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From Raw
Separator to Finished Test Package
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The raw 42" x 10' x 1440# 3 Phase Separator
At left is the raw 3 phase separator before it was cleaned and modified. The customer wanted a unit that would be able
to handle 10,000 BBL/day with a large manway. The unit has "legs" on top because it had been mounted on an off-shore rig.
The separator was transported to an "R" coded shop where it was inspected and modified to meet additional specifications required
by the customer.
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Engineering & Modifications
The "R" coded shop added a number of new ports in a variety of sizes to support addditional functionality such as the
shrinkage tester. This included a 2" water outlet, a 3" oil outlet, a 4" PSV and a 4" PSE, several drains, and ports
for pressure and temperature. In addition to modifications, the separator was sand blasted and painted with rust-resistant
primer.
The entire process took 10 weeks and included complete documentation and certification so the vessel could maintain
its ASME "U" stamp. An "R" stamp plate was added to the vessel.
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Trucked to New Mexico
Upon completion, the modified separator was trucked to the fab yard in New Mexico so it could be assembled into
a framed Test Separator unit.
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Assembley begins
The
modified separator is placed into the pre-built skid and lifting frame. |
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Bracing Added
Braces were added that connect directly to the separator's two lifting lugs. Because of this, lifting force passes
directly from the upper lift lugs located on the roof to the separator lugs. This ensures that
the frame won't twist or bow when the completed unit is hoisted. The frame and "Y" lifting braces are engineered to
handle 80,000 pounds even though the completed unit will only weigh 26,000 pounds.
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Meter Run & Valves
A 4" Daniel Senior meter run is added along with a Barton chart recorder. The 1/8" steel roof is in place. Dump valves
and the comingle manifold are almost complete. This is the beginning of week 17.
At this point, the overseas customer visited the yard in New Mexico to inspect and review the unit. Several minor
changes were requested.
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From Beast To Beauty
Two weeks later, the 42" x 10' x 1440# Testing unit is complete. The unit includes:
- 4" Rupture Disk with holder set for 1500#
- 4" Saftey Relief Valve set for 1480#
- 2" Fisher Dump Valve on oil side
- 3" Fisher Dump Valve on oil side (used if unit is making a lot of oil)
- 2" Fisher Dump Valve on water side
- Two Mallard floats w/ integral controllers
- Shrinkage Tester
- 4" Daniel Senior meter run w/ Fisher Back Pressure Valve and controller
- Barton 3 pen chart recorder (Static pres. / Differential pres. / Temp.)
- Lifting frame & skid with belly pan, grated floor, and roof
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Readied for Transatlantic Travel
The Test Separator was shrink-wrapped prior to loading onto the ship bound for Africa. Too tall to fit
into a standard shipping container, the transport company decided it could be loaded onto
the deck of the ship provided it was protected from the corrosive effects of salt spray.
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