PDOC 3phase Separator Operation Manual

OPERATION AND MAINTENANCE

MANUAL FOR

1st & 2nd STAGE 3 PHASE SEPARATOR

Petrodar Order No. : 11057-31100132-MQ01-020

Equipment Tag No. : 1V, 2V, 3V, 4V-8301

LEPS Doc No. : LEPS-20071005-O&M

Higleig Doc No. : PDOC-236207-VD-MEC-075

Issue and Revision Record

016-03-

09Submitted for Approval LEPS LEPS

Rev

No.Date Description

Prepared by

Supplier

Reviewed by

Supplier

Approved by HDC

Owner : EPCC Contractor : Supplier / Sub-Contractor :Document No: LEPS-20071005-O&M

Petrodar Operating Company

Moleeta FPF Oil Development Project

Petrodar Operating Company Limited

Higleig Petroleum Services & Inv. Co. Ltd.

LAKSEL EPS Technologies Pte Ltd

INDEX

1.0 SAFETY

1.1 Safety when Entering the separator1.2 Safety when filling the vessel with Oil1.3 Safety when Emptying the Vessel

2.0 EQUIPMENT DESCRIPTION

2.1 Internals2.2 Weir plates2.3 Baffle2.4 Vortex Breaker2.5 De-sanding Line and Nozzles2.6 Heating Coil

3.0 START-UP PREPARATION

3.1 Vessel and Internals3.2 Pipe Works3.3 Instruments3.4 Electricity

4.0 START-UP PROCEDURE

4.1 Filling with Crude4.2 Adjustment of Interface Level4.3 Oil Level

5.0 NORMAL OPERATION

5.1 Normal Operating and Maintenance Instructions

6.0 SYMPTOMS OF FAULTY SEPARATOR OPERATION

7.0 SHUT DOWN PROCEDURE(Normal and Emergency)

7.1 Shut down7.2 Emptying the Plant

8.0 ELECTRICAL MAINTENANCE

8.1 High Voltage Electrical Failure

Document No: LEPS-20071005-O&M

9.0 DESIGN AND PERFORMANCE DATA

9.1 Design9.2 Description9.3 Performance9.4 Hazards9.5 Information Sources

10.0 STORAGE AND HANDLING

11.0 OPERATION

11.1 Basic Principles of Operation11.2 Slugging Conditions11.3 Emergency Levels11.4 Fault Conditions

12.0 MAINTENANCE

12.1 Recommended schedule of Maintenance12.2 Maintenance Requirements12.3 Vessel

13.0 ANNEXURES

13.1 Process and Instrumentation diagram13.2 General Arrangement Plan13.3 Instrument Schedule13.4 Correction for Buoyancy type Level Gauge


PRE START-UP CHECKS OF FOR THREE PHASE SEPARATOR

NOTE – Read this instruction completely prior to introducing Crude Oil in the Separator. Contact your Laksel Representative for start-up assistance.

WARNING Perform all of the following steps in order to ensure personnel safety and equipment protection.

Preliminary Inspection

Perform the following preliminary inspection before putting the Separator online

Isolate all power sources to the Instruments and Controls to be certain that no short circuit takes place

Bypass all interlocks to the Separator

Recheck/correct the Separator and piping installation

Ensure that all the external/internal bolts are fully tightened as per the required torque range. Make sure all the Baffle plate, Weir plate, Vortex breaker are in order and in place. Looseness and misalignment during transportation should corrected during inspection

Make certain that all piping are securely connected and properly supported

Inspect all Separator control components (control valves, flow metering devices, check valves, strainers, gauges, etc.) to make certain that these components are correctly oriented in the piping scheme in order to achieve the proper direction of flow and functional operation

Inspect the Separator inlet to make certain that the inlet screen and clean-out connections have been properly made and are free of tools, equipment and debris

Fully open the inlet and discharge line manual valves of the Separators

Open the Valves in the drain lines

All the instruments and the valves which are damaged during the transportation are replaced with the new items are rectified with the spares

All the pipe lines are cleaned and flushed with the water to remove all the loose items , dust and other matters


1.0 SAFETY

SAFETY RULES AND RECOMMENDATIONS APPLICABLE ON SITE WILL

BE APPLIED DURING ERECTION, NORMAL OPERATION AND

MAINTENANCE WORKS ON UNITS.

All procedures indicated in this manual that could be in contradiction with applicable safety

rules on site, will be modified to meet site requirements

In any case, if several safety rules govern the same application, the most constraining ones

will be applied

1.1 Safety when entering the separator

When entering the separator the safety rules applicable to process vessel should be

followed. As example some of these rules are listed here under:

Authorization permit to enter the vessel should be delivered by the relevant

authority

All vessel flanges connected with process lines should be blinded

Vessel must be free of oil, water gas or dirt

An explosivity test must be carried out in all accessible parts of the vessel internal

Internal temperature must be acceptable

Natural or mechanical ventilation should be sufficient to permit work inside the

vessel without risk

Etc

1.2 Safety when entering the vessel with oil

In order to avoid the information of explosive mixture, the vessel should be totally

purged from air before charging with hydrocarbons

This purging can be done using nitrogen or other inert gas which is not harmful if

released to atmosphere

1.3 Safety when emptying the vessel

In order to avoid formation of explosive atmosphere when emptying the vessel , it is

absolutely imperative to replace pumped put product by inert gas(ex. Nitrogen) or

water under low pressure(<15psig)


Special care will be taken also to avoid any vacuum in each vessel compartment

during pumping out.

2.0 EQUIPMENT DESCRIPTION

2.1 I nternals

Separators are horizontally mounted on a skid. The separator is divided in to two

compartments be a weir plate. i.e the water side and the oil side. Internals consist of

weir plate, baffles, vortex breaker and diverter. Internals are of SS316 and are bolted

to the vessel with fittings which are SA516Gr.70

2.2 Weir Plate

Crude and water mixture enters to the left side of weir. The interface is controlled and

not allowed to rise above the height of the weir. This weir keeps the separated water

in left compartment. During low production rates the oil will overflow to the oil

compartment over the weir. During high production rates the oil level will be above

the weir and both compartments will be flooded with oil

The height of weir plate is adjustable. For the first stage, 3 levels (1585,

1905&2105mm) of adjustability is possible and for second stage, 2 levels (xxxx). Weir

should be fixed to the flat bars on vessel shell through neoprene rubber. Neoprene

rubber is also used to seal the bolt holes

2.3 Baffle

Baffle plates are fitted on the water side to enhance separation. Inlet crude oil mixture

enters the separator on the left side of the baffle and has to pass through the baffles

to get transferred to the right side of the baffle. All the baffle through the baffle plates

except the bottom plate can be unbolted and removed through the manholes for the

1st stage and second stage

2.4 Vortex Breaker

Vortex breaker is placed at the outlet of both crude oil and produced water. It helps to

break the vortex formation on the outflow


2.5 Desanding Line and nozzles

Inlet crude mix brings with it sand particles, which get settles in the vessel. Desanding

needs to be done to remove the accumulated sand in the vessel. Frequency of

desanding operation depends on the sand content in a given crude mix. De-sanding

water is circulated through the desanding line and it is sprayed on the accumulated

sand at the bottom of the vessel through the spray nozzles, which are fitted to the

desanding pipes. Desanding line is of SS316 Material

2.6 Heating Coil

In order to maintain a temperature of 50 degrees C in the separator at all times, even

while it is not in operation, hot oil is circulated through the heating coils. Inlet hot oil

temperature is 250ºC

3.0 START – UP PREPARATION

* IMPORTANT NOTE : BEFORE STARTING ANY OPERATION, PLEASE REFER TO CHAPTER 1.0. “SAFETY”.

3.1 Vessel and Internals

Ensure the condition of the pressure vessel and the internals.

Check the maximum allowable working pressure and the operating temperature,

which are marked on the name plate of the vessel.

3.2 Pipe Works

Ensure all pipe work is correctly installed

3.3 Instruments

Check all instruments for correct function

Check all relief/safety system for correct operation

Check all control valves and associate system for correct function including

“failure” modes.

3.4 Electricity

All electrical part should be carefully checked – wiring of all elements should be checked

as well as their satisfactory connection, Earthling circuit should be checked


4.0 START UP PROCEDURE

(See chapter 1.0 “SAFETY”)

4.1 Charging with Hydrocarbon

*IMPORTANT NOTE:

Before charging with hydrocarbon, the vessel should be completely free of air. This

purge should be done with nitrogen or any other insert gas not harmful to the

atmosphere. Check that all valves. Drains vents sample are closed and their caps are

installed. When the level of oil is between the low level and high level, then reset the

low and high alarm of the interface by pressing the reset push button on the control

panel.

4.2 Adjustment of Interface Level

Follow the development of the interface level by using the level gauge on the

standpipe. When the set supper level is reached, the control valves opens in

accordance with the controller signal and allows produce water to flow out of vessel.

The preferred settings at design production rates for First Stage Separator are as

follows:

Interface Liquid Level: ILHH

ILH

ILL

ILLL


Preferred setting for Second Stage Separator is:

Interface Liquid Level: ILHH

ILH

ILL

ILLL

Control valves operation taken place such that the interface layer stays between ILH and ILL

additional low level and high level cut offs are provided between ILH and ILL.

Check alarm and trip circuit for high and low levels by stimulating abnormal level conditions.

4.3 Oil Level

Oil levels are maintained on the basis of following oil level settings.

The preferred settings at designed production rates are as follows:

Liquid Level in Separator: LHH

LH

LL

LLL

Preferred settings for 2nd stage are

Liquid Level in Separator: LHH

LH

LL

LLL

Levels are controlled between LH and LL. Additional cut offs are provided at LHH and

LLL.

Check alarm and trip circuits for high and low level by stimulating abnormal level

condition.

5.0 NORMAL OPERATION

5.1 Normal Operation and Maintenances Instructions (See Chapter 1.0 SAFETY”)


5.1.1 Operation Data Sheet

If required a daily operating data sheet will be issued. This data sheet

allows all essential parameters that allow operation and control of the

plant.

5.1.2 Preparation for the Inspection of the Vessel

When a vessel inspection is foreseen, the following recommendation

should be applied

Stop the plant

Check that there is no voltage on the Power unit

Drain the vessel according to Chapter 9.2

Isolate the vessel by placing blind flanges on all the inlet and outlet

nozzles.

Open both manholes and top vent of vessel.

Vent the vessel with low pressure steam if available (Lower than 3

bar) for 274 hours.

Connect a stripped cable to an earthling pad or to vessel wall, then

connect it to the electrode. No spark or presence of current should be

detected.

Clean the internal walls of vessel with pressurized water, hot if

available.

Before entering the vessel ensure that the temperature has dropped

sufficiently to allow entry and that any harmful or flammable gas has

been purged.

5.1.3 Maintenance and trouble – shooting

The separator until offers high operating reliability because all parts of the units:

vessel and internal (baffles, weir, etc ) piping etc…static elements .It trouble on the

treating operations occurs, then refer to chapter 8.0

All items of equipments (Instruments, vessels, power units, piping etc) should be kept

in good condition and clean (free of rust) they should be checked regularly for good

operation and sealing.

If a part or equipment appears to be faulty or out of order, then refer to the trouble –

shooting guide in the manufacturer’s manuals


It is recommended that when the vessel is opened or maintenances internal

distribution and collection pipe work together with the electrode s grids and the vessel

shell are inspected for signs of erosion and/or corrosion.

5.1.4 Power and control Panel

Equipment on the control panel such as relays, contactors, voltmeter, ammeter and

push buttons will be checked and maintained regularly.

6.0 SYMPTOMS OF FAULTY SEPARATOR OPERATION

*NOTE: Before adjustment in the plant, check that operating conditions are in conformity with required specifications.

FAULT PRIMARY CAUSE SECONDARY CAUSE REMEDY1 High oil ppm in

produce water outlet

A Ineffective separation

B Level setting of interface level not effective

a. Control valve defective

b. Connection fault at LTc. Fault in DCS signals

Leakage through Baffle PlatedHigher production rates over the design rates

Reduce production to design limits

Low operating temperatureHigh viscosity

2 High water ppm in oil outlet

A Leakage through weir plates

a. Bolts on weir loose/gasket not defective

Check and tighten

B Level setting of interface level not effective

a. Control valve defective

b. Connection fault at LTc. Fault in DCS signals

Leakage through Baffle platesHigher production over the design rates

Reduce production to design limits

Low operating temperatureHigh viscosity


3 Sand content high in outlet water

A Sand accumulation too high

a. Carry out desanding operation

B a.4 No outflow in

outflow linesNo gas content b. Use inert gas

c.

5 Improper functioning of vortex meter

C a.

b.

6 Improper functioning of PD meter

A

B

7.0 SHUT DOWN PROCEDURE (NORMAL AND EMERGENCY)

(Before any operation, please refer to chapter 1.0. “Safety”)

7.1 Shut Down

The following procedure should be followed

Close all manual valves Stop the oil pumps Close isolation valves of unit Stop electrical feed of heat tracing lines

* REMARKS:

When the vessels are to be taken out of service the drain lines and any compartments

should be blown down to remove all the material that has been collected.

Vessels to be fully vented before man ways are released and purged with nitrogen.

Gas masks to be worn when entering the vessel until it is certain that all happens and

compartment are clear of gas and free of hazardous contaminates.

7.2 Emptying the Plant

When it is necessary to completely empty the vessel, apply the following procedure Close the inlet valves of Crude Drain the oil and the water As soon as the draining is complete Carry out Desanding operation and flush

out sand Open both manholes Place blind flanges or spectacles on at each nozzle connected to pipe work.


7.2.1 IMPORTANT NOTES:

During the operation it is absolutely imperative to replace the pumped-out product by

inset gas (e.g. Nitrogen) or water under low pressure

Air must never enter the emptying vessel in order to avoid an explosive mixture

8.0 ELECTRICAL MAINTENANCE

9.0 DESIGN AND PERFORMANCE DATA

9.1 DESIGN 1st STAGE SEPARATOR

MANUFACTURER

PROCESS DATA (DESIGN BASIS FOR EACH SEPARATOR IS 75% OF GROSS TRAIN THROUGHOUT

INLET CONDITION TO 1ST STAGE SEPARATOR TAG NO: 1V/2V/3V/4V-8301 ARE AS FLOWS (EACH)

DESCRIPTION UNIT DESIGN OUTLET FLOW

FIRST YEAR (MAX OIL)LATER YEARS

(MAX Gross Liquid)TOTAL FLOW Kg/hr 161200.9 163337OIL (REFER PRODUCT SPEC.) Kg/hr 76980 30780WATER Kg/hr 83520 132300GAS Kg/hr 700.9 257TEMPERATURE °C 50 50PRESSURE kpag 800 800DENSITY OF OIL EMULSION Kg/m3 943.7 943.5DENSITY WATER Kg/m3 988.4 988.5VISCOSITY OF OIL EMULSION cP 1687 1709VISCOSITY OF WATER cP 0.5417 0.5431

PRODUCT SPECIFICATION1. Liquid particles of sizes 150pm and above shall be removed from outlet gas(100% REMOVAL)2. Oil Retention time shall be 10 minutes (minimum)3. water retention time shall be 10 minutes (minimum)4. water cut in outlet oil stream shall be less than 30% v/v/

Design Codes ASME VIII DIV 1 U-STAMP

FLUID Oil, water & GasSWEET SERVICE


OPERATING TEMPERATURE AND PRESSURE

INTERNAL 850 kPag @ 50 °C

EXTERNAL - kPag @ - °C

DESIGN TEMPERATURE AND PRESSURE

INTERNAL 1380 & FULL Vacuum kPag @ 125 °C


MAWP 1425.75 kPag @ °C

MINIMUM DESIGN METAL TEMPERATURE

PWHT REASON IF REQD., AS PER CODE

RADIOGRAPHY JOINT EFF: SHELL 100% HEAD 100%

HYDROTEST 1794 kPag Horizontal position

WIND VELOCITY 135 km/h EARTHQUAKE ZONE UBC1, Z=0.075

CAPACITY 91.82 m3

INSULATION 38mm THICK Hot, As per PDOC-SP-MEC-014

REMARKS APPLICABLE PDOC SPECIFICATION: PDOC-SP-MEC-020


MATERIALSSHELL TYPE Cylindrical Shell ASME MATERIAL SA 516 Gr 70 DESIGN THICK Mm 18.54 CORROSION ALL. Mm 3 MILL TOLERANCE Mm 0.3TOTAL THICK Mm 18.54NOMINAL THICK Mm 19.06HEADTYPE 2.1 SE ASME MATERIAL SA 516 Gr 70 DESIGN THICK Mm 18.75 CORROSION ALL. Mm 3 MILL TOLERANCE Mm 0.3

TOTAL THICK Mm 18.75NOMINAL THICK Mm 22.23SADDLE PLATES / WRAPPER PLATE

SA 36 / SA516 GR 70

TRAYS NOSUPPORT INT SA 516 GR 70 EXT SA 516 GR 70 / SA 36BOLTS INT SA 193 GR B7M EXT SA 193 GR B7NUTS INT SA 194 GR2HM EXT SA 194 GR 2HFLANGES SA 105 NNOZZLE -NECKS SA 106 GR BGASKETS SPIRAL WOUND SS 304VESSEL TRIMHEATING COIL SS 316LINTERNALS SS 316 L

DESIGN 2ND STAGE SEPARATOR

MANUFACTURER

PROCESS DATA (DESIGN BASIS FOR EACH SEPARATOR IS 75% OF GROSS TRAIN THROUGHOUT

INLET CONDITION TO 2ND STAGE SEPARATOR TAG NO: 1V/2V/3V/4V-8302 ARE AS FLOWS (EACH)

DESCRIPTION UNIT DESIGN OUTLET FLOW

FIRST YEAR (MAX OIL)LATER YEAR

(MAX Gross Liquid)TOTAL FLOW Kg/hr 112816 45111.1OIL (REFER PRODUCT SPEC.) Kg/hr 76630 30650WATER Kg/hr 35720 14290GAS Kg/hr 466 171.1TEMPERATURE °C 105 105


PRESSURE kpag 400 400DENSITY OF OIL EMULSION Kg/m3 887.4 877.2DENSITY WATER Kg/m3 944 944VISCOSITY OF OIL EMULSION cP 93.7 93.39VISCOSITY OF WATER cP 0.2653 0.2652

PRODUCT SPECIFICATION1. Liquid particles of sizes 150pm and above shall be removed from outlet gas(100% REMOVAL)2. Oil Retention time shall be 10 minutes (minimum)3. water retention time shall be 10 minutes (minimum)4. water cut in outlet oil stream shall be less than 30% v/v/

Design Codes ASME VIII DIV 1 U-STAMP

FLUID Oil, water & Gas

SWEET SERVICE

OPERATATING TEMPERATURE AND PRESSURE

INTERNAL 300 kPag @ 105 °C


DESIGN TEMPERATURE AND PRESSURE

INTERNAL 1380 & FULL Vacuum kPag @ 125 °C


MAWP 1425.75 kPag @ °C

PWHT REASON IF REQD., AS PER CODE

RADIOGRAPHY JOINT EFF: SHELL 100% HEAD 100%

HYDROTEST 1794 kPag Horizontal position

WIND VELOCITY 135 km/h EARTHQUAKE ZONE UBC1, Z=0.075

CAPACITY 77 m3

INSULATION 38mm Hot, As per PDOC-SP-MEC-014

REMARKS APPLICABLE PDOC SPECIFICATION : PDOC-SP-MEC-020


MATERIALSSHELL TYPE Cylindrical Shell ASME MATERIAL SA 516 Gr 70 DESIGN THICK Mm 18.56 CORROSION ALL. Mm 3 MILL TOLERANCE Mm 0.3TOTAL THICK Mm 18.56NOMINAL THICK Mm 19.05HEADTYPE 2.1 SE ASME MATERIAL SA 516 Gr 70 DESIGN THICK Mm 18.43 CORROSION ALL. Mm 3 MILL TOLERANCE Mm 0.3TOTAL THICK Mm 18.43NOMINAL THICK Mm 22.23SADDLE PLATES / WRAPPER PLATE

SA 36 / SA516 GR 70

TRAYS NOSUPPORT INT SA 516 GR 70 EXT SA 516 GR 70 / SA 36BOLTS INT SA 193 GR B7M EXT SA 193 GR B7NUTS INT SA 194 GR2HM EXT SA 194 GR 2HFLANGES SA 105 NNOZZLE -NECKS SA 106 GR BGASKETS SPIRAL WOUND SS 304VESSEL TRIMHEATING COIL SS 316LINTERNALS SS 316 L

9.2 Description

See General arrangement plan

9.3 Performance

The PPM of oil in water at the outlet meet shall be less than 2000 ppm Liquid particles of size 150 microns and above shall be removed from the outlet

gas (100% removal).. Oil retention time shall be minimum of 10 minutes Water retention time shall be minimum of 10 minutes Water cut in oil stream shall be less than 10% v/v

9.4 Hazards

This separator contains hot, high-pressure H/C fluids. Observe statuary regulations for operating vessel. Do not enter vessel until it has been purged and spaded-off. Do not operate vessel outside of design conditions. Do not subject to surges/slugs outside of design conditions.


9.5 Information Sources

Address queries on separator performance (not vessel) to :

Hup Seng offshore and Engineering Pte Ltd152 Gul Circle, Jurong, SingaporeTel +65 68614449

10.0 STORAGE AND HANDLING

11.0 OPERATION

The separators are in the form of horizontal pressure vessels fitted with internals to effect separation of oil, water and gas.

11.1 Basic Principles of Operation

Three phase crude oil consisting of oil, associated gas and water enters the separator at the inlet nozzle.

It first encounters a diverter, where the bulk separation of liquid and gas takes place. The mixture then passes through the perforated baffle plate which causes it to calm down and aid oil water separation. After the baffle plate major separation of oil and water takes place and two separate layers of oil and gas are established. The required residence time is available to the mixture which causes the oil particles to rise upwards from the water phase and water particles to move downwards from the oil phase.

After separation the water flows out through the produce water outlet line. The control valve on this line is regulated so as to maintain a level of interface lower than the weir level. As the level of oil exceeds the weir level, the excess oil flows over the weir to the right side in the oil zone. At normal production rates the oil level would be above the weir height. The separated oil then flows out through the oil outlet.

On the left side of weir, the interface level is controlled between two preset alarm levels ie IHL and ILL. A standpipe is fitted in parallel with the separator, capable of reflecting levels in the separator. On this standpipe, there are two float type level transmitters, which transfer the signal to DCS control. DCS controls the interface level by regulating the control valve on the produce water outlet line. Alarms are also signaled at DCS at these levels.

In addition to these, for levels above IHL and below ILL, a level transmitter is fitted to initiate signal at IHH and ILL which cuts off of the inlet and outlet valves. Float type level gauge is fitted on the standpipe to indicate the interface levels.

On the oil side of weir, the oil level is controlled between the two alarm levels ie HL and LL. This control is achieved by regulating the control valve on the oil outlet and on the oil inlet. For levels beyond this range, a level transmitters is provided to initiate signal at HHL and LLL which will valve cut off inlet and outlet valves. Magnetic level gauge is provided to indicate oil levels.


All transmitters for interface detection are buoyancy tyope and those for oil level detection are diaphragm type.

11.2 Measuring and Control instruments

Flow indicator: Differential pressure type indicator is provided in the incoming crude oil line, which measures flow with the help of orifice plates.

Vortex Flow Meter: Provided on the produce water outlet line

Differential Pressure Indicator: Differential pressure transmitter and indicator are provided to measure the pressure drop across the strainer on crude oil outlet line.

Temperature Indicator: 2 nos, provided on the vessel

Pressure indicator: To indicate the pressure

Level Indicators: Fitted on the vessel to measure interface level and il level.

11.3 Control Valves

PV Valve on the Gas lineESDV : On crude inletLevel Control Valves;1 on Custody oil outlet1 on produce water outlet

11.4 Fault conditions

Provided the separators are operated within the design criteria specified in section 1.3, no faults should occur. The main ways to identify failure are:

- Excessive oil carryout in produce water downstream- Increase in normal operating pressure drop across the separators.

Because of the nature of the separators it would be impractical to mention all the possibilities which could cause the above, but in the event of any of the above occurring, this is to be reported immediately to HSOEPL with the process flow particulars as specified in section 1.3.

Trouble Shooting Guide

FAULT PROBABLE CAUSE1 Excessive pressure drop across

separatorBlockage in separator/internals damaged.Open separator and investigate.

2 Separator operating at incorrect levels Instrument/control valve fault : consult suppliers product data

3 Incorrect separation efficiencies Check 1 & 2 and also check process conditions are as stated in this manual


12.0 MAINTENANCE

12.1 Recommended Schedule of maintenance

All internals should be visually inspected every 8 weeks, unless in operation the separator fails to meet the required duty and process specification for the gas and liquid streams.

12.2 Maintenance Requirements

Internals, Routine Maintenance

The horizontal separators comprise internal baffles that have to be regularly maintained during the life of the vessels. The internals are listed in the description section of this manual and the following activities should be carried out as per recommended schedule:

1) Internals should be visually inspected for signs of cracking, erosion, damage etc., and repaired as necessary.

2) Check all internals are free of dirt, debris, blockages etc., ensure they are free of tar build-up etc.

3) Check all items show no signs of damage from erosion, surges etc., check weirs and sound.

4) Check all bolting is tight and fitted with second nut (lock nut).

5) Carry out re-certification inspection of pressure vessels in accordance with manufacturer’s instructions/statuary requirements.

If it is necessary to remove the internals from the vessels follow the reversed procedures outlined in section 3.3.

12.2.1 Vessel As required by pressure vessel code, carry out periodic re-certification requirements.Check for:

Cracking of attachment welds to shells Erosion of vessel shells at areas around inlet/outlet nozzles Corrosion around drain connections and instrumentation connections Clogging, plugging of instrumentation connections Pitting or scuffing of any gasketed faces

Always use gaskets when re-making nozzle/manway flange connections.


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PDOC 3phase Separator Operation Manual

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