Saes A 010

Engineering Standard
SAES-A-010
26 February 2013
Gas Oil Separation Plants (GOSPs)

Document Responsibility: Process Engineering Standards Committee
Saudi Aramco DeskTop Standards

Table of Contents
1 Scope................................................................. 2
2 Conflicts and Deviations..................................... 2
3 References......................................................... 3
4 Definitions........................................................... 4
5 GOSP Product Specification.............................. 7
6 Overall Process Design...................................... 8
7 GOSP Equipment Design Considerations.... 10
7.1 Flowlines/Trunklines
7.2 Production Manifold
7.3 Production Separators
7.4 3-Phase Production Separators
7.5 2-Phase Production Separators
7.6 Charge Pumps
7.7 Crude Oil Dehydration/Desalting
7.8 Booster/Shipping Pumps
7.9 Gas Compression
7.10 Gas Conditioning
8 Auxiliary Systems............................................. 21
8.1 Wash Water Systems
8.2 Chemical systems
8.3 Hot Oil Systems
8.4 Closed Drain System
8.5 Instrument and Plant Air Systems
8.6 In- Plant Piping
Previous Issue: New
Next Planned Update: 26 February 2018

Page 1 of 32
Primary contact: Fernandez, Gabriel Thomas on +966-3-8809476

CopyrightSaudi Aramco 2013. All rights reserved.

Issue Date: 26 February 2013
SAES-A-010
Table of Contents (contd)

9 GOSP De-Bottlenecking................................... 26
Appendix I Simplified Schematic of
Satellite On-Shore GOSP........................... 27
Appendix II Simplified Schematic of
Off-Shore GOSP......................................... 28
Appendix III Simplified Schematic of
Simple GOSP with Gas Compression. 29
Appendix IV-Simplified Schematic of Complex
GOSP with Gas Compression
and Crude Stabilization.. 30
Appendix V Simplified Schematic of
Hot Oil System............................................ 31
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
The standard also provides the minimum requirement for debottlenecking an

existing GOSP.
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.
Conflicts and Deviations

2.1
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.
Page 2 of 32

2.2
SAES-A-010
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
Saudi Aramco References

Saudi Aramco Engineering Procedures
SAEP-14
Project Proposal
SAEP-250
Safety Integrity Level Assignment & Verification
SAEP-302
Instructions for Obtaining a Waiver of a Mandatory

Saudi Aramco Engineering Requirement
SAEP-354
High Integrity Protective Systems Design

Requirements
SAEP-363
Pipeline Simulation Model Development and Support
SAEP-364
Process Simulation Model Development and Support
SAEP-1663
Design Guidelines for Gas Oil Separation Plant

(GOSP)
Saudi Aramco Engineering Standards

SAES-A-020
Equipment Specific P&ID Templates (ESPT)
SAES-A-400
Industrial Drainage Systems
SAES-A-401
Closed Drain Systems (CDS)
SAES-A-403
Off-Shore Platform Drainage Systems
SAES-B-006
Fireproofing for Plants
SAES-B-014
Safety Requirements for Plants and Operations

Support Buildings
SAES-B-062
Onshore Well Site Safety
SAES-D-001
Design Criteria for Pressure
SAES-H-001
Coating Selection and Application Requirements for

Industrial Plants and Equipment
Page 3 of 32

SAES-A-010
SAES-H-002
Internal and External Coatings for Steel Pipeline

and Piping
SAES-J-005
Instrumentation Drawings and Forms
SAES-J-601
Emergency Shutdown and Isolation Systems
SAES-J-901
Instrument Air Supply Systems
SAES-K-402
Centrifugal Compressors
SAES-L-100
Applicable Codes and Standards for Pressure

Piping Systems
SAES-S-020
Oily Water Drainage Systems
SAES-Z-003
Pipelines Leak Detection Systems
Saudi Aramco Best Practices
3.2
SABP-A-015
Chemical Injection Systems
SABP-A-018
GOSP Corrosion Control
SABP-A-036
Corrosion Monitoring Best Practice
SABP-K-401
Site Performance Testing of Centrifugal

Compressors
Industry Codes and Standards

American Petroleum Institute
API SPEC 12J
Specification for Oil and Gas Separators
Institute of Electrical and Electronic Engineers (IEEE)

IEEE 519
Guide for Harmonic Control and Reactive

Compensation of Static Power Converters
Terms and Definitions

AC: Alternating Current
AC/DC: Alternating Current/Direct Current
AFD: Adjustable Frequency Drive
APSD: Advanced Process Solutions Division
BPD: Barrels Per Day
BS&W: Basic (Bottom) Sediments and Water
Page 4 of 32

SAES-A-010
CDS: Closed Drain System

CFD: Computational Fluid Dynamics
CML: Corporate Model Library
Crude Types: (Degree API: Typical range for various Saudi Aramco crudes)
ASL
: Arab Super Light
(49-52 API)
AXL
: Arab Extra Light
(37-41 API)
AL
: Arab Light
(32-36 API)
AM
: Arab Medium
(28-32 API)
AH
: Arab Heavy
(26-28 API)
CSD: Consulting Services Department

DCS: Distributed Control System
Dehydrator: Electrostatic Coalescer for removal of majority of water and salt from
Crude Oil.
Desalter: Electrostatic Coalescer for removal of residual Water and salt from crude oil.
(Identical to dehydrator).
DBSP: Design Basis Scoping Paper
Disposal Water: Treated produced water for downhole/surface disposal/injection
DFD: Dual Frequency Desalter
DF-LRC: Dual Frequency-Load Responsive Controller
DPD: Dual Polarity Desalter
E&P: Exploration and Production
EIV: Emergency Isolation Valve
EPD: Environmental Protection Department
ESD: Emergency Shutdown
ESI: Emulsion Separation Index to measure Emulsion Stability
ESP: Electrical Submersible Pump
FEA: Finite Element Analysis
Page 5 of 32

SAES-A-010
FEED: Front End Engineering Development

Flowline: Pipelines connected to a single Oil, Gas or water wells for production or
Injection.
Formation (Produced) Water: Water produced from Reservoir with Oil and Gas
production
FPD: Facilities Planning Department
GOR: Gas Oil Ratio in Standard Cubic Feet of Gas per Barrel of Stock Tank Oil
GOSP: Gas Oil Separation Plant
GOSP (Satellite): Onshore Gas Oil Separation Plant without oil dehydration/desalting,
produced water separation and treatment facilities
GOSP (Offshore): Offshore Gas Oil Separation Plant without oil
dehydration/desalting, produced water separation and treatment facilities
EPD: Environmental Protection Department
H2S: Hydrogen Sulfide
HP: High Pressure
HPPT: High Pressure Production Trap (2 or 3-phase separator)
Injection (Power) Water: Treated Sea Water or aquifer water for reservoir pressure
support
IPPT: Intermediate Pressure Production Trap (2 or 3-phase separator)
L/D: Length to Diameter Ratio
LPDT: Low Pressure Degassing Tank (2 or 3-phase separator)
LPPT: Low Pressure Production Trap (2 or 3-phase separator)
MBCD: Thousand Barrels per Calendar Day
MBOD: Thousand Barrels per Operating Day
MBOD= MBCD/Overall Operating Factor
MCC: Mechanical Completion Certificate
MOC: Management of Change
Page 6 of 32

SAES-A-010
MOV: Motor Operated Valve

OOK: Out of Kingdom
OSPAS: Oil Supply Planning and Scheduling Department
Overall Operating Factor: Factor accounting for shrinkage and downtime (Fraction)
PPM: Parts Per Million
P&CSD: Process and Control Systems Department
P&FDD: Production & Facilities Development Department
PFD: Process Flow Diagram
P&ID: Piping and Instrumentation Diagram
PM&OU: Process Modeling & Optimization Unit
Production Manifold: Piping manifold where all incoming Trunklines/Flowlines
combine within the GOSP battery limit to feed the production Trap
PTB: Pounds of salt per thousand Barrels of Crude oil
Remote Production Manifold: Piping Manifold where Trunklines/Flowlines combine
into one Trunkline outside the GOSP fence to feed the GOSP Production manifold
RMD: Reservoir Management Department
RVP: Reid Vapor Pressure
Shrinkage: Decrease in oil volume caused by the evaporation of solution gas or by
lowering of fluid temperature during storage
Stock Tank Oil: Stabilized dry oil as it exists at atmospheric conditions in a stock tank.
TDS: Total Dissolved Solids
TEG: Tri-Ethylene Glycol
Trunkline: Pipeline to which two or more flowlines are connected
TT: Temperature Transmitter
Turndown: The ratio of normal maximum flow to Minimum controllable flow of the
GOSP, expressed in a percentage
Page 7 of 32

SAES-A-010
TVP: True Vapor Pressure (@ temperature)

VSD: Variable Speed Drive
Wash Water: Low salinity water used to wash the crude oil and dilute the formation
water in the crude desalting process.
Water cut (Percent): Produced water rate*100/(Crude rate+ Produced water Rate)
Well-head Piping: Piping system connecting the well head to the flowline first
isolation valve
WOSEP: Water Oil Separator. Collect and treat separated water mainly from the
3-phase separators and dehydrator to remove the entrained oil before disposal to the
reservoir.
5
GOSP Product Specification

5.1
Desalted Dry Crude

- Salt-in-Crude to Pipeline: 10 PTB (Max)
- BS&W to Pipeline:
5.2
5.3
0.2 Vol% (Max)
Stabilized Crude (for GOSPs with Stabilizers)

- H2S in Crude:
70 PPM by weight (Max)

30 PPM by weight (Design conditions)
1-60 PPM by weight (Operating Range)
- True Vapor pressure
13 psia (Max) at export or storage temperature,

(whichever is higher).
Disposal Water (for GOSPs with Produced Water Treatment Units)

- Target Oil-in-water
100 mg/L (Max), when treated produced water is

injected in oil reservoir for pressure maintenance
When treated produced water is injected in tighter disposal reservoir:

- Target Oil-in-water
Note:
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.
- Disposal Header Pressure: Specified by E&P based on Injection well pressure

Page 8 of 32

Note:
SAES-A-010
Maximum injection pressure is recommended to be below 3000 psig at

disposal pump shut off so that 1500# rating disposal piping can be used.
Overall Process Design

6.1
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
Steady State Process simulation shall be based on the latest version of

the approved simulation Software package based on SAEP-363 and
SAEP-364. The Process simulation software package that will be used
in the project shall be concurred by P&CSD.
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
The Final Process simulation models shall be included as part of the

project deliverable during the FEED and Detailed Design Stage.
All final process simulation models, with their documentation, during
FEED and Detailed Design stage shall be delivered to P&CSDs CML
coordinator through document transmittal.
6.3.6
Transient Dynamic process simulation shall be performed for each gas

compressor system during the detailed design stage to confirm the
functionality of the compressor control system under all start-up,
operating and shutdown conditions per SAES-K-402.
Page 9 of 32

6.4
6.3.7
Transient Dynamic simulations shall also be performed on parallel gas

compression trains to confirm the functionality of the compressor
control system during start-up, operating and shutdown conditions of
individual or multiple gas compressors.
6.3.8
The Transient Dynamic simulations of the Gas compressors individually

and combination of parallel trains shall be reviewed and approved by
P&CSD/APSD/PM&OU. The final dynamic Simulation Models shall
be delivered to P&CSDs CML coordinator as part of the MCC.
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
Design Water Cut
6.4.1.2
Initial Water cut
6.4.1.3
Final Water Cut
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
Energy System Optimization Assessment study shall be conducted

based on the preliminary PFDs per SAEP-14. The energy optimization
shall satisfy all operating conditions for summer, winter and the life
cycle of the project per paragraph 6.8.1.
6.4.4
The simulations and PFDs to be finalized after completing the Energy

system Optimization Assessment Study.
6.4.5
Stream Data for Summer, Winter and Design condition shall be

provided in the PFDs.
P&IDs
6.9.1
SAES-A-020 shall be used as a building block to develop the project

P&IDs.
6.9.2
SAES-J-005 provides the Instrument data to be included in the P&IDs.

The following additional instrument data shall be included in the P&IDs:
a)
Orifices- Orifice Bore and Flow Transmitter Range

Page 10 of 32

b)
Control Valves- Tight Shut-Off requirement
c)
Level Transmitter- Type of level transmitter, Calibration Range
d)
Additionally, the vessel template shall show the various level

alarm settings as height from vessel bottom for horizontal vessels
and Tan line for Vertical vessels. Level alarm settings shall be
shown as actual levels (instead of percentages) in DCS block or
display.
e)
Level Gauge: Type of Level Gauge, backlighting requirement
f)
Temperature Transmitter- Type of TT and Range. Alarm setting

on the DCS block or display
g)
Temperature Gauge- Range of Temperature Gauge
h)
Pressure transmitter/gauge- Range of the pressure

transmitter/gauge. Alarm settings on the DCS block.
i)
All shutdown switch settings
j)
All shutdown Alarms shall be shown connected to the Sequence

of Events Recorder.
Note:
SAES-A-010
The above required instrument details can be included in SAES-J-005.
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.
GOSP Equipment Design Considerations

7.1
Flowlines and Trunklines

7.1.1
Flowlines and trunklines sizing shall be based on transient simulations

over the full field life including turndown conditions and trunkline
scraping. The outcome of the transient analysis shall be applied in the
design of GOSP.
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
The flowlines and trunkline network shall be designed to the maximum

shut-in pressure of the field including future artificial lift (Gas lift, ESP
or multiphase pump).
Page 11 of 32

Note:
7.1.4
7.2
For existing Flowline/Trunkline networks, HIPPS to be evaluated in

accordance with SAEP-250 and SAEP-354 if the shut-in well head
pressure exceeds the design pressure.
Slug flow in trunklines shall be avoided and slug mitigation measures

to be provided to minimize production trap level and pressure upsets.
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
Flowline/Trunkline connections to the Production Manifold shall be

from the Top for new facilities.
7.2.3
As per RMD/P&FDD requirements, spare connections with blinds

shall be provided on the production manifold for connecting future
trunklines. To avoid dead legs, the active trunklines to be connected at
the ends of the production manifold with the spare connections in the
middle.
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
Two parallel production separators (HPPTs) can be connected to one

production manifold with symmetrical piping arrangement downstream
of the T dividing the flow to the two production separators.
However, the inlet to the T shall be from below the horizontal.
7.2.6
Long Radius elbows (5D) shall be provided on the production header

downstream of the inlet ESD valve to the first Production Separator.
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
Page 12 of 32

SAES-A-010
P&CSD and FPD based on life cycle economics during the initial field
development study.
7.3.2
The flash stage pressures shall be based on Flowing well head

Pressures, Individual stage GORs, reservoir production strategy over
the field life and crude type to optimize production cost during the
field life and maximize reservoir recovery.
Note:
The number of flash stages increases at higher GOR and higher

Flowing Well Head pressures to optimize the gas compression cost.
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 following requirements shall be met in all production Separators:
The bottom of the feed inlet nozzle shall be at least 6 above the
HH liquid level shutdown
Perforated (not Slotted) Anti-Wave baffles shall be provided.
Any internals for optimum separation efficiency shall be selected

based on the results of the Computational Fluid Dynamic Model.
The low low liquid level alarms and shutdowns shall be minimum
12 above the bottom of the vessels.
Vortex breakers shall be provided in all liquid outlet nozzles of

production separators
Non-Slam type check valve shall be provided on the common Gas

outlet
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
The first Production Separator receiving the well production fluids

from the production manifold shall be equipped with suitable inlet
device (Vane type, impingement plate or cyclonic device). The inlet
device shall be designed to withstand the forces over the full operating
range based on transient simulation of the flowline/trunkline network.
Note:
7.3.7
Finite Element Analysis (FEA) of the inlet device support structure is

recommended.
Mist eliminators shall be provided in production separator vessels to
Page 13 of 32

SAES-A-010
minimize liquid carry over in the Gas. Liquid carry over in gas shall
be less than 1 gal/MMSCF.
7.3.8
7.4
The design pressure of Tanks in low pressure production separation

service shall be minimum 10 psig.
GOSP Three Phase Production Separators

7.4.1
The 3-phase Production Separator shall be designed for the design

water cut or minimum 30% water cut whichever is higher.
7.4.2
Typical liquid retention (Holdup) time for water-oil separation shall

comply with API standard, i.e., API Spec 12J.
7.4.3
The minimum seam-seam to Vessel Diameter ratio (L/D) shall be 7 for

the horizontal 3-phase production separator vessel.
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
Between High interface and Low interface alarms: 5 minutes or

1 height
Between Low interface and Low Low interface shutdown:

3 minutes or 1 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
The selected 3-phase separator sizing shall be approved by P&CSD.
Page 14 of 32

7.5
7.7
Two Phase Production Separators

7.5.1
The 2-phase production separator upstream of the crude oil

dehydration/desalting train shall be sized for 30% water cut.
7.5.2
The minimum seam-seam to Vessel Diameter ratio (L/D) shall be 7 for

the horizontal 2-phase production separator vessel.
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
Between Lo Oil level alarm and Lo Lo oil level shutdown: 1 minute
The selected 2-phase separator sizing shall be approved by P&CSD.
Charge Pumps
7.6.1
Minimum 3 x 50% capacity charge pumps shall be provided for

pumping the wet crude through the crude desalting train.
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.
Crude Oil Dehydration and Desalting (Production Field)

7.7.1
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
or crude production interruptions during maintenance of one stage.

7.7.2
For GOSPs processing AM and AH crude grades minimum 3 stage

dehydration/desalting shall be provided.
Notes: Two stage dehydration/desalting can be considered in AH and AM
crude production with new technology internals provided the Vendor
is guaranteeing the desalted crude specification with single stage
operation at minimum 60% dry crude throughput. The two-stage
desalting in AH and AM crude service shall be concurred by both
P&CSD and Operations.
For ASL crude grade and Khuff gas condensate processing, the need
of crude desalting to be evaluated based on the formation water TDS
and Emulsion stability Index to meet the specification to the pipeline.
7.7.3
The dehydrator and desalter piping configuration shall be designed to

operate with the any one vessel bypassed at a time. The bypass
capability shall be provided for both vessels.
7.7.4
Where reservoir pressure support is provided by power water injection,

the crude dehydration and desalting trains shall be designed for 30%
water cut. Reduced trims to be installed on control valves for better
controllability during the initial production phase where the water cut
is low.
7.7.5
The dry crude viscosity in all desalting vessels shall be below 10 cP

and preferably below 5cP. The feed to the dehydrator/desalter shall be
heated to achieve the desired viscosity.
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
Recommended Desalting technologies:

- AC Field Desalting: Double volt; Tri-Volt; 0-30% Water cut
Note:
AC Field Bi-electric designs with emulsion feed distributed between

the grids shall not be used in the production field. Bi-electric
desalting designs shall be limited to refinery applications.
- Dual Polarity Desalting: AC/DC field 0-10% water cut
Page 16 of 32

SAES-A-010
- Dual Frequency Desalting: Upgrade of Dual Polarity Desalting

technology with Frequency modulation and Arc control. 0-30%
water cut
7.7.8
Minimum two levels of charged grids (double volted) shall be

provided for the AC field dehydrator/desalter in the production field.
Single Volted Electrical grid configuration (Bottom grids charged and
Upper Grid Grounded) shall not be used in the production field.
7.7.9
The electrostatic grids of AC field and DPD shall be charged by

3 single phase step-up transformers. The preferred primary supply
voltage to the AC field and DPD technology transformers is
4160 Volts. The transformers shall be equipped with external tap
changers to adjust the secondary voltage for the required voltage level.
7.7.10
The electrostatic grids of the DFD desalters shall be charged by

3 power units. The primary supply to the Power units shall be
480 volts, 3 Phase, 60 Hz. The DFD power unit harmonics level shall
be below the TIF values identified within IEEE 519. If necessary a
filtering system shall be used to meet the criteria.
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
Oil immersed High pressure entrance bushings rated above the

maximum secondary voltage of the transformer shall be provided to
connect the transformer secondary to the vessel internal grids. High
pressure bushing is also recommended at the transformer secondary.
7.7.14
Vessel nozzle size for the entrance bushing shall be minimum 6,

300# rating. A spacer with vent connection between the vessel nozzle
and the entrance bushing standpipe shall be provided to eliminate
vapor. The spacer vent shall be connected to the oil outlet pipe.
Page 17 of 32

SAES-A-010
7.7.15
The entrance bushing standpipe shall be equipped with a transparent

type level gauge and a sampling point for periodic sampling of the
standpipe oil for analysis of di-electric constant on a quarterly basis as
a minimum.
7.7.16
Emulsion Feed distributors shall be designed based on CFD modeling

for uniform distribution of the feed over the electrical grid area and
prevent channeling/ recirculation. The distance between the top of the
feed distributor and bottom of the charged grids shall be minimum
3.3 feet (1 meter).
7.7.17
Electrical grid loading for the AC field desalting systems in the

production field shall be the following:
AXL crude service: 150 BPD/Square Feet of grid area
AL crude service: 150 BPD/Square Feet of grid area
AM crude service: 110 BPD/Square Feet of grid area
AH crude service: 80 BPD/square Feet of Grid area
Note:
The above grid loading is field proven with the minimum life cycle
operating costs for the AC field systems.
7.7.18
Internal Interface skimming header and water (sand) jetting header

shall be provided. Interface sampling valves to collect interface
samples shall be provided.
7.7.19
All internal piping below the center line of the vessel shall be
internally and externally coated.
7.7.20
Minimum 2 out of the following 3 types of interface measuring devices

shall be provided to control the interface level:
Nucleonic type- Top mounted
Microwave type (2 probes)- Side mounted
External displacer type directly mounted on vessel nozzles
Flexibility shall be provided to select any one of the interface

measuring instruments to control the interface level.
Note:
Nozzles shall be provided for installing all three types of instruments.

Adequate clearance and space shall be provided to measure the
various interfaces including solids at the bottom of the vessel.
The probes shall be retrievable type for on-line maintenance.
Page 18 of 32

7.7.21
Two Transparent type interface monitoring sight glasses with

backlighting shall be provided. The sight glasses shall be located at
both ends of the vessel and directly connected to vessel nozzles taken
from the side.
7.7.22
Level switch shall be installed and connected to permissive circuit to

ensure the vessel is filed with liquid before applying the power.
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:
For DFD technology internal floats to ground the grids is not

recommended due to concern on life expectancy of the electronics.
7.7.24
For AC field and DPD technology desalters a local panel shall be

provided with a power switch, transformers secondary voltage
indication, current indication, green/red pilot lights for each secondary
phase and a local panel light. The transformer secondary voltage shall
also be indicated in the DCS.
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
GOSPs with crude desalting shall be designed to start on wet crude.

GOSPs shall be designed for recycling off-spec dry crude.
7.7.27
Online BS&W analyzers shall be provided at the outlet of the desalter.

Insertion type sample take off installed on vertical main pipe to be
provided for representative stream.
Note:
7.7.28
7.8
SAES-A-010
Online salt-in-crude analyzer (without using chemicals) to be tested

to prove the accuracy and repeatability.
The Dehydrator/Desalters shall be designed to withstand the shut-off

head of the charge pump with the design margin per SAES-D-001.
Booster and Shipping Pumps

7.8.1
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 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
Compressor suction drum shall be equipped with mist eliminator to

remove 99.99% liquid droplets of 6 microns and larger. Fiber Glass or
other synthetic coalescing packing shall not be used in the compressor
suction drums. Large capacity HP gas compressors suction drums in
the GOSPs shall be equipped with V type mist eliminator.
7.9.3
CFD shall be performed on the gas compressor suction drum to

confirm the liquid removal efficiency over the full operating range of
the compressor.
7.9.4
The compressor discharge temperature under normal operating

conditions shall not exceed 320F. For higher compressor discharge
temperatures, the materials selected, specially the O rings for H2S
service shall be approved by CSD.
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
The number of gas compressors shall be determined based on the

production forecast over the life cycle of the project to minimize
compressor recycling.
7.9.7
Spare gas compressor shall be provided to eliminate gas flaring.

Reduction of crude rate and operating on one gas compressor is
acceptable.
Note:
7.9.8
The deletion of spare gas compressor shall be concurred by

Operating organization, P&CSD/UPED and EPD.
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.
Page 20 of 32

7.10
SAES-A-010
7.9.9
Fixed speed motors of Spheroid and LP gas compressor shall be sized to

start the compressor at normal operating pressure. Refer SAES-K-402
for start-up capability requirements of fixed speed motors for low
suction pressure gas compressors.
7.9.10
Field performance testing shall be conducted on all new process gas

compressors within 6 months of start-up or immediately after overhaul
to establish the baseline performance per SABP-K-401. Compressor
performance testing to repeated on a 3-6 years interval in GOSPs.
All compressor performance records shall be maintained by the
respective plant engineering Unit.
7.9.11
The maximum approach temperature of after cooler (Air) is 15F based

on summer design dry bulb temperature @ 1%.
Gas Dehydration and Hydrocarbon Dew Point Control

7.10.1
Gas dehydration and hydrocarbon dew point control shall be provided

in the following applications:
Lift Gas for producing wells
Sub-sea gas pipelines transporting compressed associated gas to

on-shore.
On-shore gas pipelines transporting compressed associated gas

through populated area as defined by SAES-B-062.
Note:
In dense phase gas injection systems, only gas dehydration is

required to remove the water.
7.10.2
A knock out drum shall be installed upstream of the Gas dehydration

unit coalescing filter to knock out liquid droplets carried over in the
flashed gas from the production traps. The knock out drum shall be
equipped with mist eliminator to remove 99.99% of liquid droplets
6 microns and larger. Compressor discharge drums located upstream
of the dehydration unit coalescing filter shall be equipped with mist
eliminators to remove 99.99% of liquid droplets 6 microns and larger.
7.10.3
The water content of dehydrated gas shall not exceed 7 lb/MMSCF.
7.10.4
Hydrocarbon dew point control units shall be designed to eliminate

liquid dropout in the gas transfer lines.
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
Gas Dehydration standard is under development by P&CSD / UPED /

GPU.
Note:
SAES-A-010
The requirements for gas dehydration included in this standard are in

addition to the Gas dehydration standard.
Auxiliary Systems
8.1
Wash Water Systems for Crude Oil Desalting

8.1.1
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
The design mixing efficiency shall exceed 50%. High efficiency

Mixing control valves shall be used for mixing wash water with the
crude at the inlet of the final stage desalter. Mixing pressure drop
range is 7 -25 psid.
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
A gas blanketed surge drum shall be provided to receive the wash

water from its source. The wash water shall be pumped from the Wash
Water surge drum by the Wash Water pumps to the desalting facility.
8.1.6
Wash water shall be controlled by flow control to provide steady

required wash water rate to crude oil desalting. Wash water supply
shall not be based on level control of the surge drum.
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
Sand/sludge recovery system shall be provided on the water jetting

effluents from the dehydrator/desalter.
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:
The need of chemical systems for Biocide, Oxygen Scavenger and

Methanol injection need to be evaluated on a case by case basis.
8.2.2
All chemical storage tanks and injection skids shall be preferably

located at one location. Large chemical storage tanks shall be
accessible for road tankers.
8.2.3
The chemical dosing pumps shall be positive displacement, metering

type capable of adjusting the dosage rates both locally and remotely
from the control system. Pump rate shall be confirmed by graduated
cylinder installed on the pump suction. Refer to SABP-A-015.
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
Strainers shall be provided upstream of the chemical dosing points.

Two parallel strainers with isolation valve shall be provided if
chemical dosing cannot be interrupted.
8.2.6
With the exception of Demulsifier and methanol, all other chemical

dosage rates and injection locations shall be finalized in consultation
with CSD and Plant Corrosion control. Refer to SABP-A-018 and
SABP-A-036.
8.2.7
On line corrosion monitoring system (MICROCOR or equivalent)

shall be provided in the GOSP to monitor corrosion. The locations for
on-line corrosion monitoring shall be reviewed with CSD and Plant
corrosion control. Refer to SABP-A-018 and SABP-A-036.
Note:
8.2.8
Recommended locations for on-line corrosion monitoring are:

Production Manifold, Wash water supply, HPPT water Out, LPPT Oil
out, Dehydrator water out, Disposal Water out to disposal Line,
GOSP crude to pipeline and Gas to pipeline.
Corrosion monitoring coupon locations shall be finalized in

consultation with Plant Corrosion Control. Required space shall be
provided for on-line coupon retrieval and installation tools. Refer to
Page 23 of 32

SAES-A-010
SABP-A-018 and SABP-A-036.

8.2.9
Anode Monitoring System (AMS) shall be provided on all vessels

(HPPT, IPPT, LPPT, Dehydrator, desalter, WOSEP) that handle wet
crude and are installed with anodes for cathodic protection.
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
The demulsifier injection points shall be provided at the production

manifold and at the inlet of the dehydrator. For multiple desalting
trains the demulsifier injection point to be located downstream of the
common Charge pump discharge header. Mixing devices to mix the
injected demulsifier with the wet crude shall be provided.
Note:
8.2.12
8.3
Refer SAEP-1663 for typical demulsifier dosage rates for different

crude grades.
The Demulsifier injection rate shall be automated to optimize the

demulsifier consumption.
Note:
8.2.14
3-phase demulsifier mixing device will be tested at the production

manifold. Approved mixing valve at the dehydrator inlet is available.
Minimum three 100% capacity demulsifier dosing pumps shall be

provided for demulsifier injection.
Note:
8.2.13
To ensure good mixing the pipeline corrosion inhibitor injection point

can be upstream of the crude tie-line control Valve or suction of the
shipping pump.
P&CSD/Plant Engineering to be consulted for finalizing the

Algorithms for demulsifier automation.
Minimum one month storage capacity shall be provided for the

demulsifier.
Hot Oil Systems

8.3.1
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
Page 24 of 32

SAES-A-010
coke build up tendencies besides process heating requirements. Auto

ignition temperature of the heating media shall be at least 50C above
the max operating temperature.
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
Minimum 3 x 50% capacity Hot Oil circulation pumps shall be

provided. The hot oil pump suction temperature shall be connected to
the DCS.
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
All off-shore GOSPs, Well Platforms shall be provided with Closed

Drain Systems per SAES-A-400/SAES-A-403 and Oily Water Drain
System per SAES-S-020.
Note:
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
Lined Pit shall be provided outside the GOSP Fence to collect

emergency drains.
Page 25 of 32

8.5
8.6
SAES-A-010
Instrument Air/ Plant Air systems

8.5.1
The Instrument Air system shall be designed in accordance with

SAES-J-901.
8.5.2
The reciprocating Instrument air compressors at on-shore GOSPs shall

be water-cooled.
8.5.3
Plant air connection shall be provided at all utility stations besides

nitrogen, LP steam and water connections.
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.
GOSP In-Plant Piping

8.6.1
The GOSP piping system shall be designed based on SAES-L-100.
8.6.2
The Spec breaks between two piping codes shall be connected by

flanges. A spectacle plate shall be provided at the spec break flange.
8.6.3
Non-slam type Check valves shall be installed at the following

locations:
Gas outlets of all Production Separators( HPPT, IPPT, LPPT, LPDT)
Gas slug catchers, receiving gas from satellite GOSPs
Crude Charge Pumps, Booster Pumps and Shipping Pumps

discharge
Bypass lines of Booster and Shipping Pumps
Crude oil stabilizer gas outlet
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.
Page 26 of 32

SAES-A-010
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
A process study shall be conducted to establish the equipment or pipelines

limitation at the plant capacity established by the flare and relief system
capacity.
9.4
A Plant test shall be conducted with concurrence from P&CSD/UPED/OPU and

P&CSD/DPED/F&RSU to confirm the equipment limitations.
9.5
A Management of Change (MOC) process shall be completed for any changes to

facilities including the Design Capacity of the plant.
26 February 2013
Revision Summary
New Saudi Aramco Engineering Standard.
Page 27 of 32

SAES-A-010
Appendix I Simplified Schematic of Satellite On-Shore GOSP
Page 28 of 32

SAES-A-010
Appendix II Simplified Schematic of Off-Shore GOSP
Page 29 of 32

SAES-A-010
Appendix III Simplified Schematic of Simple GOSP with Gas Compression
Page 30 of 32

SAES-A-010
Appendix IV Simplified Schematic of Complex GOSP

with Gas Compression and Crude Stabilization
Page 31 of 32

SAES-A-010
Appendix V Simplified Schematic of Hot Oil System
Page 32 of 32

Saes A 010

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Saes A 010

Загружено:

Авторское право:

Доступные форматы

Engineering Standard

Gas Oil Separation Plants (GOSPs)

Saudi Aramco DeskTop Standards

Previous Issue: New

Next Planned Update: 26 February 2018

Primary contact: Fernandez, Gabriel Thomas on +966-3-8809476

Document Responsibility: Process Engineering Standards Committee

Table of Contents (contd)

The standard also provides the minimum requirement for debottlenecking an

Conflicts and Deviations

Document Responsibility: Process Engineering Standards Committee

Saudi Aramco References

Safety Integrity Level Assignment & Verification

Instructions for Obtaining a Waiver of a Mandatory

High Integrity Protective Systems Design

Pipeline Simulation Model Development and Support

Process Simulation Model Development and Support

Design Guidelines for Gas Oil Separation Plant

Saudi Aramco Engineering Standards

Equipment Specific P&ID Templates (ESPT)

Industrial Drainage Systems

Closed Drain Systems (CDS)

Off-Shore Platform Drainage Systems

Fireproofing for Plants

Safety Requirements for Plants and Operations

Onshore Well Site Safety

Design Criteria for Pressure

Coating Selection and Application Requirements for

Document Responsibility: Process Engineering Standards Committee

Internal and External Coatings for Steel Pipeline

Instrumentation Drawings and Forms

Emergency Shutdown and Isolation Systems

Instrument Air Supply Systems

Applicable Codes and Standards for Pressure

Oily Water Drainage Systems

Pipelines Leak Detection Systems

Saudi Aramco Best Practices

Chemical Injection Systems

GOSP Corrosion Control

Corrosion Monitoring Best Practice

Site Performance Testing of Centrifugal

Industry Codes and Standards

Specification for Oil and Gas Separators

Institute of Electrical and Electronic Engineers (IEEE)

Guide for Harmonic Control and Reactive

Terms and Definitions

Document Responsibility: Process Engineering Standards Committee

CDS: Closed Drain System

: Arab Super Light

: Arab Extra Light

CSD: Consulting Services Department

Document Responsibility: Process Engineering Standards Committee

FEED: Front End Engineering Development

Document Responsibility: Process Engineering Standards Committee

MOV: Motor Operated Valve

Document Responsibility: Process Engineering Standards Committee

TVP: True Vapor Pressure (@ temperature)

GOSP Product Specification

Desalted Dry Crude

0.2 Vol% (Max)

Stabilized Crude (for GOSPs with Stabilizers)

70 PPM by weight (Max)

- True Vapor pressure