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Technical Specs Annexure A

Title : Specification for three phase test separator (sour service) Date : Nov 28, 2014 Page 1 of 21

Oil & Gas Development Company Ltd. Islamabad PAKISTAN

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)


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


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: For Type-I Vessel Sizes: Maximum Vessel length T/L to T/L = 20 ft. Minimum ID of vessel = 5 ft Nozzle Sizes: Gas Inlet = 8 Gas Outlet = 6 Oil Outlet = 3 Water Outlet = 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




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.




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.

3 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.

3.3 All flanges shall conform to ANSI B16.5. All studs and nuts shall conform to ASTM A-193 and A-194 and cadmium plated. All carbon steel pipes shall conform to ASTM A-106 for sour service.

COMPONENTS 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




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.

4 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




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 Approved Vendor Flow Transmitters Force Balance D/P cell Emerson, Honeywell, Foxboro Flow Indicator Field Mounted Bellows Type Rota meters

Taylor, Barton, Fisher, Porter & Brooks

Liquid Electronic Flow Meter (Oil & Water) Yokogawa ,Emerson , Rockwell, Krohne , Invensys (Schnieder Electric)

Level Controllers, Transmitters Displacement, with tore tube

Emerson, Honeywell, Foxboro, Norriseal

Level Switches External, Displacement, with Torque tube or magnetic follower

Magnetrol, Merciod, Yamatake,

Level Gauges Steel armored, Reflex or Transparent with illuminator

Jerfuson, Penberthy, Greenwood, Sparton Controls, Cesare Bonetti SPA - ITALY, Samil Industry Co. Ltd. Korea , Simco Engineers Ltd. U.K. , Vaihinger GMBH Germany

Pressure Transmitter Indicating, motion/force balance

Rosemount, Honeywell, Foxboro

Pressure Switches- Electrical Process- 3.6 SS Bourdon tube Air 3-15 PSI

ASCO, Dresser (Ashcroft)

Pressure Gauges 4 316 SS Bourdon Tube Seals

Aschroft, Wika, Nuova Fima

Temperature Remote Indication or Recording Resistance bulbs (RTD) with Thermowellss-100 OHM Platinum

Conax, Taylor, Honeywell

Temperature Switches Electrical (Blind, Gas Filled)

United Electric, Aschroft

Temperature Gauges (Dial Type)

Ashcroft, Wika




Temperature Switches Pneumatic (Blind)

Mason-neilan

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

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

Temperature Transmitter (Blind or indicating , Force or Motion balance with SS well)

Emerson, Honeywell, Foxboro, Rochester Instruments System Ltd. U.K., Yokogawa, ABB

Relief Valves (General Steel Bodies, Flanged 150# RF Inlet and Outlet min., Full nozzle type)

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

Field Mounted Recorders/ Indicating Controllers

Taylor, Foxboro, Honeywell, ITT Barton (Cameron), ABB

Panel Mounted Recorder/Indicating Controllers Taylor, Foxboro, Honeywell, ITT Barton

Tubing/Fittings (Instrument Air)

SS/Hokes

Gas Regulators Fisher, ITT Conoflow , Fukui Seisakusho Japan ,Hartmann & Braun Germany , Hirata Japan, Valvitalia

Pneumatic Relays Moore Honeywell, Foxboro Solenoid Valves Asco, Maxseal UK (Thompson

Valves), Konan Electric Japan, Herion Draft Gauges Hays, Baileys Rupture Discs Black Sivalls & Bryson (Insert Type) Annunciators Ronan, RIS Switch Timers Automatic Timing & Control Panel Mounted Indicators

Taylor, Ashcroft, Foxboro, Honeywell

Pressure Switch-Differential 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

Ball / globe Valve Valvatalia, Petrol Valve, Newco, Orbit, GWC V/V USA, KITZ Euorpe, Ringo Euorpe, Dafram Italy,Velan Canada/USA/Euorpe, MSA Italy

Senior Orifice Assembly Daniel, FMC, Precision 6 TEST REQUIREMENTS




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.

7 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.




7.6 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.

8 IDENTIFICATION 8.1 Nameplates

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

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

8.2 Equipment Tags

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

9 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.

10 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.).




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




Systems

11.2 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

11.3 American National Standards Institute (ANSI)

ANSI B16.5 Pipe Flanges and Flanged Fittings

11.4 NACE International

NACE MR0175-96 Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment

11.5 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 H

02 Material Procurement R

03 Heat Treatment Certificates R

04 Mill Test Reports R




05 Welding Procedure Qualification H

06 Welder Qualifications R

07 Fabrication H (see note)

08 Radiographic Testing H (see note)

09 Hydrostatic Testing H

10 Welding Repairs M

11 Painting and Coating M

12 Prepare for Shipment H

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. 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.

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.

13 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.




d. 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.

14 BIDDERS QULAIFICATIONS All the following docs. must be provided with technical proposal by the bidder.

1. Vessel manufacturer must have U-stamp authorization and valid certificate. Bidder to provide last 05 years U-Stamp certificates in continuation.

2. Bidder to provide the Design calculations of the package. 3. 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.

4. Bidder must have the manufacturing experience of such separators in last 05 years. Jobs carried out as repair/maintenance/refurbishment shall not be acceptable.

5. Bidder must submit the details of last 05 years project record for the manufacturing and supply of same type of separators mentioning the following.

a. Name of the company to whom separators are provided b. Capacity of the separator c. Year of supply d. Contact details of the purchaser

6. Bidder must provide valid IS9001-2008, ISO 140001:2004, BS-OHSAS 18001:2007 certificates.

7. bidder must provide last 05 years financial reports to ensure financial standings to provide such a equipment.

8. Bidder must provide detail project schedule in the form of Gantt Chart. 9. Bidder must provide the P & ID of the separators and its accessories as per ITB. 10. Bidder has to comply 100% to the annexure A of technical specifications.




DATA SHEETS: DATA SHEET : SPEC-3PS-01 Date By Originator Number Checked Sheet of

THREE-PHASE SEPARATOR Approved Rev. Date Approved P.O. Number Approved Specification No. GENERAL INFORMATION Project Model No. Site Equipment Tag No. Service Condensate/Water/Gas Separator No. Required 02 Vendor Project No. Delivery Period: 180 Days STANDARDS TO BE FOLLOWED ASME Boiler and Pressure Vessel Code Section VIII, Division I. (Comply /Not Comply) API 12-J (API specifications for the Oil and Gas Separators) (Comply /Not Comply) ASME B31.8 Natural Gas Piping (Comply /Not Comply) ASME B31.3 Liquid Piping (Comply /Not Comply) NACE MR-01 75 (Comply /Not Comply) AISC (American institute for Steel Construction) (Comply /Not Comply) OPERATING DATA (A-1) Fluid Handled Oil, Gas and Water Design pressure 2200 PSIG Design Temperature 180 F Max. / Min. Operating Pressure 1600/800 PSIG Pressure Class 900 # Gas Flow Rate 40 MMCFTD Oil Flow Rate 2000 BPD Water Flow Rate 1500 BPD Specific Gravity (Gas) 0.60-0.80 Specific Gravity (Oil) 36-65oAPI Specific Gravity (Water) 1.0 1.07 Service Sour CO2 10% H2S 1% Chlorides up to 70,000 ppm PH of water 3.5 7.5 Retention Time (Minimum) 3 (three) Minutes. Liquid separation 100% Max Oil in Water 1000 mg/liter Corrosion Allowance 1/8




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 __________________ Design Pressure PSIG Design Temperature _________ F 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 No SIZE RATING FACE TYPE SERVICE N1 N2 N3 N4 N5 N6 N7 N8 N9 N10




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 ITEM NO. BRAND TYPE / DESCRIPTION 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




COATING & PAINTING: External Coating:

i- Surface preparation: sand blasting according to SSPC-10 ii- Primer coat: Zinc Chromate @ 50 micron DFT iii- Under coat: Alkyd @ 50 micron DFT iv- Top coat: Alkyd @ 75 micron DFT v- Colour: Dark Blue.

Internal Coating: NACE Complied internal coating required: Ceram Kote @ 375 mils DFT SKID FRAME i. Skid construction: 4 runner I-Beams (suitable for oil field condition) Yes/No ii. Material ASTM A-36 Yes/No iii. Detailed drawing for skid Yes/No DIMENSIONS AND WEIGHTS A H O B I P C J Q D K R E L S F M T G N U

Approximate Weights in Pounds/Kgs: Shipping Hydro test Erected Operating NOTES Reference Drawings - P&ID No

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




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




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.

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.

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