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SAES-A-010
26 February 2013
SAES-A-010
Gas Oil Separation Plants (GOSPs)
Scope
1.1
This Standard provides the minimum mandatory requirement for the design of a
grass root Gas Oil Separation Plant (GOSP) with or without crude stabilization.
1.2
1.3
The crude Oil stabilization, Produced water treatment & disposal and Heat
Exchangers are excluded from the scope of this standard.
Other support systems that are part of the GOSPs (e.g. Fire water system, Fire &
Gas detection, Plant alerting & Alarm system, Safety equipment, Flare system,
etc.) are also excluded from this standard. These shall be referenced in the
relavant SAESs.
Any conflicts between this standard and other applicable Saudi Aramco
Engineering Standards (SAESs), Materials System Specifications (SAMSSs),
Standard Drawing (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer's Representative through the
Manager, P&CSD of Saudi Aramco, Dhahran.
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2.2
SAES-A-010
Gas Oil Separation Plants (GOSPs)
Direct all requests to deviate from this standard in writing to the Company or
Buyer's Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, P&CSD of Saudi Aramco.
References
All referenced Specifications, standards, Codes, Forms, Drawings and similar material
shall be considered part of this standard and shall be the latest issue (including all
revisions, addenda and supplements unless stated otherwise).
3.1
Project Proposal
SAEP-250
SAEP-302
SAEP-354
SAEP-363
SAEP-364
SAEP-1663
SAES-A-400
SAES-A-401
SAES-A-403
SAES-B-006
SAES-B-014
SAES-B-062
SAES-D-001
SAES-H-001
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
SAES-H-002
SAES-J-005
SAES-J-601
SAES-J-901
SAES-K-402
Centrifugal Compressors
SAES-L-100
SAES-S-020
SAES-Z-003
3.2
SABP-A-015
SABP-A-018
SABP-A-036
SABP-K-401
SAES-A-010
Gas Oil Separation Plants (GOSPs)
(49-52 API)
AXL
(37-41 API)
AL
: Arab Light
(32-36 API)
AM
: Arab Medium
(28-32 API)
AH
: Arab Heavy
(26-28 API)
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
5.2
5.3
As stated by RMD,
The 100 mg/L mg/L oil-in-water of disposal water quality is the maximum
allowable requirement. The required Disposal water quality is to be
specified by Upstream based on the disposal reservoir permeability and the
economics of the water disposal over the life Cycle. DBSP shall refer to the
final agreed disposal water specification.
SAES-A-010
Gas Oil Separation Plants (GOSPs)
The GOSP design shall progress through conceptual study, pre-DBSP study,
DBSP approval, Project Proposal or FEED followed by Detailed Design and
construction. The data required to conduct GOSP process studies during the
various phases shall be referred in SAEP-1663. RMD/P&FDD shall provide the
required data. The necessary Safety Reviews (HAZOP, SIL, Building Risk
Assessment, etc.) shall be conducted per applicable sections of SAEP-14,
SAES-J-601, and SAES-B-014 respectively.
6.2
The Base Case production option and other alternative production Options shall
be finalized in discussion with Upstream, P&CSD and FPD.
6.3
Simulations
6.3.1
6.3.2
The GOSP simulations shall be carried out for summer and winter
conditions at Design Water cut, initial Water cut and intermediate
production phase.
6.3.3
The Gas compression simulations shall be carried out for summer and
winter conditions. The gas compression to be sized on the controlling
gas rates based on the simulations.
6.3.4
The Process simulation during the FEED and Detailed Design Phase
shall be reviewed and approved by P&CSD.
6.3.5
6.3.6
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6.4
6.3.7
6.3.8
PFDs
6.4.1
6.5
SAES-A-010
Preliminary PFDs showing the heat & material balances for Summer and
Winter conditions of the GOSP and the crude stabilizer (if included in
the GOSP) for the following conditions shall be developed:
6.4.1.1
6.4.1.2
6.4.1.3
6.4.2
The Preliminary PFDs showing the Heat & Material Balances for
Summer and Winter conditions shall be developed for the Gas
compression. Preliminary gas export pipelines pressure shall be
available to determine the Gas compression HP requirement.
6.4.3
6.4.4
6.4.5
P&IDs
6.9.1
6.9.2
b)
c)
d)
e)
f)
g)
h)
i)
j)
Note:
SAES-A-010
6.10
All the GOSP shall be designed for 40% turndown. For GOSPs with crude
stabilization, the stabilizer column turndown will be the controlling factor for
the GOSP turndown.
6.11
All GOSPs shall be designed for Wet Sour Service for potential souring of the
production field during the life cycle unless RMD recommends otherwise.
7.1.2
The selected trunkline size shall satisfy both minimum and maximum
velocities at minimum water cut and design water cut including
turndown.
7.1.3
7.1.4
7.2
Production Manifold/Header
7.2.1
For new GOSPs the Production manifold and the production header to
the last block valve to the inlet of the first production Separator (Trap)
shall be designed for the maximum shut-in pressure of the field
including future artificial lift (Gas lift, ESP or multiphase pump).
Note:
7.3
SAES-A-010
For existing GOSPs, HIPPS to be implemented at the subject wellheads that exceeds the design pressure of the production manifold.
7.2.2
7.2.3
7.2.4
Each crude increment shall have its own production manifold and all
trunklines shall be connected to the individual increment production
manifolds. This will enable selecting the trunklines to the desired
increment for uniform distribution of the field production to the
individual crude increments.
7.2.5
7.2.6
7.2.7
The inlet header from the production manifold to the first production
separator shall be sized to avoid mist/spray flow.
Production Separators
7.3.1
The number of Flashing stages and Flash pressures in the GOSP for the
crude production shall be determined by Upstream in consultation with
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
P&CSD and FPD based on life cycle economics during the initial field
development study.
7.3.2
7.3.3
The number of flash stages and flash pressures shall be specified in the
DBSP along with the flash stage descriptions.
7.3.4
The bottom of the feed inlet nozzle shall be at least 6 above the
HH liquid level shutdown
The low low liquid level alarms and shutdowns shall be minimum
12 above the bottom of the vessels.
All gas relief valves shall be installed directly above the vessel with
minimum pipe length.
7.3.5
Crude oil heat exchanger shall not be located between the production
manifold and the first production separator.
7.3.6
7.3.7
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
minimize liquid carry over in the Gas. Liquid carry over in gas shall
be less than 1 gal/MMSCF.
7.3.8
7.4
7.4.2
7.4.3
7.4.4
The water weir for the 3-phase production separator vessel shall be
located at least one vessel diameter from the vessel tan line.
7.4.5
The normal oil level in the 3-phase production separator vessel shall be
at least 6above the Weir top. The High-High Interface level alarm
setting shall be at least 6 below the weir top.
7.4.6
Following are the minimum surge times between different level settings
for the 3-phase production separator vessels based on design flow rates:
Between High High oil level shutdown and High oil Level alarm:
1 Minute
Between High oil Level alarm and Low Oil level alarm: 3 minutes
Between High High interface level alarm and high interface level
alarm: 2 Minutes or 6 height
7.4.7
The nozzles for the interface level instruments shall be located close to
the water weir. The nozzles for the interface level instruments shall be
taken from the side of the vessel.
7.4.8
Page 14 of 32
7.5
7.7
7.5.2
7.5.3
The typical retention time (Hold up) for Gas-oil separation for 2-phase
vessels are given in API SPEC 12J.
7.5.4
Following are the minimum surge time between the oil-level settings
based on design flow rates:
7.5.5
7.6
SAES-A-010
Between High High Oil level shutdown and High Oil level alarm:
2 Minutes
Between High Oil level alarm and Lo Oil level alarm: 2 Minutes
Charge Pumps
7.6.1
7.6.2
The charge pumps shall be Vertical Can type. Gas supply connection
shall be provided to pressurize the pump can to displace the wet crude
to the suction vessel.
7.6.3
The charge pump isolating MOVs (EIVs) shall be located outside the
fire hazard zone as defined by SAES-B-006 to avoid the need of
fireproofing
7.6.4
The charge pump discharge pressure at pump shut-off shall not exceed
the design pressure of the dehydrator and desalter vessels.
7.6.5
The charge pump seals shall be flushed by dry crude oil or other
suitable buffer fluid.
For GOSPs processing AXL and AL crude grades, minimum two stage
dehydration/desalting shall be provided to minimize instances of offspec crude to the crude stabilizer/pipeline during electrostatic grid upsets
Page 15 of 32
SAES-A-010
Gas Oil Separation Plants (GOSPs)
7.7.3
7.7.4
7.7.5
7.7.6
The operating pressure of the last stage desalting vessel shall be at least
25 psig above the vapor pressure of the crude at the operating
temperature. Power to the electrical grids shall be switched off after a
time delay of 20 sec if the last stage desalter pressure drops to 10 psig
above the crude vapor pressure. The system shall be designed to allow
for a 20 sec delay for 10 psi below vapour pressure. The crude export
to pipeline shall be stopped if the power is not restored to the electrical
grids within 5 minutes.
7.7.7
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
7.7.9
7.7.10
7.7.11
The AC field desalters shall be equipped with Carbon Steel rod type
electrostatic grids. The rods shall run parallel to the length of the
desalters and not across the cross-section. At least 6 clearance shall
be provided between the rod ends and the vessel dished end to prevent
arcing to the vessel wall.
7.7.12
Carbon Steel Plate electrostatic grids shall be provided for DPD and
DFD technology desalters. The DPD desalters are limited to 0-10%
water cut due to the lack of arc control which could potentially damage
the carbon steel plates. The DFD desalters are equipped with arc
control and additionally will drop out majority of the water before it
reaches the grids. Composite plates are not recommended due to the
short service life.
7.7.13
7.7.14
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
7.7.15
7.7.16
7.7.17
Note:
The above grid loading is field proven with the minimum life cycle
operating costs for the AC field systems.
7.7.18
7.7.19
All internal piping below the center line of the vessel shall be
internally and externally coated.
7.7.20
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7.7.21
7.7.22
7.7.23
Internal floats shall be provided to ground the grids in case the crude
oil level drops for AC field and DPD technology. For DFD
technology, external level switch to be connected to the ESD system to
switch-off power in case of falling oil level.
Note:
7.7.24
7.7.25
For the DFD technology desalters all feed-back signals and control
signals that are displayed in the DF-LRC II panel shall be interfaced to
the DCS system.
7.7.26
7.7.27
7.7.28
7.8
SAES-A-010
Variable speed drives shall be evaluated for crude oil shipping pumps
without booster pumps.
7.8.2
The Booster pumps and Shipping Pumps isolating MOVs (EIVs) shall
be located outside the fire hazard zone as defined by SAES-B-006 to
avoid the need of fireproofing.
Page 19 of 32
7.9
SAES-A-010
Gas Oil Separation Plants (GOSPs)
Gas Compression
7.9.1
Each GOSP gas compressor shall be provided with its own suction
drum, after cooler and compressor discharge KO drum.
Notes: Individual Compressor discharge drum can be deleted in lean gas
compression where negligible liquids are formed after cooling.
7.9.2
7.9.3
7.9.4
7.9.5
Variable Speed drives shall be evaluated for all gas compressors based
on SAES-K-401 and SAES-K-402. However, the GOSP gas
compressor energy consumption over the life cycle shall take into
consideration the crude production forecast, fluctuations in crude
production rate and energy loss due to compressor recycling. The life
cycle economics of compressor driver selection report shall be submitted
to CSD, P&CSD/UPED and P&CSD/Energy division for review.
7.9.6
7.9.7
7.9.8
Besides the normal operating point, 3 other operating points for summer,
winter and 105% of the normal gas rate shall be specified in the
compressor data sheet. The rated point of the compressor shall be
selected by the manufacturer based on these conditions per SAES-K-402.
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7.10
SAES-A-010
Gas Oil Separation Plants (GOSPs)
7.9.9
7.9.10
7.9.11
Note:
7.10.2
7.10.3
7.10.4
7.10.5
The design TEG circulation rate for the TEG based gas dehydration
systems in the production facilities shall not exceed 3 GPM per pound
of water removal.
Page 21 of 32
7.10.6
SAES-A-010
Auxiliary Systems
8.1
The design TDS of the Wash water used in crude oil desalting depends
on factors such as type of crude oil, formation water TDS, BS&W at
the inlet of the final stage desalter, BS&W and salt-in-crude
specification of the desalted crude, wash water rate and mixing
efficiency. Water treatment systems to reduce TDS of the wash water,
if required, shall be provided. Wash water injection points shall be
upstream dehydrator and desalter.
8.1.2
8.1.3
Wash water systems for aquifer water shall be designed for minimum
4% of the dry crude rate. Three, 50% capacity wash water pumps shall
be provided. Provide recycle line for wash water pumps to allow for
low wash water rates at low crude rates.
8.1.4
Wash water rate for Low TDS wash water from Flash evaporation shall
be minimum 1.25% of the dry crude rate. Recycle pumps shall be
provided to provide internal recycle under flow control to the inlet of
the desalter to optimize wash water (Low TDS) consumption and
maintain the minimum required wash water rate.
8.1.5
8.1.6
8.1.7
Water jetting header take off shall be upstream of the wash water flow
orifice for aquifer water based wash water systems. For low TDS wash
water systems, the desalter recycle pump discharge water to be used
for water jetting.
Page 22 of 32
8.1.8
8.2
SAES-A-010
Gas Oil Separation Plants (GOSPs)
Chemical Systems
8.2.1
All GOSPs shall be provided with facilities for bulk storage (tanks) and
injection of Demulsifier, corrosion inhibitor and Scale inhibitor.
Note:
8.2.2
8.2.3
8.2.4
Each chemical dosage point shall have its own dedicated pump or
pumps discharge manifold for dedicating the pump to one injection
point. Each chemical dosage point shall be provided with a flow meter
to monitor the chemical dosage rate and Low flow alarm.
8.2.5
8.2.6
8.2.7
8.2.8
SAES-A-010
Gas Oil Separation Plants (GOSPs)
8.2.10
Corrosion inhibitor injection of the GOSP and crude Pipelines shall not
be combined at one injection point at the production manifold.
Separate corrosion Inhibitor injection (Pump, flow meter and Injection
tubing) for the crude oil leaving the GOSP to the crude Oil pipeline
shall be provided. The Flow meter of corrosion inhibitor injection to
the crude pipeline shall be connected to OSPAS. This is applicable to
all GOSPs existing and new. Refer to SABP-A-015, SABP-A-018 and
SABP-A-036.
Note:
8.2.11
8.2.12
8.3
8.2.14
8.2.13
Specialized Hot Oil fluids including and Diesel can be used for heating
the crude Oil in the GOSP. The selection of hot oil fluids is based on
the auto ignition temperature, chemical degradation potential, scale and
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
8.4
8.3.2
Hot Oil Expansion vessel shall be provided. The Hot oil Expansion
vessel shall be provided with inert gas blanket.
8.3.3
The Hot oil return shall flow into the Hot Oil Expansion vessel.
The Hot oil circulating pumps shall take suction from the Hot oil
expansion vessel.
8.3.4
8.3.5
The wet crude shall be flowing through the tube side and the hot oil
through the shell side of the hot oil heat exchanger.
8.3.6
The Hot Oil fluid pressure shall be at least 50 psig higher than the cold
process fluid (wet Crude) pressure in the hot oil heat exchanger to
avoid chances of process fluids leaking into the hot oil system.
Drain Systems
8.4.1
All on-Shore GOSPs shall be provided with Closed Drain System per
SAES-A-400/SAES-A-401 and Oily Water Drain Systems per
SAES-S-020.
8.4.2
For all new GOSPs, the term Closed Drain System (CDS) shall be
used instead of Pressure Sewer System and Oily Water Drainage
System(OWDS) Instead of Gravity Sewer System ( consistent
terminology). For existing GOSPs a Master Plan is ongoing to
convert existing Pressure sewer and Gravity sewer systems into CDS
and OWDS.
8.4.3
The closed drain header from the production manifold shall be run
separately to the CDS drum and shall not be combined with other low
pressure closed drain headers.
8.4.4
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8.5
8.6
SAES-A-010
Gas Oil Separation Plants (GOSPs)
8.5.2
8.5.3
8.5.4
All Instrument Air Surge drums shall be internally prepared and coated
with heat cured phenolic coating APCS-100 in accordance with
SAES-H-002.
8.6.2
8.6.3
Crude oil, Gas export lines and Water disposal line exiting the
GOSP.
8.6.4
Pipe Line Leak Detection System (LDS) shall be installed on the crude
Oil and Gas export lines of the GOSP per SAES-Z-003. The leak
detection signal shall close the export ESD valve to the pipeline from the
GOSP. The Plant ESD system will activate the plant shutdown on high
trap levels on crude oil pipeline LDS. On Gas pipeline Leak Detection,
the export ESD valve shall close resulting in GOSP Gas flaring.
8.6.5
All wet crude, formation water and Wasia water piping shall be coated
as per SAES-H-001 and SAES-H-002.
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SAES-A-010
Gas Oil Separation Plants (GOSPs)
8.6.6
All bypass lines of control valves, ESD valves, Relief valves and other
similar applications shall be sloped for self-draining on both sides.
8.6.7
The design velocities in the low pressure piping from the Low pressure
degassing Tanks/vessels to the Spheroid compressor shall not exceed
40 feet/sec. The selected line size shall ensure that the minimum
velocity criteria shall be met at turn-down.
GOSP De-Bottlenecking
9.1
A flare and Relief system study shall be conducted to establish the maximum
crude capacity of the GOSP at the operating and future projected GORs of the
field.
9.2
The plant capacity to be estimated based on the Relief and Flare system capacity
at the operating GOR.
9.3
9.4
9.5
26 February 2013
Revision Summary
New Saudi Aramco Engineering Standard.
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Gas Oil Separation Plants (GOSPs)
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Gas Oil Separation Plants (GOSPs)
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Gas Oil Separation Plants (GOSPs)
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