EA-VIS-23-001 (Test Separator)

GENERAL INSPECTION REPORT
Oceaneering International Services Ltd, Sabail District, Salyan Highway, Street 6/10, AZ1023, Baku, Republic of Azerbaijan Tel: +99412 404 7546 /47 /48
Client / Project: BP-AGT Asset / Site: East Azeri Platform Report Ref.: EA-VIS-2023-001
Item ID / Tag No.: EA-V13010 Work Order: 101347087 Workpack Ref.: 560506-AG63-IM-ITP-0038-000
Item Description: Internal visual inspection of Test Separator

Item Type: Pressure Vessel System / Unit: System 13 Date of Inspection: 17/01/2023
Marei Hamad / Narmin
Inspected By: Inspection Type: Internal (intrusive) Year Commissioned: 2006
Sultanova
Inspection Routine: IIM-OPR-040.2.6 Last Report No.: EA-GVI-2013-161 Last Inspection Date: 13/12/2013
Purpose / Objective of Inspection

MO 101347087 was raised in SAP as per ad-hoc request from client for internal visual inspection of Test Separator .
Inspection was conducted as per Oceaneering procedure IIM-OPR-040.2.6 for pressure system.
Extent of Inspection
Ad-hoc WPK was provided ( 560506-AG63-IM-ITP-0038-000). As per WPK & SAP Scope description, internal visual
inspection to be conducted on all internal shell & domes and welds surfaces , nozzles bores to the extent visible and all
internals’ components to confirm integrity. External inspection of the vessel is not required because it was conducted recently
in 2022 under MO 100560950 (reference report EA-VIS-22-049).
Vessel Details
Design Code PD 5500 (2000) Cat 1

Orientation: Horizontal.
Length TAN to TAN 9000 mm
Internal Diameter 2100 mm
Joint Efficiency As per Cat 1
Shell & head Material CS + cladding with SS 904L
Shell Nominal Thickness: 31 + 3 mm.
Heads (hemispherical) Nominal Thickness: 31 +3 mm.
Corrosion allowance:. 0 mm
Contents: 3 phase hydrocarbon fluid.
Capacity 33.6 m3
Operating Temperature: 44 to 55 C
Operating Pressure:. 25 to 65 bars
Design Temperature Min -40 C & Max 70 C.
Design Pressure: Min full vacuum & Max 66 Bar.
Internals material 316L
Process description
This pressure vessel is a three-phase separator, and its function is to accommodate separation of 3 phase fluid (oil, water and
gas). The feed to the separator is well stream fluids from the platform wellheads. The separator is required to test high pressure
wells (nominal pressure of 60 brag) and low-pressure wells (nominal pressure of 25 brag). The separator will also be utilized for
well clean-up.
PSVs Details
Refer to recent External inspection report (EA-VIS-22-049) for details of Vessel PSV (2E-PSV130103).
Exceptions/Restrictions
 No External inspection of the vessel was conducted because it was completed recently in 2022 under MO
100560950 (reference report EA-VIS-22-049). External inspection omission was reflected as such in SAP and WPK
(560506-AG63-IM-ITP-0038-000). This inspection is limited to Internal close visual inspection of the vessel.
 No NDT was conducted either as this was optional requirement (to be opportunely conducted in case NDT team are
available onboard) as per the above mentioned WPK.
The results stated above relate exclusively to the objects inspected.

This inspection report shall not be reproduced except in full, without prior written approval from Oceaneering
IIM-FRM-125 4.0 General Inspection Report Page 1 of 17


Sultanova
Internal Inspection History:

 Year 2013 (EA-GVI-2013-161):
The report covered internal and external visual inspections. No major finding that threatened vessel integrity.
However, several grinding marks were noted randomly. Nozzle N10A & N5B showed corrosion on flange face and
reported as being repaired.
Anomaly management records:

 FM-EA-2020-007 – Open: Surface cracks and minor top coating breakdown was found
in PFP coating on east saddle support of 2E-V13010 (external Finding).
Pre-cleaning Findings
Upon opening of both Manways M 1&2, the internal condition of test separator (pre cleaning condition) was noted full of oily
sludge / debris almost covering distributor plate hatch height) Refer to last photos 41 to 44 of this report). The vessel was
thoroughly cleaned using hot water jets and offered for internal inspection
Internal Findings (post cleaning):

Internal visual inspection findings were segregated based on features / components basis as follows:
1. Shell & Heads:
 Two remarkable linear grinding marks (length 150 mm & 40 mm, max depth 1 mm) were noticed at 7 o’clock
position (adjacent to weir plate to the shell weld). Refer photos 1 to 4.
 No pitting corrosion was noted (SC 0 condition) all over shell and heads cladded surfaces apart from random pin
holes / pitting were noticed on the west dome with maximum depth 0.7 mm (above liquid level position). Refer photos
5 to 8.
 All internal SS 904L cladding surfaces of shell and heads plates including circumferential and longitudinal welds
were found free from any visible cracks, distortion or mechanical damage. Several & random grinding marks were
noticed all around circumferential and longitudinal welds. Refer photos 9 to 12.
2. Perforated distributor plate:
 All segments of distributor plate were found securely fitted & in satisfactory condition. No corrosion cacks or
mechanical damage was noted. No missing or loose bolts / nuts were noted. One hatch was removed to for
inspection access of east dome and then was properly fixed back once all inspection were completed. The support
brackets & its bolts / welds were found secured and free from any visible cracks. Refer photos 13 to 16.
3. Inlet diffuser + cascade tray:
 Inlet diffuser & its cascade tray were found free from any cracks, mechanical damage, erosion or any integrity
threats. The bolting system was found intact. Generally, no concerns noted. Refer photos 17 to 18.
4. Sand Wash / Jetting System:
 There are two manifolds for Sand jetting system (Tore type). Both manifold piping assembly was found in acceptable
condition. No corrosion / erosion, cracks or mechanical damage were noted. All flanges’ joints & Their bolting system
were found securely tightened and in a good condition (SC 0 Condition). Both manifolds supporting system were
found intact. Generally, no concerns noted. Refer photos 19 to 22.
5. Weir plate:
 No concerns or integrity threats were noted on the weir plate assembly. No corrosion or mechanical damage was
noted. The plate bolting system was found securely fitted. The weir plate to shell weld was found free from any
visible cracks. Refer photos 23 to 24.
6. Gas Outlet Mist Extractor (vane pack):
 Vane pack assembly was found free from any cracks mechanical damage or corrosion. The drainpipe & its bolted
joint were found in acceptable condition (SC 0 condition) Refer photos 25 to 26.
7. Vortex breakers:
 All existing vortex breakers were found intact. No cracks or mechanical damage noted. Refer photos 27 to.



Sultanova
8. Nozzles bores:
 All nozzles were inspected for blockage to the extent possible. No blockage was noticed apart from Nozzle N3 (oil
Outlet) was found full of oily debris (Refer photo 28). This was reported to MTL for flushing upon deisolation of the
Test separator. No visible pitting was noted to the accessible extent on all nozzle’s bores (example photos 31 & 32).
9. Manways M1 & M2:
 Both Manways bores overlay welds were found free from any visible cracks, pitting or mechanical damages.
However, several grinding marks were noted.
 Both flanges face of manway nozzles were found in good condition. However, two minor mechanical gouges (5mm
long & 1 mm deep) were noted inward of gasket seating area of M2 Manway (located at 5 & 7 o’clock position).
These gouges have no threat to sealing integrity as they were located beyond the gasket sealing area (refer to
photos 33 to 36)
10. Nozzles Flange face inspection:
 Refer to section 9 above for Manways FF inspection.
 FF of Nozzle N8 (connected to vessel PSV) has minor gouge at west side (No concerns – located outside of gasket
seating area) (refer to photos 37 to 38).
 Remaining nozzles were not offered during the internal inspection as the nozzles were positively isolated. MTL was
notified to offer remaining nozzles for FF inspection upon vessel deisolation. A follow up inspection report would be
generated accordingly.
11. Miscellaneous devises:
 Dip Pipe and thermowell element were found in acceptable condition (refer to photos 39 to 40).
Attachments:
 Photos 1 to 44 (inclusive).
 Markup GA drawing.
 P&ID Drawing.
Recommendations:
It is recommended to:
 offer nozzles flanges for FF visual inspection (apart from the ones covered in section 9 & 10 above). MTL was
notified to offer remaining nozzles for FF inspection upon vessel deisolation. A follow up inspection report would be
generated accordingly.
 Flush out Nozzle N3 (oil Outlet) upon vessel de-isolation as it was found full of oily debris (Refer photo 28). Nozzle
bore cleanliness would be verified during FF inspection.
 No further action is recommended regarding the finding reported in section 1 above- grinding marks (Refer photos 1
to 4) and pitting noted on west dome (Refer photos 5 to 8). To be monitored at next internal inspection opportunity.
 No further action is recommended regarding gouges reported on FF of Manway M1 (photos 33 to 36) & Nozzle N 8
(photos 37 to 38) as these were located outside of gasket seating area. To be monitored at next internal inspection
opportunity.
Conclusion:
In general, no major threats to integrity were noted.



Sultanova
Flush out Nozzle N3 (oil Outlet) upon

Markup GA Drawings with key findings vessel de-isolation as it was found full
of oily debris (Refer photo 28). Nozzle
bore cleanliness would be verified
during FF inspection.
No further action is
recommended regarding gouges Two remarkable linear grinding
reported on FF of Manway M1 marks (length 150 mm & 40 mm,
(photos 33 to 36) & Nozzle N 8 max depth 1 mm) were noticed
(photos 37 to 38) as these were at 7 o’clock position (adjacent to
located outside of gasket seating weir plate to the shell weld).
area. To be monitored at next Refer photos 1 to 4.
internal inspection opportunity.



Sultanova
P&ID Drawing



Sultanova
Photo2: General view of two linear grinding marks (

150 mm & 40 mm) adjacent to weir plate weld at 7
o’clock position
Photo 1: General view of the internal of Test Separator

(looking from East). Marked-up Location of two linear
grinding marks ( 150 mm & 40 mm) adjacent to weir
plate weld at 7 o’clock position
Photo 3: Close view of photo 2 - two linear grinding

marks ( 150 mm & 40 mm) adjacent to weir plate weld
at 7 o’clock position Photo 4: Closer view of phot 3 - 150 mm linear
grinding mark (max depth 1mm) ( adjacent to weir
plate weld at 7 o’clock position)



Sultanova
Photo 5: Showing general view of random pin holes / Photo 6: Showing close view of photo 5 - random
pitting were noticed on the west dome with maximum pin holes / pitting was noticed on the west dome with
depth 0.7 mm (above liquid level position). maximum depth 0.7 mm (above liquid level position).
Photo 7: Showing close view of Photo 5 & example of

random pin holes / pitting were noticed on the west
dome with maximum depth 0.7 mm (above liquid level Photo 8: Showing close view of Photo 5 & example of
position). random pin holes / pitting were noticed on the west
dome with maximum depth 0.7 mm (above liquid level
position).



Sultanova
Photo 9: Showing close example view of T-joint at

shell to east dome weld free from any visible cracks
Photo 10: Showing close example view of T-joint at
shell to east dome weld free from any visible cracks
Photo 11: Showing general example view of T-joint

at shell longitudinal weld free from any visible Photo 12: Showing close example view of T-joint at
cracks. shell circumferential weld free from any visible
cracks.



Sultanova
Photo 13: Showing general view of Perforated Photo 14: Showing close view of Perforated distributor
distributor plate arrangement segments securely fitted plate arrangement segments securely fitted & in
& in satisfactory condition. One hatch was removed satisfactory condition. No missing or loose bolts / nuts
for inspection access of east dome were noted
Photo 15: Showing example close view of the support Photo 16: Showing distributor plate removed hatch
brackets & its bolts / welds were found secured and being reinstated upon completion of east dome
free from any visible cracks inspection



Sultanova
Photo 17: Showing general view of Inlet diffuser & its Photo 18: Showing general view of Inlet diffuser & its
cascade tray (3 phase fluid inlet )were found free from cascade the bolting system was found intact
any cracks , mechanical damage, erosion or any
integrity threats. The bolting system was found intact
Photo 19: Showing general view of east Sand jetting

manifold & its supporting system in acceptable
condition. No corrosion / erosion, cracks or mechanical
damage were noted.
Photo 20: Showing close example view of flanged

joints & its bolting system (east Sand jetting manifold)
found securely tightened and in a good condition ( SC
0 Condition).



Sultanova
Photo 22: Showing close example view of flanged

Photo 21: Showing general view of west Sand jetting joints & its bolting system (west Sand jetting
manifold & its supporting system in acceptable manifold) found securely tightened and in a good
condition. No corrosion / erosion , cracks or condition ( SC 0 Condition).
mechanical damage were noted.
Photo 23: Showing General view of the weir plate

assembly with No corrosion , mechanical damage or
visible cracks noted. Photo 24: Showing close view of phot 23 - the weir
plate assembly with No corrosion , mechanical damage
or visible cracks noted.



Sultanova
Photo 25: Showing close view of Vane pack assembly

(gas outlet) was found free from any cracks
mechanical damage or corrosion. Photo 26: Showing close view of The Vane pack
drainpipe & its bolted joint were found in acceptable
condition (SC 0 condition). .
Photo 28: Showing close view of photo 27- nozzle bore

N3 full of oily Debris ( it was reported to MTL for flushing
upon positive Deisolation of Test separator)
Photo 27: Showing close view of vortex breakers at
nozzle N3 found intact. No cracks or mechanical damage
noted.



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nozzle N4 found intact. No cracks or mechanical damage
noted.

nozzle N5B found intact. No cracks or mechanical damage
noted.
Photo 31: Showing example close view of PSV nozzle Photo 32: Showing example close view of nozzles
bore (N8) no concerns were noted. bore N 1 B ( Level Indicator) (No visible pitting was
noted to the accessible extent).



Sultanova
Photo 33: Showing close view Manway M1 bore

overlay welds found free from any visible cracks, Photo 34: Showing General view of Manway M1 & its
pitting or mechanical damages. However, several cover flanges faces found in good condition.
grinding marks were noted.



Sultanova
Photo 35: Showing close view of Manway M2 & its

cover flanges faces found in good condition. two Photo 36: Showing close view of Manway M2 FF (
minor mechanical gouges ( 5mm long & 1 mm deep) two minor mechanical gouges ( 5mm long & 1 mm
were noted inward of gasket seating area of M2 deep) were noted inward of gasket seating area of
Manway ( located at 5 & 7 o’clock position). M2 Manway ( located at 5 & 7 o’clock position).
Photo 37: Showing General view of FF of Nozzle N8 Photo 38: close view of photo 37 FF of Nozzle N8
(for vessel PSV) (for vessel PSV) showing minor gouge at west side (No
concerns - inward of gasket seating area)



Sultanova
Photo 40: Showing thermowell element acceptable

condition
Photo 39: Showing Dip Pipe in acceptable condition
Photo 41: Showing General view of internal condition Photo 42: General view of internal condition of test
of test separator upon opening of Manway M2 ( pre separator upon opening of Manway M1 ( pre cleaning
cleaning condition) – oily sludge noted almost covering condition) – oily sludge noted under sand wash
distributor plate hatch height ) manifolds )



Sultanova
Photo 44: Showing sample view of oily sludge / debris

removed from test separator
Photo 43: Showing sample view of oily sludge / debris

removed from test separator
UKAS
Endorsements Name Position Signature & Date Remarks
Category
Marei Hamad/ Narmin Digitally signed

Digitally signed by:
Offshore Inspection
Narmin Sultanova
by Marei Hamad DN: CN = Narmin
Inspected By: Sultanova Cat 2/4 Date: 2023.01.18

Sultanova email =
Remarks
Engineer/ 20:04:56 +04'00'
NSultanova@oceanee
ring.com C = US
Date: 2023.01.18 19:
43:14 +04'00'
Vaibhav Digitally signed by

Vaibhav Khedekar
Approved By: Name of Approver Select Position Cat. Khedekar Date: 2023.01.19 Remarks
08:48:55 +05'30'
Next Date Due: 18/01/2033 RBI Assessment: 1803-005

Note: Next Date Due is as currently established in long-term work planning and / or in the Client’s CMMS, for information only, and
may be amended following authoritative review of the RBA on the basis of the inspection findings and other relevant history updates.


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GENERAL INSPECTION REPORT

Item Description: Internal visual inspection of Test Separator

Purpose / Objective of Inspection

Design Code PD 5500 (2000) Cat 1

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 1 of 17

Item Description: Internal visual inspection of Test Separator

Internal Inspection History:

Anomaly management records:

Internal Findings (post cleaning):

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 2 of 17

Item Description: Internal visual inspection of Test Separator

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 3 of 17

Item Description: Internal visual inspection of Test Separator

Flush out Nozzle N3 (oil Outlet) upon

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 4 of 17

Item Description: Internal visual inspection of Test Separator

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 5 of 17

Item Description: Internal visual inspection of Test Separator

Photo2: General view of two linear grinding marks (

Photo 1: General view of the internal of Test Separator

Photo 3: Close view of photo 2 - two linear grinding

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 6 of 17

Item Description: Internal visual inspection of Test Separator

Photo 7: Showing close view of Photo 5 & example of

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 7 of 17

Item Description: Internal visual inspection of Test Separator

Photo 9: Showing close example view of T-joint at

Photo 11: Showing general example view of T-joint

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 8 of 17

Item Description: Internal visual inspection of Test Separator

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 9 of 17

Item Description: Internal visual inspection of Test Separator

Photo 19: Showing general view of east Sand jetting

Photo 20: Showing close example view of flanged

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 10 of 17

Item Description: Internal visual inspection of Test Separator

Photo 22: Showing close example view of flanged

Photo 23: Showing General view of the weir plate

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 11 of 17

Item Description: Internal visual inspection of Test Separator

Photo 25: Showing close view of Vane pack assembly

Photo 28: Showing close view of photo 27- nozzle bore

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 12 of 17

Item Description: Internal visual inspection of Test Separator

Photo 29: Showing close view of vortex breakers at

Photo 30: Showing close view of vortex breakers at

The results stated above relate exclusively to the objects inspected.

IIM-FRM-125 4.0 General Inspection Report Page 13 of 17

Item Description: Internal visual inspection of Test Separator

Photo 33: Showing close view Manway M1 bore

The results stated above relate exclusively to the objects inspected.