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Updated
Standard Operation Manual For
Inlet Separators (V-140 / 150)
Feb. 2013

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BASIC FLOW AND THEORY

Gas separation signifies the separation of gas and liquids which occurs when there is a
reduction of pressure in the incoming flow
The method of stage separation employs two or more separator connected in series, with
the oil and gas being separated at gradual decreasing pressures.
The gas separation system at mubarraz terminal facility consist of:Inlet Separator

Operating at 50 psig

Degassing Boot

Operating at 4.6 psig

Settling Tank

Operating at Positive pressure.

The crude oil enters the inlet separator where oil / gas and water separated. The liquids and
gas separate due to the different specific gravity. The separated gas goes to Amine units
where it is treated and used as a fuel gas. The crude oil goes in to the degassing boot. The
water continuously drained out to the waste water treatment unit. The normal operating
pressure of the inlet separator is controlled at 50 psig by PCV-141 / 151. There is also
PCV-140 / 150 which relieve excess pressure to the high pressure flare line. (Now isolated)
These pressure control valves, PCV-140 / 141 / 150 / 151 act on a split range basis. This
means that when the out put air pressure of the controllers PC-140 / 150 is 15 psig , both
valves will be full closed. At 9 psig PCV-141 / 151 will be fully open and PCV 140 / 150 will
be fully closed and at 3 psig both valve will be full open. The oil level in the inlet separators is
controlled by LCV-140 / 150 at a level between 40 ~ 50%. Oil interface level is controlled by
LCV-140 / 150.
INTERNAL FEATURE OF THE INLET SEPARATOR
Cyclone separator
Fixed at the crude oil inlet of the separator. This provides a centrifugal action and helps in
gas / liquids separation.
Zinc Anodes
To provide the cathodic protection ( against corrosion of the internal shell due to brine )
Number of anodes
6 Pcs
Weight of each anode
60.1 kgs
Mist eliminator
Placed at the gas out let of the separator. These Vane type mist eliminator are baffles which
give obstruction to the gas flow. The liquid particles entrained in the gas stream, knock on
the baffles and drop down.
Demister
Placed over the Mist eliminator. This is the wire mesh pad which prevents the liquid particles
escaping with the gas.
Vortex breaker
Fixed at the oil outlet nozzle to prevent the formation of eddies.

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EXTERNAL FUTURE OF THE INLET SEPARATOR
1LCV- 140 / 150 ( LEVEL CONTROL VALVE FOR OIL ZONE )
SIZE
10"
ACTION
REVERSE ( AIR LESS SHUT )

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2-

LCV-140 / 150 (Water / oil inter face level control valve )

SIZE
2"
ACTION
REVERSE ( AIR LESS SHUT )

3-

PCV - 140 / 150 - PRESSURE CONTROL VALVE TO FLARE HEADER.

(Now isolated).
SIZE
4"
ACTION
DIRECT (AIR LESS OPEN)

4-

PCV - 141 / 151 - PRESSURE CONTROL VALVE TO AMINE UNIT.

SIZE
6"
ACTION
DIRECT

5-

PSV - 140 / 141 / 150 / 151 - PRESSURE SAFETY VALVE TO FLARE HEADER.
SIZE
6" X 8"
TYPE
PILOT OPERATED
SET PRESSURE 100 PSIG

6-

LAH - 140 / 150 - HIGH LIQUID LEVEL ALARM.

TYPE
FLOAT OPERATED / MICRO SWITCH

7-

LAL - 140 / 150 - LOW LIQUID LEVEL ALARM.

TYPE
FLOAT OPERATED / MICRO SWITCH

8-

PSH - 140 / 150 - HIGH PRESSURE SWITCH ALARM.

SET PRESSURE 75 PSIG

9-

LG 140 / 150 - GAUGE GLASS FOR OIL ZONE.

10-

LG 141 / 151 - GAUGE GLASS FOR OIL / WATER INTERFACE.

11-

FT - 140 / 150 - MEASURES THE GAS FLOW RATE.

TYPE
ORIFICE (DANIEL)

12-

FS - 150 - OIL FLOW RATE

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START-UP & SHUTDOWN:

1-

Commission all instruments (air supply on, all valves, tapping etc. open).

2-

Check the movement of all control valves.

3-

Set all the controllers to their desired values.

4-

Open the block valves upstream and downstream of all control valves.

5-

Inform the power house that there may be a fluctuation in the gas flow.

6-

Slowly open the separator inlet valve (Chain valve) and raise the separator
pressure to 50 psig. (Normal pressure of stand-by separator is 40 psig.)

7-

Continue to open the inlet valve until fully open and at the same time close the inlet
valve on the other separator so that all of the flow is diverted.

When all of the flow has been diverted, ensure that the controllers / control valves
are operating correctly and confirm that the level and pressure are normal.

8-

Ensure that the inlet valve to the stand-by separator is fully closed.

9-

Close the block valves upstream and downstream of all control valves on the
stand-by separator.

10-

Open the bypass valve of the PCV-141 / 151 to the amine unit 10% and drop the
pressure in the stand-by separator to 40 psig.

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TROUBLE SHOOTING AND COUNTER MEASURES:

1-

High Liquid Level

LCV stuck in closed position. Open by-pass valve and control

manually until LCV is operating normally.

2-

Low Liquid level

LCV stuck in open position. Close block valve of LCV to raise

the level , then control manually on by-pass valve until LCV is
operating normally.

3-

High pressure

PCV stuck in the close position. Open by-pass valve and control
manually until PCV is operating normally

4-

Low pressure

PCV stuck in open position. Close block valves of PCV

and control on bypass valve until PCV operating normally.

PSVs may be Passing check by touching with hand. Isolate if

passing.

In all the above cases, it will be necessary to call the instrument department to correct the
problems

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CHECK POINT ACTIONS

1-

OIL LEVEL

Normally between 30 ~ 50%

LC set point 40%

counter check the level indication with the level gauge.

Important : keep the level gauge isolation valves fully open during operation
operation. This will stop the fluid gushing out even if the glass breaks. The internal
ball will isolate the glass automatically.
2-

OIL WATER INTERFACE

Normal water level about 100% on LCI.
LIC set point 98 ~ 100%
check the color of the water through sight glass. ( Clean the sight glass when dirty)

3-

PRESSURE
Normal 50psig
Counter - check the PIC with the pressure gauge. Check the position of PCVs.
Normal opening of PCV 141 / 151 ( AMINE SIDE) is about 45%. PC output
pressure about 10 ~ 12psig. PCV 140 / 150 fully closed.

4-

CHECK FOR CONDENSATE

Drain out FT 140 / 150 tapping daily. Condensate in the tapings will result in wrong
gas flow.

5-

PSV LEAK
Check by touching the up stream and downstream side of the safety valve. The
temperature change on the out let pipe may give indication of safety valve leaking.