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Wellhead Heaters, UN Model

TECHNICAL SPECIFICATION

Scope of Supply

The Supplier shall design, manufacture, test, inspect and supply a complete Wellhead Heater, UN Model, suitable for heating crude oil and/or oil emulsion at the wellhead during transportation through field gathering systems.

The Wellhead Heater shall be supplied as a complete packaged unit including, as a minimum:

Heater vessel
Combustion chamber/furnace
Gas burner assembly
Gas separator
Ventilation system
Flue gas stack
Skid/base frame
Safety and control instrumentation
Temperature and pressure instruments
Fuel gas train
Shut-off and control valves
Safety relief devices
Local control panel
Required piping and fittings
Drain and sampling connections
Complete accessories required for safe and reliable operation

The heater shall be suitable for continuous outdoor operation at the oil/gas wellhead.

Equipment Description

Item	Specification
Equipment	Wellhead Heater
Model	UN-0.2M3 / UN Model
Service	Crude Oil / Oil Emulsion Heating
Installation	Wellhead / Field Gathering System
Heating Type	Direct Heating
Heating Medium	Combustion Products
Fuel	Natural Gas / Associated Gas
Installation	Skid Mounted
Operation	Continuous
Location	Outdoor
Design	Horizontal Cylindrical Vessel
Construction	Welded Steel Construction

The heater shall transfer heat from the combustion chamber to the process fluid through the furnace/heating surface. The equipment shall be designed to provide uniform heating and prevent local overheating of the process fluid.

Design and Performance Requirements

Main Performance Data

Parameter	Required Specification
Rated Thermal Capacity	200 kW (0.2 Gcal/h)
Oil Throughput	50–100 t/day
Maximum Operating Pressure	1.6 MPa
Maximum Thermal Efficiency	≥80%
Process Fluid	Crude Oil / Oil Emulsion
Minimum Oil Inlet Temperature	+20°C
Oil Outlet Temperature	+60 to +70°C
Fuel Gas	Natural Gas / Associated Gas
Fuel Gas Pressure at Burner	30–70 kPa
Fuel Gas Consumption	Approx. 15–25 Nm³/h
Heater Wall Temperature	Approx. −20 to +70°C
Installation	Skid Mounted

The above values are based on published UN-0.2M3 reference data and should be finalized against the Purchaser's actual process conditions.

Process Connections

The following connection arrangement may be adopted for the UN-0.2M3 configuration:

Connection	Service	Qty.	Nominal Pressure	DN
A1	Oil Inlet	1	1.6 MPa	DN100
B1	Oil Outlet	1	1.6 MPa	DN100
C1	Safety Valve	1	1.6 MPa	DN80
D1	Drain	1	1.6 MPa	DN50
E1	Sampling Connection	1	1.6 MPa	DN15
F1	Gas Outlet to Flare/Candle	1	0.15 MPa	DN15
G1	Flue Gas Outlet	1	0.01 MPa	DN250

These connection sizes correspond to the published UN-0.2M3 configuration. The Supplier shall verify all connection dimensions against the final approved GA drawing before manufacture.

Heater Vessel The heater vessel shall be: Horizontal cylindrical type Welded construction Provided with suitable heads Designed for the specified operating pressure and temperature Suitable for crude oil/oil emulsion service Equipped with required inlet and outlet connections Provided with drain and sampling connections Suitable for outdoor installation The vessel shall be designed to withstand the applicable design pressure, temperature, thermal stresses and operating loads.

Combustion Chamber The combustion chamber shall: Be designed for continuous firing Provide uniform heat distribution Minimize local hot spots Be suitable for the specified fuel gas Be manufactured from suitable heat-resistant material Allow inspection and maintenance

Burner The burner shall be suitable for natural gas and associated gas operation. The burner system shall include, as applicable: Gas burner Ignition system Flame monitoring Gas pressure regulator Gas shut-off valves Gas control valve Filter/strainer Pressure gauges Automatic safety shut-off system The burner shall automatically shut down in the event of flame failure, low/high fuel-gas pressure or other critical unsafe conditions.

Automatic Control The control system shall maintain the required outlet oil temperature by automatic modulation of the burner/fuel gas supply. The system shall provide automatic shutdown in case of: Flame failure Excessive process temperature Excessive process pressure Low fuel gas pressure High fuel gas pressure Loss of combustion air Emergency stop activation

Safety Requirements The heater shall incorporate all necessary safety devices to ensure safe operation in an oil and gas production environment. Minimum safety features: Flame failure protection Emergency shutdown system Pressure relief valve Fuel gas isolation Automatic burner shutdown High-temperature protection Gas leakage protection where applicable Safe ignition sequence Flame arresting/protection arrangement where required Proper venting Earthing/grounding provisions The Supplier shall submit a complete Cause & Effect / Shutdown Logic document.

Design Standards and Codes The equipment shall comply with applicable editions of the following standards, as applicable: ASME BPVC Section VIII – Pressure Vessels ASME B31.3 – Process Piping API 520 / API 521 – Pressure Relief Systems API RP 14C – Safety Analysis / Safety Systems for Offshore Production Facilities, where applicable IEC 60079 series – Explosive Atmospheres IEC 60529 – IP Protection ISO 9001 – Quality Management System Applicable GOST / GOST 15150 requirements where specified by the Purchaser For the published UN-0.2M3 equipment, the climatic versions are indicated as U / HL according to GOST 15150-69, with placement category 1. Important: The final applicable code/standard list should be agreed between Purchaser and Supplier according to the project location and hazardous-area classification

Hazardous Area Classification The Wellhead Heater is intended for installation in an oil and gas production environment. All electrical and instrumentation equipment installed within the classified hazardous area shall be suitable for the specified: Zone Gas group Temperature class Ambient temperature The Purchaser shall provide the project hazardous-area classification drawing. Supplier shall clearly identify all Ex-certified components in the equipment documentation.