FUNCTIONAL SPECIFICATIONS

FOR
SEPARATION MODULE

0 06.12.2007

REV. DATE PREPARED BY CHECKED BY APPROVED BY

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 TABLE OF CONTENTS

1.0 INTRODUCTION
1.1 Scope
1.2 Definitions and Abbreviations
1.3 Definitions
1.3.1 Abbreviations

1.3.2 Units of Measurements & Language

2.0 SCOPE OF SUPPLY
2.1 Engineering Design
2.2 Equipment Supply
2.3 Options
2.4 Exclusions
3.0 REFERENCED DOCUMENTS & ATTACHMENTS
3.1 Acts, Codes, Standards and Regulations
3.1.1 Codes and Standards
3.2 Requirements of Statutory Authorities
4.0 OPERATING CONDITIONS
5.0 PROCESS
5.1 Process Description
5.2 Process Design Data
5.3 Product Specification
5.4 Measurement and control Philosophy
5.5 Process Guarantee
5.5.1 Guarantee
5.5.2 Guarantee Period
6.0 MODULE
7.0 EQUIPMENT
7.1 Pressure Vessels
7.1.1 General
7.1.2 Design
7.1.3 Assembly

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7.2 Piping & Valves
7.2.1 Design
7.2.2 Installation
8.0 OPERATION AND CONTROL
9.0 ELECTRICAL DESIGN
10.0 MAINTENANCE
11.0 PAINTING & PRESERVATION
12.0 QUALITY ASSURANCE, INSPECTION AND TESTING
13.0 CONTRACTOR DATA REQUIREMENTS
14.0 SPARE PARTS AND SPECIAL TOOLS

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1.0 INTRODUCTION

1.1 Scope

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

painting, inspection and supply of Separation Modules for onshore applications.
This Specification is based on a two-phase vertical separator vessel and describes
a module where all necessary equipment is completely confined within the
boundaries of and mounted upon a single structural module.

The Modules shall be equipped with Separation Vessel, baffles, latest type internals
including Mist Extractor, internal / external piping, control devices and other
accessories to make a complete and functional unit.

This Functional Specification will cover few different module sizes for LP / HP and
VHP service to enable the Company to have flexibility in its operations. Detailed
below are the SIZES of required LP/HP/VHP modules:

LP Modules *capacity(m3/d)
• Module1: Small 250
• Module 2: Medium 500
• Module3 : large 1000
TOTAL 03 modules
HP Modules(m3/d)
• Module1: Standard Module 500
TOTAL 01 module

VHP Modules(m3/d) Gas

• Module1: Standard Module 50000**

TOTAL 01 module
*liquid handling capacity ** gas handling capacity
Numbers of separators under each category of modules are listed in the scope of
work of GGS.
This Specification should be regarded as the Company’s minimum requirements for
this equipment. Where the Codes and Standards has more stringent requirements
for design, safety and testing, those requirements shall be notified to the Company
and shall not be reduced in order to meet this Specification without the Company’s
prior agreement.
The separation modules shall be designed in accordance with the process design
criteria stipulated in Section 5.0. In addition, the Company requests the Vendor to
investigate and incorporate proven state of the art technology especially for
Internals that can improve the separation process. The findings should be provided

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 to the Company, highlighting the process or cost benefits and these shall be
included as part of scope without any cost & time implications.

1.2 Definitions and Abbreviations

1.2.1 Definitions

Company Oil and Natural Gas Corporation Limited (ONGC).

Contractor The party responsible for the design and supply of goods and/or
services, for a complete project or installation.

Inspector The person appointed by the Contractor to carry out engineering

inspection in the Supplier’s works.

Project Assam Renewal Project

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

goods or services to the Contractor.

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

Inspector that designs and/ or manufacture satisfy the specification and
purchase order requirements.

1.2.2 Abbreviations

BRH Borholla (oil and gas field)

CTF Central Tank Farm

DGMS Directorate General of Mines Safety

DML Demulgaon (oil and gas field)

ETP Effluent Treatment Plant

GLK Geleki (oil and gas field)

GCP Gas Compressor Plant

GGS Group Gathering Station (for oil)

LKW Lakwa (oil and gas field)

LPN Laiplingaon (oil and gas field)

ONGC Oil and Natural Gas Corporation Limited

OISD Oil Industry Safety Directorate

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 PFD Process Flow Diagram

P&ID Piping and Instrumentation Diagram

RDS Rudrasagar (oil and gas field)

TPL Trunk/Feeder/Collector Pipe Line

WIP Water Injection Plant

WHI/EPS Well Head Installation / Early Production System

1.3 Units of Measurements & Language

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

Standard conditions at 101.325 kPaa and 15.56°C.

All documents to be in the English language.

2.0 SCOPE OF SUPPLY

The Separation Modules (“the Module”) shall include all the equipment identified
within this Functional Specification.

The Module shall be completely packaged with the related components and
accessories ready for operation.

No fabrication shall commence until the Company, or their designated

representative, has approved the approval drawings. Approval of construction
drawings does not relieve the Contractor of compliance with process performance,
codes, standards, specifications, safety design or meeting the requirements of
governmental agencies.

The final sizing and design of the Module, including all internal components, shall
be the responsibility of the Contractor.

New technology options and developments are acceptable provided they give
equivalent or better process performance. The alternative options must be proven
and tested at a commercial level. Vendor to list advantages of new technology
proposed.

2.1 Engineering Design

The Modules shall be designed in accordance with the process design criteria
stipulated in Section 5.0.

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 The Contractor shall be responsible for the detailed design of seven different
Separation Modules as detailed in Section 5.0, Module should include the
following;

Item Qty Notes

Separation Vessel 1 Including internals

Base Assembly Module only
Piping Module only
Electrical & Instrumentation Module only
Controls Module only

The Module, and internal equipment, shall be constructed of materials appropriate

for the installation and long-term operation in the area with ambient conditions as
identified in section 4.0. Materials and components for this unit shall be new and
unused.

The Modules design shall be based on the process information provided within this
document.

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

2.2 Equipment Supply

The equipment supply shall include design, fabrication and supply of the following
main items:

Item Qty Notes

Separation Vessel Including internal piping, baffles, relief

1 valves, internals including Mist Extractor,
drains and external insulation
Base Assembly Module only
Piping Module only
Electrical Module only
Control valves & Module only
Instrumentation including PSV,
PCV ,LCV, PT ,TTetc.
Controls Module only
Insulation Vessels, pipes. To conform with process
and safety standards.
Heat Tracing As required to meet process
requirements
Measurement Systems for Module only.

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 Liquid and produced gas • For Liquid Metering: Coriolis Mass
quantity and emulsion BS&W. Flow Meters / Ultrasonic Meters.
• For Gas Measurement - Orifice
Metering

2.3 Options
The Contractor may provide options to the scope detailed in this Specification.

2.4 Exclusions
Supply and installation of equipment, piping, electrical, instrumentation, structural
and civil installations outside of the module boundaries.

Supply of feed or discharge pumps.

Fire & Gas detection and suppression systems.
.

3.0 REFERENCED DOCUMENTS & ATTACHMENTS

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

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

3.1 Acts, Codes, Standards and Regulations

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

delivered in accordance with the requirements of the latest editions of the following
Codes, Standards and Regulations:

3.1.1 Codes and Standards

3.1.1.1 Indian

OISD-STD-106 Process Design and Operating Philosophies on

Pressure Relief and Disposal System

OISD-STD-109 Process Design and Operating Philosophies on

Blowdown & Sewer System

OISD-STD-110 Recommended Practices on Static Electricity

OISD-STD-111 Process Design and Operating Philosophies on Fired

Process Furnace

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 OISD-STD-113 Classification of Area for electrical installations at
Hydrocarbon processing and handling facilities

OISD-STD-118 Layouts For Oil & Gas Installations

OISD-STD-128 Inspection of Unfired Pressure Vessels.

OISD-STD-132 Inspection of Pressure relieving Devices

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

OISD-STD-152 Safety Instrumentation for Process System in

Hydrocarbon Industry

OISD-STD-164 Fire Proofing in Oil & Gas Industry

OISD-STD-173 Fire Protection System for Electrical Installations

OISD-STD-180 Lighting Protection

OISD-GDN-192 Safety Practices during Construction

OISD-GDN-201 Recommended Practices for Environmental

Protection in upstream Petroleum Sector.

OISD-GDN-206 Guidelines on Safety Management System in

Petroleum Industry.

3.1.1.2 ANSI/API/NACE Standards

API RP 520 Sizing, Selection and Installation of Pressure-

Relieving Devices in Refineries

API RP 521 Guide for Pressure-Relieving and Depressurising

Systems

API RP 550 Manual on Installation of Refinery Instruments and

Control Systems

API Spec 12J Oil and Gas Separators

ASME VIII Div 1 Boiler & Pressure Vessel Code

ANSI / ASME B31.3 Chemical Plant and Petroleum Refinery Piping

ANSI / ASME B16.5 Pipe Flanges and Flanged Fittings

ANSI / AWS D1.1 Structural Welding Code-Steel

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 NACE-RP-0472 Methods and Controls to Prevent In-Service
Environmental Cracking of Carbon Steel Weldments
in Corrosive Petroleum Refining Environments

3.2 Requirements of Statutory Authorities

The Assam onshore facilities operate within the legal domain of India. The
Contractor, and sub-Contractors, must comply with the Regulations of India. These
include, but are not limited to:
• Equipment and Materials in accordance with Directorate General of Mines
Safety – India

• DGMS, Oil Mines Regulations, 1984

• Central Pollution Control Board(CPCB) & Assam Pollution Control

Board(APCB)

4.0 OPERATING CONDITIONS

The Module will be designed, fabricated and installed to accommodate the local
environmental conditions of the Assam .

4.1 Local and Environmental Conditions are given in Appendix C

4.2 Utilities available are given in Appendix C

5.0 PROCESS

The separation train is critical in the separation of well fluids into gas and liquid
phases. The Modules will be designed so as to ensure that appropriate gas/liquid
separation takes place in the two-phase vertical vessel. Separation trains will
operate in Three modes, LP, HP & VHP based on the specific requirement. For
each installation, LP trains should cater for 100% of design throughput . This
Functional Specification will cover several different module sizes to enable the
Company to have flexibility in its operations.

5.1 Process Description

Well fluids are diverted to LP, HP, VHP and test headers where they are preheated
by a Preheater or well fluid / thermal fluid (Geleki GGSII) followed by a bath heater
to 60 deg C. liquid from the VHP/HP separator is routed to either the HP/LP
separator or heater treater . Oil from the LP separator is routed directly to the heater
treater for oil / water separation. LP separator gas will be further routed for
compression by LP compressor at the centralised GCP or at the same GGS

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 premises as the case may be before export to the GCP for further compression.
Both LP and MP compressors will have suction scrubbers with a Class above
design to counteract any slugs arrival.

For VHP/HP separation, well fluids are directly routed from the header into the bath-
heater where they are heated to 60 deg C. Well-fluids from bath heater is then sent
to VHP / HP separation from where the fluids will be sent to LP separator or heater
treater. VHP Gas will be used for Gas Lift requirement in Borholla / Koraghat GGS
and HP Gas from GGS-V, Lakhmani will be transported to the gas compressor
station (GCP).

5.2 Process Design Data

LP Modules
Typical LP Operating Pressure: 2.0 – 3.0 kg/cm2g
Operating Temperature: 60 deg C
Orientation: Vertical

Module 1
• Total Liquids Rate: 250 m3/day
• GLR 60-500
Module 2
• Total Liquids Rate: 500 m3/day
• GLR 60-500
Module 3
• Total Liquids Rate: 1000 m3/day
• GLR 60-500
HP Modules
Typical HP Operating Pressure: 16 kg/cm2g
Operating Temperature: 60 deg C
Orientation: Vertical
Module 3
• Total Liquids Rate: 500 m3/day
• GLR: 350
VHP Modules
Typical HP Operating Pressure: 70 kg/cm2g
Operating Temperature: 60 deg C
Orientation: Vertical
Module 4
• Total Gas Rate: 50000 m3/day
• GLR: 350

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 The supplier is to provide a design calculations for each of the different sized
modules. The total number of modules provided above are also preliminary and
may change subject to finalisation and validation of process data. The well fluid
parameter & gas composition is given in the design Basis.
Surge and Swell factor: Surge factor of 25% on maximum well fluid flow rates and
swell factor of 15% on maximum oil flow rates shall be considered for design
Liquid Residence Time: 3 (three) minutes (minimum) on maximum liquid flow
including surge and swell factors

Demister Performance requirements:Demister assembly to have both top & bottom

retention grids, with adequate support, and shall consist of 2” upper layer, 2” middle
layer & 2” bottom layer. For demister sizing normal liquid load shall be taken as 0.1
vol% of max. vapor flow.

Separation Efficiency: 99%

Max. Allowable Pressure Drop: 100 mmWC

Max. Liquid Level: Center line of vertical vessel at surge conditions

5.3 Product Specification

Gas: Liquid Carry-over – Max 13.4 litres / MMSCM of Gas
Liquid particle size is not more than 10 Microns
Liquid: LP separators should have a three minute (minimum) residence time for the
liquid phase.

5.4 Measurement and Control Philosophy

The inlet separator level is controlled via a control valve on the liquid outlet of the
vessel. The primary aim is the level control of the inlet separator. A cascade
system is proposed where the level output from the inlet separator vessel cascades
onto the flow control loop on the liquid outlet from the inlet separator.

Within the central level zone for the separator, the control loop will be in flow control
and the level may fluctuate within the present bands, When the level approaches
the high and low levels more closely, the level controller will adjust the set-point of
the “flow control valve” to open or close the valve separator level returns to normal.

An alarm will be will be provided for high level and low level in the separator.

When the level rises above high-level, the inlet valve closes and this decreases the
liquid flux into the inlet separator and thereby decreasing the level.

The inlet shut-down valve will close when the level rises to HH level.

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 An alarm will be provided for low-level in the Inlet Separator.

The outlet shut-down valve will close if LL level is reached.

For pressure control PCVs will be fitted to the gas outlet lines (both flare side as
well as compressor side ) from the inlet separator which is controlled by PIT.

The vendor has the option of complying with the above control philosophy or
proposing an alternative design provided the control system offers advantages in
terms of process performance and cost savings.
Measurement systems to be provided for emulsion and produced gas quantity
measurement as well as for BS&W measurement. For Liquid Metering: Coriolis
Mass Flow Meters Meters shall be used ( for non custody transfer case) and for
Gas Measurement - Orifice Metering shall be used.

5.5 Process Guarantee

5.5.1 Guarantee

The subcontractor guarantees and warrants for the duration of the Guarantee
Period described below that the Process System will be:

a) Designed, manufactured and commissioned in accordance with and will meet or

exceed the Specifications; and

b) free from all defect in design and workmanship; and

c) operable in accordance with, and based on the design data contained in the
Specifications; and

d) suitable for its intended purpose as per the Specifications.

5.5.2 Guarantee Period

The Guarantee Period will be for a period of twenty four (24) months from the date
of Delivery, or twelve (12) months from the date of completion of installation and
commissioning of the Process System at the Company’s Production Site, whichever
is the less. During the Guarantee Period, Subcontractor at its cost, risk and
expense, will repair, redo or replace any part of the Process System which fails to
meet the above warranty or guarantee which manifests itself during the Guarantee
Period.

The Guarantee Period for any executed repairs and replacement shall be eighteen
(18) months from the completed repair or replacement.

Any repairs should be carried out on-site if at all possible, and so as to minimise
any disruption to the working of the Process System and any other parts of the
Installation/Plant to the greatest possible extent.

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6.0 MODULE

Refer to Appendix C: “Module”.

7.0 EQUIPMENT

Adequate sampling connections and future connections for chemical additives shall
be provided and appropriately located.

7.1 Pressure Vessels

7.1.1 General

All vessels shall be code stamped to ASME VIII unless noted otherwise. All vessels
shall be registered with a suitable third party verification body (e.g. Lloyd’s, DNV).

7.1.2 Design

All pressure vessels shall be of welded construction in accordance with ASME

Boiler and Pressure Vessel Code, Section VIII Division 1.

Vessels shall be designed to withstand the loading exerted by internal or external

pressure, weight of vessel, wind, seismic, reaction of supports, impact and
temperature. Detailed vessel design including internals shall be the responsibility of
the Contractor.

Vessels shall have adequate shell thickness not to be overstressed at mid-span and
near saddle supports with design loads under the following conditions;

• Full of water at atmospheric pressure.

• Full of water at hydrostatic test pressure.

• At operating liquid level and specific gravity at maximum allowable working

pressure (MAWP) with shell corroded.

Unless noted otherwise an internal corrosion allowance of 3mm is to be used in the

vessel design.

7.1.3 Assembly

All bolts in manholes, handholes and nozzles shall straddle the normal vessel
centrelines.

All pressure bearing flanges shall comply with ASME B16.5 unless stated
otherwise.

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 The Contractor shall design, furnish and install all internal support rings,
downcomer supports, bars, grating supports, wire mesh, seat angles, special
breakers, baffles, impingement and wear plates etc.

Reinforcing pads or doubler plates shall be provided beneath all attachments where
loading creates stress concentration or where attachment welds for external
appurtenances may cause locked thermal stresses.

All structural members, attached by welding to the outside of the vessel, shall be
seal welded continuously to the vessel.

Lifting lugs shall be installed to facilitate the handling of the vessel.

Vessel testing and inspections shall be in accordance with ASME VIII and to
Company approved standards.

7.2 Piping & Valves

7.2.1 Design

All piping shall be designed in accordance with ANSI / ASME B31.3 and this
Specification unless otherwise noted.

Process liquid lines shall be sized for fluid velocities in accordance with industry
standards.

The minimum required pipe wall thickness for any service shall be calculated in
accordance with ANSI / ASME B31.3.

Unless otherwise specified, all pressure piping shall have a minimum corrosion
allowance of 1.6mm. This is in addition to mechanical allowances.

7.2.2 Installation

“Stub-in” branch connections shall not be permitted.

A sufficient number of flanges or unions shall be provided in all piping to allow

disconnection of valves and equipment for maintenance.

Piping shall be arranged in a neat and simple manner. Piping, including supports,
valves and controls, shall be located so as not to present obstructions or stumbling
hazards nor interfere with equipment operation and maintenance. At least 600 mm
clear space shall be provided for access to equipment.

The minimum overhead clearance for piping or walkways shall be 2 metres. Piping
installed in pipe racks shall be grouped to have common bottom pipe elevations.

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 Piping headers shall generally be terminated with flanges and shall be installed to
allow for future expansion of the header.

Pipe systems shall have block valves, by-passes and cleanouts to provide
convenient access and repair.

Piping shall be designed to minimise pockets and low points.

Drain and vent connections as required for testing, maintenance and operation shall
be provided on piping. As a minimum, lines shall have ½ “ vent connections at high
points and shall have ½ “ drain connections at low points. Connections only for
hydrotest do not require valves.

Valve drains shall be installed on equipment that is not self draining.

Pipe elbows shall be long radius bends unless approved otherwise.

Where threaded pipe or fittings are used in hydrocarbon service, the piping between
any vessel or bridle and the first valve shall be a minimum of schedule 160.

Piping at equipment shall be supported in such a manner that the equipment may
be removed without effecting the piping and shall be supported to prevent
transmission of excessive moments and forces to equipments.

Adequate provisions shall be made in piping systems for thermal expansion and
contraction in accordance with ANSI / ASME B31.3.

Eccentric reducers with flat side up shall be used in pump suction connections.

8.0 OPERATION AND CONTROL

Refer to Appendix A, “Instrumentation and Control Guidelines”.

9.0 ELECTRICAL DESIGN

Refer to Appendix B: “Electrical Guidelines”.

10.0 MAINTENANCE

Refer to Appendix C: “Maintenance”.

11.0 PAINTING & PRESERVATION

Refer to Appendix C: “Painting & Preservation”.

12.0 QUALITY ASSURANCE, INSPECTION AND TESTING

Refer to Appendix C: “Quality Assurance , inspection and testing”.

13.0 CONTRACTOR DATA REQUIREMENTS

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 Refer to Appendix C: “Contractor data requirement ”.

14.0 SPARE PARTS AND SPECIAL TOOLS

Refer to Appendix C: “Spare parts and special tools”.

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