PETROBEL

BELAYIM PETROLEUM COMPANY

SINAI FIELDS
INSPECTION DIVISION

MEMO

FROM : SF.GEN.MGR/INSP.GEN.MGR
TO : F.MAINT.GEN.MGR
: CORRDIV.MGR
CC : F.PROD.GEN.MGR./ONSHORE PROD.DIV.MGR
DATE :25/03/2023
REF. : 81/RACO.SEP./49/2023

SUB. : INSPECTION FOR RACO SEPERATOR 2nd STAGE (200-VS-l02) AND PIPING

SYSTEM AT PETRE CO.

Reference to the above mentioned, please be informed that visual inspection and
thickness measurements had been carried out for the leakage observed for RAeo SEP.
the results are as the technical report.

For your kind information and action,

Thanks.i.,

IPagel
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

Table of content

Item Description Page

1 SEPARATOR DATA 3
2 INTRODUCTION & GENERAL VIEW 4
3 Reason for Inspection 4
4 INSPECTION REGISTER. 4
5 EXTEND AND METHODS OF EXAMINATION(check list) 5

6 THICKNESS MEASUREMENT 6
7 VISUAL INSPECTION EXAMINATION FOR EXTERNAL, INTERNAL AND PIPING 7-19
SYSTEM

8 ANOMALIES AND FINDINGS FOR EXTERIOR INSPECTION 20

9 FITNESS FOR SERVICE 21
10 Recommendation 22-23
11 CML Drawing and P&ID 24-30

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 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

Visual inspection report

Date 12-01-2023 PRESSURE VESSEL W.O
INSPECTION FOR PETfRACO
Description Tag No. 200-VS-I02 Report No. SEP.l49.12023
RACO SEPERA TOR

1. SEPARATOR DATA:

DlSCRIPTION RACO SEPARATOR 200-VS-I02

LOCATION PETRECO

PRODUCT NAME Crude oil

SERVICE CRUDE Oil

DESIGN CODE ASME VIII (DIVISION 1)

INSPECTION CODE API 510

INSTALLATION DATE MARCH 2006

ORIENTATION HORIZONTAL

MATERIAL C.S

DIAMETER 4000mm

LENGTH 18000mm

DESIGN PRESSURE 12.24 Kg/cm2.g

DESIGN TEMPRETURE 90 'c

OPERATING PRESSURE 1.6 bar

OPERATING TEMPRETURE 65 ·C

FLOW RATE 1000000 BBl/D

MATERIAL HEAD SA-516-70

LAST RE-HABITATION N/A

P&ID 1910-01-CPFM-00114

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 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

2. Introduction:
• A cylindrical or spherical vessel used to separate oil, gas and water from the total fluid stream
produced by a well. Separators can be either horizontal or vertical. Separators can be classified
into two-phase and three-phase separators (commonly called free-water knockout). The two-
phase type deals only with oil and gas, while the three-phase type handles oil, water and gas, this
type (RACO SEP.200-VS-102).

3. Reason for Inspection:

1) To determine the physical condition of the vessel and to determine the type, rate, and causes of
damage mechanisms and associated deterioration.
2) To determine the work necessary to restore a vessel to a condition suitable for safe operation at the
design conditions.
4. Inspection Register:

Report No. Recommendation

• Clean the inner surface from any liquids by opening the drain point in order To avoid
cracks in the surfaces.
• Clean the leakage area from the outside well and add a patch plate (40 cm x 30 cm as
per attached photo) with thickness}'2" Min. material spec. ASTM 516 -70 using a
suitable welding electrode e-7018-1, 2.5 dia. After Preheat the surface to 70°C to
100°e.
03/PET-49/2022 03/01/2022
• Intensive measurement of the separator wall thickness in an attempt to reach a
nearest estimate of the thickness at the repair area and arrange Suitable temporary
repairs if needed.
• During the temporary repair process, any weakly-thickened area to be temporarily
strengthened until the permanent repair is done
• Testing the repair area using Magnetic Particle inspection
The vessel shall be put out of service as soon as possible in order to perform the
316/PET-43/2021 03/01/2021
complete internal inspection to ensure the vessel reliability.
For assessment of second separators further inspection will be performed internally
112/PET-49/2018. 19/05/2018
after desludging and sweep blast to define the required repair.
153/PET.49/2017 09/07/2017 The vessel shall be put out of service for complete internal inspection

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 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

5. Extend and Methods of Examination:

5.1 CHECK UST FOR PRESSURE VESSEL INSPECTION

No. Description Current condition photo Remarks
EXTERIOR VISUAL INSPECTION
1 Name plate Fixed But not clear Extemal ins~ction
There are missing bolts
In general is good except one ladder need to for the ladder and
2 Ladders No.8
be repair handrail at SeQ.
shell.(beside head-2)
3 handrail Good External ins~ction

4 platform Good No.8

5 walkways Good External ins~ction
6 Grating Good 21,22
7 Foundation Good No.5
8 supports Good No.5
9 Concrete foundation Good External ins~ction
11 Anchor Bolts Rusted External ins~ction
12 Soil Corrosion N.A -
13 Leaks Last point leaked at first course No.9 at external insl1. Installl1atch I1late
There are rusted in bolts
14 Safety valve condition Ok, shall be check and test External ins~ction
and nuts
15 Vessel buckling and bulging N/A =
16 Vessel support lugs N/A =
17 Fire-proofing for support beams N/A -
18 Fire-proofing for guy wires N/A --
19 Grounding connections ok ,connected External insQection
20 Auxiliary equipment's should be checked by instrument External insl1ection
21 Flanges / Bolts Conditions some points is rusted 5
22 Deformation N/A --
23 Nozzle Welds Conditions Good External nozzle Qic.
Localized and uniform
24 N/A --
corrosion(pitting),cracking

INTERIOR VISUAL INSPECTION

No. Descri tion Current condition No. Of hoto Remarks
Need to be internal repair (cap at the sea
1 Head
side)
2 Shell Need to be repair 9(020 From 30'clock to 90'clock
7,8 (part internal Some the nozzles is closed and
3 Internal nozzles Some closed and need to be cleaning.
nozzles) another it need to be cleaning.
Missing last 4 steps And need to be fixed and
4 Internal two ladder 4
Missing last 3 steps for oil room.
Dismantle for check and
S Baffles plate Need to be cleaning
clean in
9 Cathodic protection anode are fully depleted 21 All anodes shall be b new one
Mix extractor (outlet gas) Is damage 28 Shall be fixed

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 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

S.2 Ultrasonic Thickness Measurements Test (UT):

12
Description O'CLOCK 5 O'CLOCK 6 O'CLOCK 7 O'CLOCK Remarks
O'CLOCK
27.93 29.02
Head-2 28.43 28.01

Location

COURSE 1

COURSE 2 SEE
DRAWING
OF RAeo
SEP.

-5

Section
-6

Section
-7
COURSE 3

Section
-8

Section
-9

COURSE 4 Section
-10

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 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

25.31 25.25 24.93 24.35 25.20 25.31 Section

25.35 25.35 24.97 24.66 25.32 25.25 -11
25.32 25.60 22.14 24.91 25.21 25.37
25.24 25.19 23.44 23.12 25.19 25.40
Section
25.20 25.17 23.56 22.93 25.21 24.34
-12
25.53 25.32 22.70 23.58 25.40 25.30
25.28 25.42 22.81 23.18 25.24 25.46
25.33 25.51 23.56 23.78 25.46 25.44
Section
25.35 25.47 22.66 25.81 25.54 25.25
-13
COURSE 5 25.29 25.28 22.87 24.69 25.46 25.58
25.34 25.38 22.82 22.88 25.43 25.26
24.84 24.36 24.32 24.89 25.32 25.23
Section
25.00 25.37 24.91 24.48 25.35 25.35
-14
24.40 26.21 24.31 24.98 25.30 24.30
25.04 25.38 23.92 25.25 25.28 24.32

5.3 Visual Inspection for attached nozzles:

Flanges: Many rusted points were

observed. and RF a bad condition
3'" DRAIN NOZZLE
Welding: good condition.
NECK: bad condition.

~ Many rusted points were

N-2 3" DRAIN NOZZLE observed. and RF a bad condition
Welding· good condition.

~ Many rusted points were

N-3 4" DRAIN NOZZLE observed, and RF a bad condition
Welding: good condition.

~ Many rusted points were

N-4 3" DRAIN NOZZLE observed, and RF a bad condition
Welding: good condition.

Flanges: Many rusted points were

observed. and RF a bad condition
Welding: good condition.
6" DRAIN NOZZLE
NECK: there is mechanical clamll
around nozzle.

~ Many rusted points were

N-6 3'" DRAIN NOZZLE observed. and RF a bad condition
Welding: good condition.

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 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

Flanges; Many rusted points were

N-7 3" DRAIN NOZZLE observed. and RF a bad condition
Welding; good condition.

~ Many rusted points were

observed.
N-S 18" OUTLET Welding· good condition.
Bolts; many rusted points were
observed.

~ Many rusted points were

N-9 3" DRAIN NOZZLE observed. and RF a bad condition
Welding; good condition .

.EI.angj:s.; corroded corrosion were

observed. (Shall be repair by weld
20" MANWAY
(THE SEA BESIDE) metal.
Welding; good condition.

Flanges; Many rusted points were

MANWAY-2
20" MANWAY observed.
(TOP SEP.)
Welding; good condition.

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 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

5.4 Visual Inspection Examination:

DEFINITION OF SEP. CONDITION

c- Nothing to report 8- Less Significant Al- Significant Fault Al-Imminent Danger
Excellent condition: no signs of Surface rust, light scale. Corrosion greater than O.Smm. Possible Heavy corrosion and / or deep pitting or
damage or corrosion - nothing cracking adjacent to welds - more significant cracking of any description; vessel operating
to report. damage than B but no immediate risk of above SOL- significant damage with risk of
failure. imminent danger.

IPage9
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

A2- Significant Fault (welded patch plate was installed) on shell B- Less Significant Fault ( found rusted at shell Sep. and soil at
plates Be side weld course shell weld course shell )

A2- Significant Fault (missing bolts and nuts for inlet line 12") A2- Significant Fault (soil corrosion at two flanges inlet line
12"

I P age 10
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

A2- Significant Fault (soil corrosion at two flanges drain 8- less Significant Fault (Supports steel and concrete)
nozzle.)
Photo No.13 Photo No.14

Shall be check and test Shall be check and test by instrumentation div.
Photo No.IS Photo No.16

Outlet gas nozzles

Photo No.17 Photo No.18

IPagell
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

Photo No.2l

I P age 12
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

A2- Significant Fault (sour water corrosion at section-l beside baffles)

I P age 13
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

section -1 after baffles corroded corrosion at A2- Significant Fault ( section -1 after baffles corroded corrosion at 5
6 o'clock) o'clock)

A2- Significant Fault Some pits corrosion at internal Sep. from 5 A2- Significant Fault Cathodic protection anode are fully depleted at
0' clock to 7 0' clock section-l. And section-2)

I P age 14
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

A2- Significant Fault Some pits corrosion at internal Se A2- Significant Fault Some pits corrosion at internal Sep, at 6
o'clock o'clock and undercut for weld shell Sep.

A2- Significant Fault Some corrosion reduction 8mm

A2- Significant Fault Some sour water corrosion reduction A2- Significant Fault Some sour water corrosion reduction l4mm
IOmm at 7 o'clock During thickness measurements at 6 o'clock During thickness measurements

I P age 15
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

A2- Significant Fault Cathodic protection anode are fully depleted at

section -4)

Photo No.21 Photo No.22

I P age 16
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

A2- Significant Fault cutting in steps for internal ladder for oil

INSPECTION OF PIPING SYSTEM FOR RACO SEP. (200-VS-I02)

Photo No.3 Photo No.4

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 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

Photo No.8

8- Less Significant udge & oil) and the

I P age 18
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

B- Less Significant Fault ( was found rusted and the valves During apply UT thickness at piping system
shall be check
Photo No.13 Photo No.14

I P age 19
 PETROBEL
BELAYIM PETROLEUM COMPANY
SINAI FIELDS
INSPECTION DIVISION

6. ANOMALIES AND FINDINGS

~ FOR EXTERIOR INSPECTION:

1) One fillet-welded patch was installed on shell plates (circumference weld between 1't course and 2nd
course from inlet nozzle side) but internal baffles covers its location from inside. See photo no.9 (part
external insp.)
2) Two drain nozzles found in bad condition including found clamp around the nozzle N-5. See photo nO.7
(part external insp.)
3) Manhole (head) found corroded and projection is rusted. See photo nO.10 (part external insp.).
4) There is spot rusted and soil at shell separator. See photo no.11 (part external insp.).
5) There is soil corrosion at tow flange inlet line 12". See photo no.12 (part external insp.).
6) There is cutting in ladder with handrail, see photo nO.8 (part external insp.)

~ FINDING FOR PIPING SYSTEM:

1) There are piping system observer oil around pipes and sludge. See photo no.8 (part piping system insp.)
2) There are some pipes without painting. See photo no.7. 10 (part piping system insp.).
3) There are rusted of pipes attached top shell Separator. See photos (5-11-12-13) part piping system.

~ FINDING FOR INTERIOR INSPECTION:

1) Many pits & sour water corrosion area observed inside surface of shell and head. See photos part interior
shell
2) Reduction of the thickness more than 3mm to 14mm. according of fitness of services calculation.
19.20mm with corrosion allowance. See photos part interior shell
3) The weld for shell courses a bad condition. See photos part interior shell
4) The weld for internal nozzles (drains and instruments) nozzles a bad condition. See photos part interior
shell
5) The Cathodic protection anode are fully depleted at section-l & section -3 and bottom Sep. See photos
part interior shell
6) There is the intemalladder a cutting for last 4 steps and not fixed with bolts. See photos part interior shell
7) There is the ladder for oil room a cutting for last 3 steps and not weld with bottom. See photos part interior
shell

I P age 20
 PETROBEL ~.Jfo.
BELAYIM PETROLEUMCOMPANY ~r ----.!lp~~ J.Jfo. 4.sJ.l---'~.
SINAI FIELDS ~~Jjb
INSPECTION DIVISION
~~I ul'.;'iii'l elb!

7. FITNESS FOR SERVICE:

a. The minimum required thickness for shells under pressure shall not be less than that
computed by the following formula:

t=PR/ (SE-O.6P)
E = Joint efficiency =1.0-RT-2
P = Design pressure = 12.24 Bar=177.53 PSI
R = Radius of the shell = 2000 mm = 78.74 In.
S = Maximum allowable stress value (ASTM A516 G,7D S=22000 PSI),
t = Minimum required thickness of shell =0.638 in = 16,20 mm without corrosion allowance,

_ 0 638' - 16 20
t -- 177,53 X 78,74
-. In - . mm.-__ __. 16.20 + C.A ()3mm = 19.20mm.
22000.1-0,6.177.53

b. The required thickness of a TORISPHERICALHEADshall be determined by the followinl:

formula:

t = 0.88SPL r
I. SE-O,lP

E = Joint efficiency =1,0

P = Design pressure = 12,24 Bar=177 .53 PSI
L = inside spherical or crown radius = 4000mm = 157.48 In.
S = Maximum allowable stress value (ASTM A516 G.7D S=22000 PSI).
t = Minimum required thickness of head =1.126 in = 28.6 mm without corrosion allowance.

t - 0.885 X 177.53X 157.48 _ 24742 - 1125' - 28 57

- 22000.1-0.10177.53 - 21982 -. In - • mm.
. rate (L T) = -._ __;;luiur/ where
CorrosIOn lClU3I
;:;;;:_...;;;;;._-
time between 1.'1lI1 and laclllll (years)
'india! is the ilitial thickness at the same CML as '1CIIIli.1t is either the first thickness measurement at th~ CML
or the thickness at the slart of a new OOITosioo rate envilOllment, in in. (mm);
The short·term (ST) corrosion rate shall be calculated from the following formula:
'1CII li is the actual thickness of a CML, in in. (mm), measured during the most recent ins~n;
. Ipm"",,-/actull
CorrosIOn rate (ST) = --~;;....;;;;;;..._-- 'II'CVW is the previous thickness measured during the prior ins~. It s at the same location as 'aclllll
time between tjXl'WS and I,.,,,, (years) measured during a previous i1spection, in in. (mm).

CORROSIONRATE(LT) = 25 - 4.83/5 (YEARS) = 4mm

CORROSIONRATE(ST) = 24.00 - 4,83/5 (YEARS) = 3.8mm

I P age 21
 PETROBEL
BELAYIM PETROLEUMCOMPANY
SINAI FIELDS
INSPECTION DIVISION

8. Recommendation:

~ Exterior vessel:
a) According to API 510 The fillet welded patch plate shall be removed and repair its location by
insert weld patch plate as following:-
• Shape: rectangular shape have a rounded corner (2in) radius (R) except when intersect
with circumference weld shall have right-angle.
• Thickness: not less than 20mm.
• Should have good fit-up and root pass (if the back weld is impossible).
b) Replace drain nozzle (N-5) 6" which include the clamp (See table of nozzles).
c) The weld ladder with handrail beside head-1 shell of Sep.
d) Deposited weld metal for manway (M-1) the sea beside. (See table of nozzles).
e) Apply Paint system for shell vessel.

~ Interior vessel:
a) Thickness of the (pits-sour water-hydrogen) corroded portions (internal) shall be restored by
deposited weld metal, thickness shall be not less than 19.00mm. (See table thicker.).
b) solution for shell and internal baffles plates due to exist patch on external separator
• Dismantles baffles plates for cleaningto increase efficiency of separator and checkshell of
separator under baffle (ifthe baffle in bad condition should be replace by new one)
• Any defect appear in shell of separator after dismantle the baffle should be repair by
deposited weld metal from 30'clock to 90'clock, thickness shall be not less than
19.00mm.
c) Re-weld internal instruments nozzles.
d) Re-welding longitudinal circumference of separator as possible
e) Re-weld internal drains nozzles.
f) Re-weld the internal ladder
g) Installing cathodic protection anode by corrosion.div.
h) Repair internal two ladder and fixed or replaced.
i) Repair and fixed mix extractor outlet gas (see pic. 28 at interior inspection)
j) Repair procedure (WPS, PREHEAT NDT AND HYDROTEST) as referred in ASME VIII, SECTION.IX.
k) Apply internal Paint system for shell vessel.

~ Piping system around RACO SEP.:

a) Shall be dismantle inlet line 12" for check two flanges and gasket.
b) All valves shall be dismantle for check and test by instrumentation div.
c) The two PSV shall be dismantle for inspection and calibration.
d) Installing all missing bolts and nuts for flanges (piping system).
e) Apply paint system for piping.

Apply (UT)
INSPECTION PIPING SYSTEM /INSP.MECH.ENG INSP.ENG.API510 INSP.GEN.MGR.
THICKNESS
RABEAI
ELSAYED
KARIM ATTEF I MAHMOUD MEGAHED ABDHAMEED HASSAN / ALHASSAN ISAMAEL SAID SAKR

I P age 22