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Oil & Gas Development Company Ltd.

Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : Nov 28, 2014

Page 1

of 21

SPECIFICATION FOR
THREE PHASE PRODUCTION SEPARATOR
(SOUR SERVICE.)

Prepared by:

__________________
Irfan Zouque Butt
SE (Mech)

Checked by:

__________________
Fasih Akther
M (PF)

Approved by:

__________________
Rashid Mahmud
GM (PE & FD)

Oil and Gas Development Company Limited


Petroleum Engineering and Facilities Department,
Islamabad (Pakistan)

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : Nov 28, 2014

Page 2

of 21

TABLE OF CONTENTS
Page
1 SCOPE........................................................................................................................................ 3
2 DESIGN REQUIREMENTS .................................................................................................... 3
3 MATERIAL REQUIREMENTS ............................................................................................. 4
4 MANUFACTURING AND FABRICATION REQUIREMENTS ........................................ 5
5 APPROVED VENDOR LIST................................................................................................... 6
6 TEST REQUIREMENTS ......................................................................................................... 7
7 INSPECTION ............................................................................................................................ 8
8 IDENTIFICATION ................................................................................................................... 8
9 SHIPPING AND HANDLING ................................................................................................. 8
10 DOCUMENTATION ............................................................................................................... 9
11 REFERENCES ....................................................................................................................... 10
12 QUALITY PLAN.................................................................................................................... 11
13 WARRANTY/GUARANTY .. 12
13 DATA SHEETS ...................................................................................................................... 13

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN

Technical Specs Annexure A

Title : Specification for three phase test separator (sour service)

Date : NOV 28, 2014

Page 3

of 21

THREE PHASE SEPARATOR


1

SCOPE
1.1

This specification, in conjunction with applicable codes and standards, pertains to the
design, fabrication, materials, testing, inspection, identification and documentation of
separator vessels for use oil /gas fields to handle oil, gas and water, and located but not
limited to some point between wellhead and producing flow line or at gathering area.
Separators covered by this specification should be horizontal.

1.2

All separators shall be designed, constructed and tested in accordance with the data sheets
and the requirements of ASME Section VIII, Division 1 and API 12-J (API specifications
for Oil and Gas Separators). The vessel shell be U stamped by the authorized ASME
inspector and horizontal in design.

1.3

The term purchaser shall be defined as Oil & Gas Development Company Limited,
Pakistan.

1.4

This specification covers for the two different design data separators covered in Separator
Data Sheets SPEC-3PS-01.

2)

DESIGN REQUIREMENTS
Mechanical & Process
2.1

Three Phase Separator must be capable of separating flash gas from a liquid feed stream.
Separator internals should be suitable for most effective separation so that 100% of all
liquid particles up to 8 microns and larger and 99.5% of all liquid particles up to 0.5 to 8
microns are removed from the flash gas stream. Also the separator be capable of
separating water from hydrocarbon liquids with the maximum oil in water ratio of 1000
mg/liter. The minimum retention time should be 3 minutes.

2.2

All the control valves shall be designed on worst scenario basis i.e. maximum flow at
minimum operating pressure, max. Oil API, max. gas Specific Gravity etc.

2.3

Size limitations:
Description:
Vessel Sizes:
Maximum Vessel length T/L to T/L =
Minimum ID of vessel =
Nozzle Sizes:
Gas Inlet =
Gas Outlet =
Oil Outlet =
Water Outlet =

For Type-I
20 ft.
5 ft
8
6
3
3

The above said sizes have to be considered as minimum but bidder has to submit the
design calculations to verify their sizes. If in design the calculated sizes are below then
the above mentioned, the above mentioned sizes shall be considered. In case the
calculated sizes as per design are higher than the above mentioned sizes then calculated
sizes shall be considered accordingly. The same has to be confirmed by the bidder in its
technical proposal but at the time of design review all the design calculations shall be
provided by the bidder/manufacturer.
2.4

The vessel shall be designed, constructed and tested in accordance with the data sheets
and the requirements of ASME Section VIII, Division 1 and API 12-J (API specifications

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 4

of 21

for Oil and Gas Separators). The vessel shell be U stamped by the authorized ASME
inspector and it must be designed/constructed for horizontal installation.
2.5

All piping and assemblies provided on the vessel shall be designed, fabricated and tested
in accordance with the latest editions of ASME B31.8 for natural gas piping and ASME
B31.3 for Process Piping.

2.6

Piping arrangement for Gas, Oil and Water outlets shall be furnished with flow
measurement, sampling points, pressure & temperature indicators, regulating valves and
bypass arrangement. The strainers shall be provided at the upstream of metering devices
to avoid any malfunctioning.

2.7

The separator bypass line will be included in the design. The bypass across the separator
and bypass across all oil/gas/water controllers are designed in away to enable repair
during operation. Also block valve will be provided in addition to globe valve at
separator by-pass line for complete isolation.

2.8

Senior orifice fittings along with gas recorder shall be required on gas outlet.

2.9

Check valve shall be required at gas inlet and all the gas/oil/water outlets

2.10

All piping must terminate at the skid edge and piping ends shall be flanged together with
companion flange screwed on with studs, nuts and gaskets.

2.11

Block valves shall be full ported ball valves unless otherwise specified.

2.12

All valves shall be flanged end and the valves of 600# and above shall be RTJ type. The
by-pass valves shall be globe valves.

2.11

The safety valve and the rupture disk at vessel shall be part of design for primary and
secondary safety and must have separate nozzles on vessel.

2.13

Vortex breaker shall be provided for drains and siphons.

2.14

The manhole minimum of 20 should be provided for inspection/cleaning purpose


preferably on shell.

2.15

Thermo wells for 300#ANSI and above rating should be flange connected to piping and
vessels rather than threaded.

2.16

All the separator vessel internals shall be of material SS316.

2.17

Oil and water flow meters, strainer etc shall be of min. 2 size. If the calculated size is
more than the mentioned size, calculated size shall be considered otherwise 2 size shall
be applicable.

2.18

Separator vessel shall be horizontal vessel type having weir plate being the partitioning
plate for liquid separation i.e. oil and water. Boot type design shall not be acceptable for
liquid separation.

2.19

All the liquid (oil and water) flow meters shall be electronic flow meter instead of PD
meters.
Instrumentation

2.17

The manufacturer shall provide all instrumentation and controls equipment necessary for
providing protection and the safe operation of each vessel. The instrumentation
philosophy shall be pneumatic and no electrical equipment will be used.

2.18

The instrument gas supply required to operate the instruments will be taken from Gas
outlet of separator through pressure regulator and routed through vertical Instrument Gas
Filter Separator vessel mounted on separator skid. The provision of external source
instrument air should also be provided. The vessel unit has to provision to replace the
filters cartridges accordingly. The instrument vessel shall also be U-stamped.

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 5

of 21

Skid and Structure

2.19

The vessel must be mounted on skid with all piping and accessories.. The construction of
skid will be on 4-runner I-beam structure.

2.20

Vessels shall be designed to be self-supporting and for a wind load as specified in the
design information. The wind load will be specified based on the projected area of the
vessels including all external appurtenances such as insulation, ladders and platforms.
The vessel supports shall be adequate for the specified wind load when the vessel is full
of water.

2.21

If the data sheets specify that the manufacturer is to provide vessel trim, the vessel shall
be completely trimmed, instrumented and piped. All sizing of pipe and equipment shall
be done by the manufacturer based on data provided herein, on specification sheets or on
the purchase order. Should Company specify sizing, the manufacturer has the
responsibility of checking sizing and advising Company if sizing determined is
unsatisfactory.

MATERIAL REQUIREMENTS
3.1

Vessel materials used shall conform to those permitted in ASME Section VIII, Division
1, Sub section C. Material for shells and heads shall be limited to those permitted in Part
UCS of Subsection C, of ASME Section VIII, Division 1. Proposed materials will be
shown on the drawings and submitted to purchaser for approval.

3.2

Refer to under mentioned hydrocarbon composition, bidder has to evaluate the material
selection according to the gas composition and the materials for vessels and vessel trim
shall conform to the requirements of NACE MR0175 for and other applicable NACE
standards for sour service.

COMPONENTS

3.3

MOLE %

Methane

C1

90.6743

Ethane

C2

3.5156

Propane

C3

1.2620

Iso-Butane

IC4

0.3217

N-Butane

nC4

0.3666

Iso-Pentane

IC5

0.1323

N-Pentane

nC5

0.0890

Hexane Plus

C6+

0.0243

Carbon Dioxide

Co2

2.3851

Nitrogen

N2

0.3691

Hydrogen Sulfide

H2S

0.8600

Specific Gravity

0.6294

Gross Heating Value ( BTU / Ft3 )

1050.29

All flanges shall conform to ANSI B16.5. All studs and nuts shall conform to ASTM A193 and A-194 and cadmium plated. All carbon steel pipes shall conform to ASTM A106 for sour service.

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 6

of 21

3.4

The Skid Steel structure, support saddles, legs or skirts shall meet ASTM A36 material
requirements.

3.4

All fittings shall be seamless forged steel. Malleable, cast iron or brass shall not be
provided. Internal component materials shall be compatible with the shell and head
materials considering weldability, loading, stress relieving and toughness. Where
stainless steel is specified for shell and head construction, all fittings and internal
components shall be stainless steel. The gases and liquids being handled contain H2S and
other acid gas components.

3.5

No threaded fittings are to be provided (excluding instrument tubing) for any pressure
containing elements. Pressure gauge and thermo well connections are to be flanged (2
minimum). Flanged by threaded valves may be used to connect pressure gauges.

3.6

Vessel mounted instruments, equipments, enclosures and junction boxes, if any, shall be
explosion proof and suitable for use in the H2S environment. Purged and pressurized
enclosures shall not be provided.

3.7

All tubing shall be high quality, fully annealed, seamless type 304 /316 stainless steel,
ASTM A-632.

3.8

Instrument air/gas manifolds fabricated from pipe shall be type 316 stainless steel of
welded construction with female threaded tubing connections.

MANUFACTURING AND FABRICATION REQUIREMENTS:


4.1

All welding shall be performed according to welding procedures which have been qualified
to Section IX of the ASME Boiler and Pressure Vessel Code using low hydrogen electrodes
or a low hydrogen process. Qualification of welding procedures shall include hardness
testing to demonstrate compliance with NACE MR0175. All welders must have a current
code qualification certificate. Certificates shall be available for review by the purchaser.

4.2

Internals shall be attached to the shell using double-sided fillet welds or full penetration
welds. Internals shall always be supported near the end with intermediate supports.

4.3

Each vessel skid shall be provided with lifting lugs and cable guides designed for a single
point lift when lifting twice the dry weight of the fully assembled separator. Lifting lugs,
piping and ladder support clips shall be welded to the attachment pads using full penetration
welds and not directly to the vessel. The fabrication of skid and attachments shall comply
the AISC (American Institute of steel construction).

4.4

Vessels shall be stress relieved as prescribed in paragraph UCS-56 of Section VIII, Division
1, of the ASME Boiler and Pressure Vessel Code.

4.5

All pressure piping shall be fabricated in accordance with the minimum requirements of the
ASME B31.8 and ASME B31.3 for gas and liquid piping. The piping shall be 100% stress
relieved in accordance with the methods provided in these codes.

4.6

Piping shall terminate with either a flange or a flanged valve. Tubing shall terminate with
tubing fitting such as a tubing connector.

4.7

All piping shall be rigidly supported for service as well as for shipment. Relief valves shall
be located such that they are accessible for testing and repair. Each relief valve shall have a
full port ball valve, complete with locking device capable of locking the valve in the open
position on the inlet and outlet sides of the relief valve. Either a bleed ring or a vent valve
shall be provided between this upstream ball valve and the relief for each relief provided.

4.8

Valves, instrumentation and controls shall be installed completely and securely mounted on
the vessel and ready for service.

4.9

All instrument tubing shall be installed so that fittings are accessible for tightening and
removal. All instrument tubing and cables must be installed properly in trays/conduits. All

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 7

of 21

tubing runs shall be installed to allow for thermal expansion and removal of instruments.
Isolation valves shall be installed, as required, for maintenance and removal of instruments.
4.11 The entire vessel including pipe supports and mounting bases shall be cleaned and
abrasively blasted and prepared for painting. All piping shall be cleaned and abrasively
blasted and prepared for painting. The external painting for the vessel and piping should be
of good quality primer, undercoat and final coat with color specified by the purchaser. The
vessel shall be internally coated in accordance to NACE standards. To include the piping
internals where specified on the request for quotation or on the purchase order.
5

APPROVED VENDOR LIST:


All the required instruments and controls shall be of the following approved vendor list
preferably. However, bidder can propose other reputable equivalent vendors. Bidder to
approve the vendors from OGDCL at the time of kick off meeting. Bidder shall submit
documentary evidence to prove the equivalency of the proposed vendor with the vendors
given in preferred vendor list, such as client list, past 05 years manufacturing and supply
experience to renowned companies across the global, compliance of equipment with
API/ASME codes etc. for equivalent by OGDCL. The decision by OGDCL regarding
equivalency of the other proposed vendor shall be binding on the selected bidder. Also, all
the valves shall be from valid API-6D manufacturer. Provision of last 05 years API-6D
Certificates in continuation are mandatory along with technical proposal.
Instrumentation
Flow Transmitters Force Balance D/P cell
Flow Indicator Field Mounted
Bellows Type Rota meters
Liquid Electronic Flow Meter (Oil & Water)

Level Controllers, Transmitters


Displacement, with tore tube
Level Switches External, Displacement, with
Torque tube or magnetic follower
Level Gauges Steel armored, Reflex or
Transparent with illuminator

Pressure Transmitter Indicating, motion/force


balance
Pressure Switches- Electrical
Process- 3.6 SS
Bourdon tube Air 3-15 PSI
Pressure Gauges
4 316 SS Bourdon Tube Seals
Temperature Remote
Indication or Recording
Resistance bulbs (RTD) with
Thermowellss-100 OHM Platinum
Temperature Switches Electrical
(Blind, Gas Filled)
Temperature Gauges
(Dial Type)

Approved Vendor
Emerson, Honeywell, Foxboro
Taylor, Barton, Fisher, Porter &
Brooks
Yokogawa ,Emerson , Rockwell,
Krohne , Invensys (Schnieder
Electric)
Emerson, Honeywell, Foxboro,
Norriseal
Magnetrol, Merciod, Yamatake,
Jerfuson, Penberthy, Greenwood,
Sparton Controls, Cesare Bonetti SPA
- ITALY, Samil Industry Co. Ltd.
Korea , Simco Engineers Ltd. U.K. ,
Vaihinger GMBH Germany
Rosemount, Honeywell, Foxboro
ASCO, Dresser (Ashcroft)

Aschroft, Wika, Nuova Fima


Conax, Taylor, Honeywell

United Electric, Aschroft


Ashcroft, Wika

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Temperature Switches Pneumatic


(Blind)
Control Valves
(Steel globe body, Flanged 300# RF min. SS Trim

Temperature Transmitter
(Blind or indicating , Force or Motion balance
with SS well)
Relief Valves
(General Steel Bodies, Flanged 150# RF Inlet and
Outlet min., Full nozzle type)

Field Mounted Recorders/


Indicating Controllers
Panel Mounted Recorder/Indicating Controllers
Tubing/Fittings
(Instrument Air)
Gas Regulators

Pneumatic Relays
Solenoid Valves
Draft Gauges
Rupture Discs
Annunciators
Switch Timers
Panel Mounted
Indicators
Pressure Switch-Differential

Ball / globe Valve

Senior Orifice Assembly


6

TEST REQUIREMENTS

Technical Specs Annexure A

Date : NOV 28, 2014

Page 8

of 21

Mason-neilan
Fisher, Mason-neilan, Norriseal,
Yamatake, Welker, ABB Control
Valves, CCI A.G. Switzerland,
Dresser Italia S.P.A. Italy, Mesto
Automation, Nuovo Pignone S.P.A
Italy, Samson Ag Mess - Und
Regeltechnik Germany, The Leeds
Valve Co. Ltd. U.K, Xomox
International Gmbh & Co. Germany,
Azbil Corporation Japan
Emerson, Honeywell, Foxboro,
Rochester Instruments System Ltd.
U.K., Yokogawa, ABB
Farris, Crosby, Dresser Industrial
Valve Operations U.S.A, Fukui
Seisakusho Co. Japan, Keystone
Anderson Greenwood - U.S.A, Leser
Gmbh & Co. Kg Germany, Nuovo
Pignone, Smart Valve Co. Korea
Taylor, Foxboro, Honeywell, ITT
Barton (Cameron), ABB
Taylor, Foxboro, Honeywell, ITT
Barton
SS/Hokes
Fisher, ITT Conoflow , Fukui
Seisakusho Japan ,Hartmann & Braun
Germany , Hirata Japan, Valvitalia
Moore Honeywell, Foxboro
Asco, Maxseal UK (Thompson
Valves), Konan Electric Japan, Herion
Hays, Baileys
Black Sivalls & Bryson (Insert Type)
Ronan, RIS
Automatic Timing & Control
Taylor, Ashcroft, Foxboro, Honeywell
United Electric, Asco, Ashcroft,
Baumer Bourdon Haenni Sas
France, Delta Controls Ltd. - U.K,
Dresser Europe S.A. GERMANY,
Nuova Fima, Wise Control INC KOREA
Valvatalia, Petrol Valve, Newco,
Orbit, GWC V/V USA, KITZ Euorpe,
Ringo Euorpe, Dafram Italy,Velan
Canada/USA/Euorpe, MSA Italy
Daniel, FMC, Precision

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 9

of 21

6.1

All vessels, valves and attachments shall be hydrostatically tested at 1.3 times the design
pressure specified on the data sheets. All the piping shall be hydrostatically tested at1.5
times of design pressure as per ASME B31.3 and B31.8. Test pressure shall be
maintained within -0 psi and +100 psi tolerance.

6.2

Either the medium or ambient temperature shall be monitored continuously throughout


the duration of the test.

6.3

Calibration of all testing apparatus shall be maintained. Deadweight, recorders and


gauges shall be calibrated within the last 3 months or as per company quality plan that
shall be available for review on request.

6.4

All service piping, such as control piping or tubing, shall be pressure tested and inspected
for leaks with a soap test. All nozzle reinforcing pads shall be pneumatically tested for
leaks with soap solution as specified by ASME BPVC, Section V. Certification by letter
shall be provided indicating the tests were performed.

6.5

Test pressure recording chart or log shall include date, time of test, name of job, work
order number, purchase order number and signature of the manufacturers authorized
representative. All information shall be in ink on the surface of the test chart and/or log.
If machining, welding or cutting is performed after the hydrostatic test, an additional
hydrostatic test will be required after such work is completed.

6.6

Visual inspection of the welding and fabrication shall be done following fabrication.

6.7

The vendor shall bench calibrate and function test of all instruments prior to installation
of the instruments on the skid and the test report to be provided.

6.8

Upon mechanical completion of the vessel (and prior to the performance test) a complete
instrument and control function test shall be performed.

6.9

The vendor shall provide all test & test equipment records along with the shipping
documents.

6.10

A performance test shall be performed by the vendor on the completed package prior to
preparation for shipment. This performance testing will include testing of the equipment,
piping, electrical and instrumentation. All deficiencies will be corrected and the test
rerun. Deficiency correction and test rerun shall continue until all deficiencies have been
removed.

INSPECTION
7.1

All reasonable requests shall be granted the purchaser to enable the purchaser to verify
compliance with this specification..

7.2

The monitoring and witnessing of inspections and tests by the purchaser shall be in
accordance with the quality plan included in this specification. The purchaser reserves the
right to increase or decrease the level of inspection based on performance during production.

7.3

All pressure bearing welds of vessel and piping shall be 100% radiographed in
accordance with the ASME BPVC, Section V, Article 2, which incorporates ASTM E-94
and ASTM E-142. The essential hole size for penetrameter readings shall be in
accordance with the ASME BPVC, Section V. Manufacturer shall furnish an x-ray
report. The x-ray film shall be kept on file and be available for review on request.
Rejected film shall also be kept for purchasers review.

7.4

Radiographic examination shall be performed in accordance with a qualified written


procedure. The procedure shall comply with the applicable requirements of Section V of
the ASME BPVC. A copy of the radiographic procedure shall be furnished to the
purchaser upon request.

7.5

The magnetic Particle examination for detection of surface cracks must be performed in
accordance with ASME BPVC, Section-V.

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

7.6

Technical Specs Annexure A

Date : NOV 28, 2014

Page 10

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Bidder to confirm the compliance of Third Party Inspection as per SCOPE WORK
Attached in the Technical Proposal which includes the above inspection criteria as per
Clause 7.0. All the TPI cost shall be borne by OGDCL itself. But bidder must comply
this in his technical proposal.

IDENTIFICATION
8.1

Nameplates
A nameplate will be provided by the seller for each filter/separator. Each nameplate shall
include the following:

8.2

Design Code
Item Number
Diameter And Length
Purchase Order Number
Design Pressure And Design Temperature
Name Of Manufacturer And Year Built
Manufacturers Serial Number
Corrosion Allowance
Hydrostatic Test Pressure
Head And Shell Thickness
ASME Monogram
U-Stamp
Weight Empty

Equipment Tags
Permanent stainless steel tags with the proper equipment number inscribed shall be
provided on all major equipment and controls.

10

SHIPPING AND HANDLING


9.1

Vendor shall notify purchaser one week in advance of the completion for each vessel.

9.2

All vessels to included equipment, materials and documentation supplied shall be


prepared and packaged in a manner so as to provide both mechanical and weather
protection while in transit. All equipment shall utilize temporary bracing for shipment in
addition to permanent mounting.

9.3

The manufacturer shall accept liability for loss or damage of the vessel and equipment
during loading, transit and unloading. The Company will assume this liability upon
receipt of the same at the point of delivery.

DOCUMENTATION
The manufacturer shall supply to the purchaser all documentation necessary to verify that the
equipment supplied has been manufactured and fabricated in accordance with this specification
and the codes and regulations incorporated herein by reference.
10.1 Approval Drawings:
1) P&ID shall be submitted to the purchaser along with bid document.
2) Manufacturer shall submit 3 prints of shop detail drawings to purchaser for approval within 2
weeks after receipt of the purchase order.
3) The notes on approval drawings shall clarify all pertinent information not included on other
drawings. Approval drawings shall be complete with the following information.
1. A detail of all internal and external components.
2. The bill-of-material shall list all materials used for fabrication by the following.
4) Item number and quantity, with associated number called out on elevation or plan view.
5) Description of item (size, wall thickness, ANSI rating, material, etc.).

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 11

of 21

6) List of all specifications (purchasers or industry) and applicable codes (latest edition) used in
the design, fabrication, inspection and testing of the vessel. Include design and temperature
rating.
7) Stamp designation (ASME, U).
8) Maximum allowable operating pressure.
10.2 Certified Drawings:
Two certified copies and one certified sepia of documents and drawings approved by the purchaser
shall be provided to the purchaser prior to the start of fabrication.
10.3 Welding Records:
All of the following information shall be forwarded to the purchaser upon request. The following
information is to be available for review during fabrication by the purchasers inspecting agent and
must be reviewed and accepted prior to final equipment heat treating or hydrostatic testing.
By weld summary of all tests conducted during fabrication and results of the same in a manner
suitable for review by purchasers inspector. This summary should be supported by record sheets
of all tests with each record sheet uniquely referenced to the individual fabrication welds.
10.4Calculations:
2) Summary of design calculations for pressure containment including calculations of vessel
wall thickness, nozzle wall thickness and nozzle reinforcement thickness and area
requirements. (Bidder has to provide the same along with Technical proposal for the
evaluation)
3) Summary of calculations for sizing and mounting of vessel structural supporting skirts or
piers and lifting lugs.
4) Summary of calculations for vessel stress loading and maximum allowable expansion stresses
to be applied to nozzles.
5) Summary of calculations for flange design.
10.5 Hydrostatic Test Report:
Summary report of all hydrostatic tests is to be submitted to the purchaser prior to shipment.
10.6 Operation and Maintenance Manuals:
Two copies of the operation and maintenance manuals with each separator shall be forwarded to
the drafting coordinator at the address provided in the design information at the time of shipment.
11

REFERENCES
Pressure vessels and all component parts shall be designed, fabricated and tested in accordance
with the latest Company approved edition of the following codes and standards as applicable.
When the Company has not approved the latest edition, the latest Company approved edition will
be identified on the purchase order.
11.1

American Society of Mechanical Engineers (ASME)


ASME BPVC Section V

Boiler and Pressure Vessel Code, Section V,


Nondestructive Testing

ASME BPVC Section VIII,


Division 1

Boiler and Pressure Vessel Code, Pressure


Vessels

ASME BPVC Section IX

Boiler and Pressure Vessel Code, Welding


and Brazing Qualifications

ASME B31.3

Chemical Plant and Petroleum Refinery


Piping

ASME B31.8

Gas Transmission and Distribution Piping

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 12

of 21

Systems
11.2

11.3

American Society for Testing and Materials (ASTM)


ASTM A36

Structural Steel

ASTM A105

Forgings, Carbon Steel for Pipe


Components

ASTM A106

Seamless Carbon Steel Pipe for High


Temperature Service

ASTM A193

Alloy Steel and Stainless Steel Bolting


Material for High Temperature Service

ASTM A194

Alloy Steel Nuts for Bolts for High Pressure


and High Temperature Service

ASTM A234

Pressure Vessel Plates, Carbon Steel, for


Intermediate and Higher Temperature
Service

ASTM A490

Specification for Structural Joints Using


High Strength Bolts

ASTM A515

Pressure Vessel Plates, Carbon Steel, for


Intermediate and Higher Temperature
Service

ASTM A516

Pressure Vessel Plates, Carbon Steel, for


Moderate and Lower Temperature Service

ASTM A632

Standard Specification for Seamless and


Welded Austenitic Stainless Steel Tubing
(Small Diameter) for General Service

ASTM E94

Guide for Radiographic Testing

ASTM E142

Controlling Quality of Radiographic Testing

American National Standards Institute (ANSI)


ANSI B16.5

11.4

NACE International
NACE MR0175-96

11.5

Pipe Flanges and Flanged Fittings

Sulfide Stress Cracking Resistant Metallic


Materials for Oilfield Equipment

Steel Structures Painting Council Specifications (SSPC)


SSPC-SP6

Commercial Blast Cleaning

SSPC-SP10

Near White Metal Blast Cleaning

12 QUALITY PLAN
Sr.
Nos.

Activity

Purchaser Inspection

01

Preproduction/design review Meeting

02

Material Procurement

03

Heat Treatment Certificates

04

Mill Test Reports

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Note:

Technical Specs Annexure A

Date : NOV 28, 2014

05

Welding Procedure Qualification

06

Welder Qualifications

07

Fabrication

H (see note)

08

Radiographic Testing

H (see note)

09

Hydrostatic Testing

10

Welding Repairs

11

Painting and Coating

12

Prepare for Shipment

Page 13

of 21

These inspections/tests are considered to hold points at the beginning of production and may be
changed to monitor points based on production performance, if notified in writing by the
purchaser. 02 OGDCL Engineer and 01 SCM Officer would attend Kick off / Design review
meeting at manufacturing site for 05 days, excluding traveling time. Also, Bidder will arrange
FAT of the subjected separators to be attended by two OGDCL professionals for 05 days
excluding travelling time.
The total related cost of visit (05 days each plus traveling time) would be borne by the bidder
including visa charges, air tickets, boarding & loading costs, transportation and daily allowance
(USD 300 per day) for these meeting and inspection.

13

H-

Hold point, inspection or testing shall not proceed without the presence of the purchasers
representative.

M-

Monitor point, notification to the purchasers representative of impending inspection or


test activity is required.

R-

Review documentation, presentation of the specified.

WARRANTEE / GUARANTEE
a.

The supplier /packager shall provide equipment warranties and performance guarantee of
the supplied equipment against this requirement that supplier/packager shall essentially
furnish following Warranties and guarantees.
i.

Manufacturers warrantee and Performance Guarantee.

ii. Complete package design warrantee and guarantee by the supplier.


iii. Performance guarantee of the package by the supplier/packager.
iv. All warranties and performance guaranties shall be valid for at least 12 months after the
startup and commissioning of separator package or 18 months from the date of
shipment.
v.

Process guarantee for the approved design parameter for the separator by the supplier.

b.

The packager /contractor will warrant that all goods/ equipment supplied under this
tender/contract shall be new and have no defects arising from design, that may develop
under normal use of equipment under the design condition stated in the tender
inquiry/contract. The duration of warranty shall be 12 months from the date of
commissioning or 18 months from the date of shipment.

c.

The purchaser shall promptly notify the packager/contractor in writing of any claims
arising under this warranty. Upon receipt of such notice, the contractor shall, with all
reasonable speed, repair or replace the defective goods of parts thereof without any cost
to the purchaser.

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

d.

14

Technical Specs Annexure A

Date : NOV 28, 2014

Page 14

of 21

Free of charge replacement /repair of any defective equipment involving TPT charges, if
duly reported. Failure to which will liable the vender to refund the full purchase price.
The packager is required to confirm in their bids to provide the above warranty for
packaged equipment.

BIDDERS QULAIFICATIONS
1.
2.
3.

4.
5.
a.
b.
c.
d.
6.
7.
8.
9.
10.

All the following docs. must be provided with technical proposal by the bidder.
Vessel manufacturer must have U-stamp authorization and valid certificate. Bidder to
provide last 05 years U-Stamp certificates in continuation.
Bidder to provide the Design calculations of the package.
Bidder must submit the filled data sheets # SPEC-3PS-01.of separators duly stamped and
signed by the vessel manufacturer. Signed and stamped by the bidder and local agents
shall not be acceptable.
Bidder must have the manufacturing experience of such separators in last 05 years. Jobs
carried out as repair/maintenance/refurbishment shall not be acceptable.
Bidder must submit the details of last 05 years project record for the
manufacturing and supply of same type of separators mentioning the following.
Name of the company to whom separators are provided
Capacity of the separator
Year of supply
Contact details of the purchaser
Bidder must provide valid IS9001-2008, ISO 140001:2004, BS-OHSAS
18001:2007 certificates.
bidder must provide last 05 years financial reports to ensure financial standings to
provide such a equipment.
Bidder must provide detail project schedule in the form of Gantt Chart.
Bidder must provide the P & ID of the separators and its accessories as per ITB.
Bidder has to comply 100% to the annexure A of technical specifications.

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN

Technical Specs Annexure A

Title : Specification for three phase test separator (sour service)

Date : NOV 28, 2014

Page 15

of 21

DATA SHEETS:
DATA SHEET : SPEC-3PS-01
Date

THREE-PHASE SEPARATOR

By

Originator
Checked
Approved
Approved
Approved

Number
Sheet
of
Rev.
Date
P.O. Number
Specification No.

GENERAL INFORMATION
Project
Site
Service Condensate/Water/Gas Separator
Vendor
Delivery Period:
180 Days

Model No.
Equipment Tag No.
No. Required
Project No.

02

STANDARDS TO BE FOLLOWED
ASME Boiler and Pressure Vessel Code Section VIII, Division I.
API 12-J (API specifications for the Oil and Gas Separators)
ASME B31.8 Natural Gas Piping
ASME B31.3 Liquid Piping
NACE MR-01 75
AISC (American institute for Steel Construction)
OPERATING DATA (A-1)
Fluid Handled
Design pressure
Design Temperature
Max. / Min. Operating Pressure
Pressure Class
Gas Flow Rate
Oil Flow Rate
Water Flow Rate
Specific Gravity (Gas)
Specific Gravity (Oil)
Specific Gravity (Water)
Service
CO2
H2S
Chlorides
PH of water
Retention Time (Minimum)
Liquid separation
Max Oil in Water
Corrosion Allowance

Oil, Gas and Water


2200 PSIG
180 F
1600/800 PSIG
900 #
40 MMCFTD
2000 BPD
1500 BPD
0.60-0.80
36-65oAPI
1.0 1.07
Sour
10%
1%
up to 70,000 ppm
3.5 7.5
3 (three) Minutes.
100%
1000 mg/liter
1/8

(Comply /Not Comply)


(Comply /Not Comply)
(Comply /Not Comply)
(Comply /Not Comply)
(Comply /Not Comply)
(Comply /Not Comply)

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN

Technical Specs Annexure A

Title : Specification for three phase test separator (sour service)

Date : NOV 28, 2014

Page 16

of 21

VESSEL DATA
Design Code
ASME Section VIII, Division 1
U Stamp
(Yes/No)
Vessel Design Capacity (MMscfd) ______________
Pressure Drop @ Design Capacity ___________________
Outside Diameter (Vessel)
Inches
S/S Length
Inches
Inside Diameter (Vessel). _____________
Wight ________________ full of water
Shell Thickness ______________
Head Thickness __________________
PSIG
Design Temperature
_________ F
Design Pressure
Radiography
100% (Yes/No)
Post Weld Heat Treatment
Hydrostatic Test Pressure
PSIG
Min Design Metal Temp: _____________
Inlet Block Valve: ______________
Separator Bypass: ______________
Safety Valve: __________________
Rupture Disc: __________________
MDMT: ______________________
MATERIAL SPECIFICATIONS
NACE Materials
(Yes/No)
Metal Cladding:
Required
Type
Shell
Heads
Flanges
Nozzles
Weir Plate __________________________________ Saddle ____________________________
Internal Bolting (316/304 SS)
Studs
Support steel
Nuts
Gas Piping: _________________________________ Oil Piping __________________________
Water Piping _______________________________
Instrument Tubing ___________________
VESSEL INTRERNALS:
Mist Extractor:
Manufacturer _______________ Type ________________
Thickness _______________ Material _______________
Area of Cross Section ______________________________
Demister Pad: ___________________________________________
Vortex Breaker: ______________________________
Deflecting Plate : _____________________________
Weir Plate: __________________________________
Float Shield: _________________________________
NOZZLES AND CONNECTIONS
Total No. of Nozzles: ____________________
MK
N1
N2
N3
N4
N5
N6
N7
N8
N9
N10

No

SIZE

RATING

FACE

TYPE

SERVICE

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 17

of 21

Main Stream Inlet Connection: ________________________


Gas Outlet Connection: _____________________________
Oil Outlet Connection: ______________________________
Water Outlet Connection: ___________________________
Drain Connections: ________________________________
Sampling Points (Gas, Oil and Water): ________________
All piping terminated at skid edge and ends are RTJ flanged with companion flange secrewed with studs,
nuts and gaskets.
(Yes/No)
VESSEL TRIM
Trim Furnished by Vendor Yes (Yes/No) Trim Furnished by Company No

(Yes/No)

INSTRUMENTATION DETAIL
ITEM
Pressure Relief Valve
Pressure Control Valve
Level Gauge Water
Level Gauge Oil
Level Controller Water
Level Controller Oil
Level Control Valve Water
Level Control Valve Oil
Level Transmitter
Pressure Transmitter
Ball Valves
Needle Valves
Pressure Gauge
Temperature indicator
Thermowell
Pressure Indicator
Meter Run for orifice
Senior Orifice Fitting
Differential Pressure/Flow Recorder
Flow Computers
Oil Flow meter (Indicator & Totalizer)
Water Flow meter(Indicator &Totalizer)
Automatic Dump Valve
High/Low Liquid Level Switch
(oil/water)
Rupture Disc
Any Other

ITEM NO.

BRAND

TYPE / DESCRIPTION

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 18

COATING & PAINTING:


External Coating:
iSurface preparation: sand blasting according to SSPC-10
iiPrimer coat:
Zinc Chromate @ 50 micron DFT
iiiUnder coat:
Alkyd @ 50 micron DFT
ivTop coat:
Alkyd @ 75 micron DFT
vColour:
Dark Blue.
Internal Coating:
NACE Complied internal coating required: Ceram Kote @ 375 mils DFT
SKID FRAME
i.
ii.
iii.

Skid construction: 4 runner I-Beams (suitable for oil field condition)


Material ASTM A-36
Detailed drawing for skid

DIMENSIONS AND WEIGHTS


A
B
C
D
E
F
G

H
I
J
K
L
M
N

O
P
Q
R
S
T
U

Approximate Weights in Pounds/Kgs:


Shipping
Erected
NOTES
Reference Drawings P&ID No

c:\users\nt9\separator.dgn Sep. 25, 1996 08:56:06

Hydro test
Operating

Yes/No
Yes/No
Yes/No

of 21

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

TESTS & RECORDS


Hydrostatic test of vessel, piping and valves Report.
Leak Test of package
100% Radiography (vessel) inspection Reports/Films
100% Radiography (Piping) ) inspection Reports/Films (Yes/No)
Dimentional Inspection Record
Weld Map
Magnetic Particle Examination
Ultrasonic Test
Calibration of all Instruments before installation.
Function Test of all instruments after installation.

Page 19

of 21

(Yes/No)
(Yes/No)
(Yes/No)
(Yes/No)
(Yes/No)
(Yes/No)
(Yes/No)
(Yes/No)
(Yes/No)

INSPECTION:
Compliance of described Quality Plan in section 12 of this specifications

(Yes/No)

NOTE: Manufacturer to complete applicable vessel data sheet duly signed and stamped along with
technical proposal.

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 20

of 21

SCOPE OF THIRD PARTY INSPECTION (TPI)


Scope of this third party inspection (TPI) is to cover the project plan
review, progress review as per delivery plan, inspections / check / tests
review and facilitating the weekly progress reports for the actual work
done at the manufacturing site in a mutually agreed time bar and
descriptive review note. Identification and improvements in the earliest
(or before the contracted period) to expedite the units fabrication would
be most valued role of TPI with meaningful insight to this project. The
TPI Company is to depute its certified testing and inspections Engineers
(having relevant experience of such separator packages inspection /
testing of over 5 units) during the entire project at the manufacturers
site at the total costs whatsoever to be paid to the TPI in lumpsum
payment after the successful commissioning of the unit at site in Dakhni
Oil Field. The governing code would be ASME Section VIII, Division 1 and
API 12J for these inspection. The entire vendor supplied items and
QC/QA plans review are under this TPI plan as per contract /
agreement. The TPI inspection dossier / report to enlist the following, but
not limited to:
1.
Design / drawing / specifications / bid proposal and engineering
package review and verification
2.
Material Identification through mill test certificates or through
laboratory testing (if required)
3.
Review / Witnessing of Procedures qualification record and
welders qualification tests
4.
Inspection Regarding Construction of vessel and piping plan as
per code.
5.
Inspection of plates materials as per specification given in
agreement/code
6.
Inspection of welding consumables and to check the quality and
suitability.
7.
Inspection of Steel Structure assembly and welding.
8.
Inspection of vessel as per code.
9.
Inspection of Nozzle Orientation.
10.
Witnessing of DPT and Pneumatic Leak Test where necessary.
11.
Inspection of quality of E&I and valves as per code and sites 25
years functioning life.
12.
Witnessing of testing of all weld joints
13.
100% radiography of all the joints and review results of
radiography of all welds of the vessel and piping spools.
14.
Stage inspections / hold points to be decided according to the
Quality Inspection plan to be submitted by your manufacturer.
15.
Witnessing of Hydrostatic Testing
16.
Report of findings

Oil & Gas Development Company Ltd.


Islamabad PAKISTAN
Title : Specification for three phase test separator (sour service)

Technical Specs Annexure A

Date : NOV 28, 2014

Page 21

of 21

17.
Overall responsibility for the excellent workmanship guaranteed
through the above inspections and continuous site supervision by the
certified ASME Inspector at site during the entire phase of separators
design (its review), sizing, fabrication, testing and inspection as defined
in this document.
The owners hold points to be jointly monitored as per applicable ASME
code for vessel, 100% piping spools check, FAT of valves/E&I
packages/fittings, and functional testing before installation at the factory
of third party inspecting agency as per plan given in the Project Kick-Off
meeting with mutual agreement between TPI company, OGDCL and the
contractor. The hold points are defined as below:
Activity
Purchaser
Inspection
Preproduction Meeting
H
Material Procurement
R
Heat Treatment Certificates
R
Mill Test Reports
R
Welding Procedure Qualification H
Welder Qualifications
R
Fabrication
H, on-site
Radiographic Testing
H, on-site
Hydrostatic Testing
H, on-site
Welding Repairs
M
Painting and Coating
M
Prepare for Shipment
H, on-site
Note:
These inspections/tests are considered to hold points at the
beginning of production and may be changed to monitor points based on
production performance, if notified in writing by the purchaser.
HHold point, inspection or testing shall not proceed without the
presence of the purchasers representative.
MMonitor point, notification to the purchasers representative of
impending inspection or test activity is required.
RReview documentation, presentation of the specified.

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