instrumentation, control and all other
accessories

This specifications describe the basic requirements for design, engineering materials procurement, fabrication,
performance guarantee, and supply of above skid mounted HP gas separators. Equipment shall be skid mounted
- complete with all internal and external control, instrumentation, piping, valves and structural etc. as per
standard ASME Sec VIII.

2.0 SPECIFICATIONS OF HP SEPARATORS:

THE SEPARATOR SHALL BE DESIGNED TO PROVIDE EFFECTIVE SEPARATION OF CRUDE OIL, WATER
AND GAS PHASES BY INCORPORATION OF HIGH EFFICIENCY VESSEL INTERNALS GENERALLY
COMPRISING OF:-
a) Inlet degasser element for primary separation of gas and liquid
b) Flow smoothening assembly for reducing turbulence in the gas-stream
c) Demister assembly below the gas outlet nozzle for removal of entrained liquid droplets from the gas
d) Wave breakers to prevent wave formation in the liquids and to minimize the disturbance at the gas- oil-
interface
e) Vortex breakers at oil as well as water outlets to prevent carryover due to vortexing
f) Oil outlet nozzle located beneath the gas outlet nozzle
g) Water outlet nozzle located at the bottom of the vessel downstream of weir plate.
h) Temperature indicators, pressure indicators, level gauges and pressure safety relief valves. The safety
relief valves discharge shall be connected to the flare gas line i.e. down- stream of the flare pressure
control valve.
i) The oil, gas & water outlet lines shall be provided with sampling points.
j) Separator vessel should have 18" or more than 18” manhole with davit arrangement away from inlet for
inside cleaning and maintenance in accordance with ASME code.
k) Vessel shall be designed for outdoor location in hazardous areas as per ZONE-1, GAS GROUP IIA & IIB.

3.0 DESIGN DATA

TYPE OF SEPARATOR 3 PHASE HORIZONTAL
(HP)- STANDARD SERVICE
(Mandapeta GCS)
OPERATING PRESSURE 50 – 60 Kg/Cm2
DESIGN PRESSURE 100 Kg/Cm2
OPERATING TEMPARATURE 60 DEG C
DESIGN TEMPERATURE 150 DEC C
OIL SPECIFIC GRAVITY 0.75 - 0.85
GAS SPECIFIC GRAVITY 0.6- 0. 7 (AIR = 1.0)
WATER SPECIFIC GRAVITY 1 - 1.04
SERVICE STANDARD SERVICE

Minimum Normal Maximum

 LIQUID FLOW RATE (M3/Day) 20 30 50
WATER CUT (%) 20% 50% 80%
GAS FLOW RATE (LCMD) 1.0 2.0 3.0
RETENTION TIME 3 MINUTE
CORROSION ALLOWANCE 3 MM FOR VESSEL

PERFORMANCE REQUIREMENTS:
1. CARRYOVER OF LIQUID WITH GAS FROM THE SEPARATOR SHALL NOT EXCEED 13.4 LITERS/MMSCM
AS DROPLETS LARGER THAN 10-MICRON DIAMETER.
2. FREE WATER CONTENT OF EXIT OIL NOT TO EXCEED 0.5% BY VOLUME.
3. FREE OIL CONTENT OF EXIT WATER NOT TO EXCEED 200 PPM BY VOLUME.
4. ALL LEVEL INSTRUMENT NOZZLES SHALL BE FARTHEST FROM FEED.

4.0 DESIGN STANDARDS TO BE FOLLOWED:

 STAMPING : THE VESSEL SHOULD BE ASME “U” STAMPED.
 DESIGN CODE OF PRESSURE VESSEL : ASME SEC VIII DIVN.1, ASME SEC.IX, API 12J,

 DESIGN CODE OF PIPING : ANSI B 31.3 AND

 DESIGN CODE OF STRUCTURE : AS PER CONTAINER SPECIFICATION ISO1496

 DESIGN CODE OF SAFETY : RECOMMENDED PRACTICE FOR PROCESS AND INSTRUMENTATION
SAFETY AS PER API-RP-14 & API RP 520
 DESIGN CODE OF BALL/PLUG VALVES : API 6 D AND

 THREADING FOR TUBE FITTINGS : ANSI B.2.1

5.0 VESSEL TECHNICAL SPECIFICATIONS :

PROCESS DATA SHEET - HORIZONTAL VESSELS

   

 
N14
N9
 

 
 

NOZZLE DETAILS

MARK NO SERVICE
N1 1 INLET
N2 1 LIQUID OUTLET
N3 1 VAPOR OUTLET
N4 1 WATER OUTLET
N5 2 LEVEL GAUGE
N6 2 LEVEL SWITCH
N7 2 LEVEL TRANSMITTER
N8 2 INTERPHASE LEVEL TRANSMITTER
N9 1 INTERPHASE LEVEL SWITCH
N10 1 TEMPERATURE GAUGE
N11 1 PRESSURE GAUGE
N12 1 RELIEF VALVE
N13 1 MANHOLE
N14 1 UTILITY CONNECTION

1. The given data is indicative, contractor has to re-work and design as per ASME SEC - VIII to fulfil the process
scheme requirement and retention time.
2. Liquid carryover in gas, max.: 13.4 liters / MMSCM of gas (removal of liquid particles more than 10 microns)
3. Liquid residence time: 3 minutes (min.) On maximum liquid flow

Bidder must confirm that all the above specified parameters and nozzle positions will meet the design data
provided at Sl. No. 3.0 above and design standards indicated at Sl. No.4.0 above.

6.0 MATERIAL OF CONSTRUCTION:

SL.NO. ITEM DESCRIPTION MATERIAL GRADE

a SHELL HEAD SA 516 GR.70
b FLANGES A 105
c PIPING A 106 GR. B
d INTERNALS SS 316 L
e STRUCTURAL IS 226/IS2062

7.0 SEPARATOR PIPING

Separator piping shall be of the following size AND to be designed as per details given above at Sl. No. 3.0 and
4.0.

a. HP Separator (STANDARD SERVICE):

 Well Fluid Inlet : Minimum 4” or as per the design requirement
 Oil line : Main – Minimum 3 Inch or as per the design requirement and
Bypass – bypassing of flow meters
 Gas line Main : Main – Minimum 6 Inch or as per the design requirement
 Water line : Main – Minimum 4 Inch or as per the design requirement and
Bypass – bypassing of flow meter
  Drain line : 2 Inch should be connected to water line after control valve and before the final
Plug / ball valve near the water outlet.
 Strainers in both oil and water lines to be provided in the upstream of control valve as per good
engineering practices

All piping shall have suitable number of full bore ball/plug valves at suitable places for bypassing/online and for
isolating whenever required.

8.0 END CONNECTIONS

 Separator inlet : Flange connection of respective class / rating for HP separators

for Hook up with the existing manifold line.
 Gas outlet (Main & Flare): Flange connection of respective class / rating for HP separators
for Hook up with the existing process / flow line
 Oil outlet : Flange connection of respective class / rating for HP separators
for Hook up with the existing process / flow line
 Water outlet : Flange connection of respective class / rating for HP separators
for Hook up with the existing process / flow line