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8. Phase separation
Email:Eng20072007@gmail.com
https://www.facebook.com/elsayedameer
Phone : 01065860658
Very good grade with degree of honor
Worked for weatherford drilling for 1.5 years
BSC Of petroleum engineering
Currently, a Production and process engineer
At SUCO and RWE Dea Egypt Petroleum Co.
Eng. Elsayed Amer
Petroleum and natural gas Engineer
SEPARATOR
a pressure vessel used for separating well fluids produced from oil and gas wells
into gaseous and liquid components.
Removal of Oil from Gas
Removal of Gas from Oil
Separation of Water and solid
FUNCTIONS
• Downstream equipment cannot handle gas–liquid mixture:
SEPARATOR
Pumps require gas-free liquid
Compressor and dehydration equipment require liquid-free gas
Product specification set limits on impurities
Oil generally cannot contain more than 1% BS&W
Gas sales contracts generally require that the gas contain no
free liquids
Measurement devices for gases or liquids are highly inaccurate
when another phase is present.
Fluid from a well can include
condensable liquid
condensable vapors
Liquid water
water vapor
01
02
03
04
05
gas
crude oil
solid debris ( sand, Scale, …)
Wells are classified according to the type of fluid they produce in the greatest quantity.
A
B
1. Crude oil well
contains mostly crude oil, but
can contain
▪ solid debris
▪ water
▪ gas.
2. Dry gas well
○ contains mostly gas
○ can contain some water
○ does not contain crude or
Liquid hydrocarbons
.
3. Gas condensate well
○ contains both liquid and
gaseous hydrocarbons
○ contains some water
○ does not contain crude oil
C
Well fluids
e x i s t a s e i t h e r
A B
emulsion layered
01
Gas Solubility
The solubility of natural gas in oil is a function of pressure & temperature at
reservoir conditions.
The gas solubility is defined as the number of cubic feet of gas measured at std.
conditions which are in solutions in one barrel of S. T .O. at reservoir temp. &
pressure.
9
Separation terminology
There are two basic types of gas liberation: Flash & Differential.
Flash & Differential liberation of gas:
01
02
flash liberation
pressure is reduced by a finite amount
and after equilibrium is established the
gas is bled off, keeping the pressure
constant.
differential liberation
gas evolved is removed
continuously from contact
with the oil.
Operating pressures and temperatures
affect the density and viscosity
Gas and liquid flow rates
(minimum, average, and peak)
Physical properties of the fluids
such as density and compressibility factor
Presence of impurities
(paraffin, sand, scale, etc.)
Foaming tendencies of the crude oil
Corrosive tendencies of the
liquids or gas
B
A
E
G
C
D
F
Separation
Surging or slugging tendencies
Density difference provides the least effort
12
SEPARATION MECHANISMS
• Separation works on specific temperature & pressure
• Employs one or more mechanisms:
- Gravity Settling
- Centrifugal Force
- Baffling / Impingement
- Electrostatic / Sonic Precipitation
- Filtration
- Adhesive Separation
- Adsorption
- Heat / Thermal
- Chemical
Separator Classification
P r o c e s s p o i n t o f v i e w
14
Separators
Configuration
( Shape )
Vertical
Horizontal
Spherical
Function
Separator
Scrubber
K.O.D
Flash Drum
No of phase
separation
Two phase
Three phase
Operating
pressure
Low
( 20 – 200 Psi)
Medium
(200-750 Psi)
High
( 750 - 1500 Psi
Application
LTS
Test Separator
Production
separator
16
01
02
03
Vertical Separator
Spherical Separator
Horizontal Separator
19
Vertical Separator
Vertical Separator
Vertical Separator
24
Advantages
 ideal for high flow rate
 Good for surging flows
 Work well for high GOR applications
 can handle foaming liquids with ease
 much more economical as compared
to use of horizontal separators.
 Takes up less space than a horizontal
separator with the same capacity
 Can handle more sand, mud, paraffin,
wax without plugging.
 can be skid-mounted for quick and
easy installation
1. Vertical Separators
 Difficult for modular systems -
transport & installation.
 Some of the instruments and
safety devices may be difficult to
access without ladders or access
platforms
 Low efficient in high liquid rate
Disadvantages
25
2. Horizontal separator
A. Horizontal Separator with a Boot or Water Pot
2. Horizontal separator
A. Horizontal Separator with a Boot or Water Pot
D. Press. = 125 psi
1" Gas outlet
2" Glycol inlet
1" Cond. Outlet 1 1/2" Glycol outlet
31
2. Horizontal separator
B. Double barrel Separator
32
2. Horizontal separator
c. Double barrel Separator
33
2. Horizontal separator
Double barrel Separator
34
• Horizontal separator
Advantage and disadvantage of
Advantages
• Normally more efficient at handling
large amounts of liquid and gas
• Cheaper than Vertical separator for
same capacity.
• Large liquid surface area for foam
dispersion generally reduces
turbulence
Disadvantages
• More difficult to clean produced
sand, mud, wax, paraffin, etc.
• Larger mounting area
• Poor solids removal
• Lower surge capacity
35
36
37
Advantages and disadvantages
They are not widely used
They are difficult to fabricate
Separator Types Comparing
Parameters Vertical Horizontal Spherical
Advantages
1. Easier to clean
2. Saves space
3. Provides better
surge control
4. Liquid level control
is not critical
1. Can handle much higher gas-
oil ratio well streams because
the design permits much
higher gas velocities
2. Cheaper than the vertical
separator
3. Easier and cheaper to ship and
assemble
4. Requires less piping for field
connections
5. Reduces turbulence and
reduces foaming (thus, it can
handle foaming crude)
1. Very inexpensive
2. Good for low or
intermediate gas-oil
ratio
3. Very compact and
easy to ship and
install
Separator Types Comparing
Parameters Vertical Horizontal Spherical
Disadvantages
1.It takes a longer diameter
separator for a given gas capacity
as compared to horizontal
separator
2.More expensive to fabricate
3.Difficult and more expensive to
ship (transport)
1.Greater space
requirements generally
2.Liquid level control more
critical
3.Surge space is somewhat
limited
Much harder to clean (hence
a bad choice in any sand-
producing area)
1. Very inexpensive
2. Good for low or
intermediate gas-oil
ratio
3. Very compact and
easy to ship and
install
Separator Types Comparing
Parameters Vertical Horizontal Spherical
IdealUsage
Low to intermediate gas-oil ratio,
and where relatively large slugs of
liquid are expected
High gas-oil ratio crudes,
foaming crudes, or for
liquid- liquid separation.
Good for a diverse range of
situations
Intermediate or low
gas-oil ratio,
preferably two-
phase separation
Separator Types Comparing
Vertical Separator Horizontal Separator
Gas flows vertically upwards against liquid
settling. Therefore, gas velocity must be less
than the liquid droplet terminal velocity for
effective separation.
Gas flows horizontally and hence
perpendicular to droplet setting. Therefore,
the gas velocity can be larger than the liquid
droplet velocity
For the same application, vertical separator is
generally less efficient than horizontal
separator.
Horizontal separator is generally more effective
in separating vapour and liquid due to a larger
surface area for vapour to be released from
liquid.
Vapor flow area is constant therefore
performance of separator is not sensitive to
changing liquid level.
Vapour flow area depends on liquid level
therefore the performance of horizontal
separator can deteriorate as liquid level rises.
Vertical separator is generally used when gas is
the dominant phase.
Horizontal separator is generally used when gas
and liquids are of equal proportions or liquid is
the dominant phase.
Vertical separator generally takes less plot
space.
generally takes more plot space but less
height.
42
• How much solid (sand) is produced:
Buildup of solid material can lead to corrosion, reduction in
performance. Regular cleaning by jet-wash system or manual removal.
• How steady the flow is
Slugging and surges cause increases in feed rates causing levels to
increase. Control system needs constant adjusting.
• How much water is produced
• Is any emulsion (dispersion) formed
Long residence time unsuited for primary separators. May need to add
chemical de-emulsifier or reduce water quality.
• Is foaming a problem
Elevated separator
Stage separator
Metering separator
Foam Separator
Free water Knock out
drum
Production
Separator
Test
Separator
Low temperature
separator
1. Test Separator
A vessel used to separate and meter relatively small quantities of oil and gas. Test separators can
be two-phase or three-phase, or horizontal, vertical or spherical. They can also be permanent or
portable.
1. Test Separator
1. Test Separator
 A test separator is used to separate and to meter the well fluids.
 They can be permanently installed or portable (skid or trailer mounted).
1. Test Separator
Well manifold
2. Production Separator
pressure vessel used for separating well fluids produced from oil and gas wells into
gaseous and liquid components
2. Production Separator
3. Low temperature separator
is an on-site natural gas treatment process aimed at gas condensate recovery. it allows presence of non-hydrocarbon
components in gas, ensures compliance of the water dew point and the hydrocarbon dew point of gas with the
Industry Standards and the condensate recovery level (C5H12 + higher) up to 97 per cent (hydrocarbon dew point
corresponds to separation temperature).
3. Low temperature separator
3. Low temperature separator
3. Low temperature separator
4. Free water Knock out drum
Knockouts are also are separators & fall in two categories:
- free water &
- total liquid knockouts
4. Free water Knock out drum
1. Free water knockout
is a vessel used to separate free water from a combined gas, hydrocarbon liquid
and water stream. The gas & hydrocarbon liquid usually are allowed to leave the
vessel together through the same outlet to be processed by other equipment.
The water is removed for disposal. A free water knockout can be utilized at either
high or low pressure
4. Free water Knock out drum
No Emulsion Treatment
4. Free water Knock out drum
Emulsion Treatment by heating
4. Free water Knock out drum
1. Total liquid knockout
is normally used to remove liquids from a high pressure gas stream (3,000 psig &
above ). This vessel usually is used with a cold separation unit.
5. Foam separator
6. Filter separator
The filter separator is frequently used in some high-gas/low-liquid flow applications. It is designed to remove
small liquid and solid particles from the gas stream.
14" Outlet
14" Inlet
2" Liquid outlet 2" Liquid outlet
Mist Extractor
38 Filter elements
second stage
liquid storage
First stage
liquid storage
6. Filter separator
7. Cyclone sand separator
gas liquid condensate
water
Gas
Two Phase separator Three phase separator
Two phase Horizontal separator
Two phase Vertical separator
Three phase separator
01
02
03
04
 operate at pressures ranging from
10 to 20 up to 180 to 225 psi.
 operate at pressures ranging from
230 to 250 up to 600 to 700 psi.
 operate in the wide pressure range
from 750 to 1,500 psi.
 Most oil and gas separators operate
in the pressure range of 20 to 1
,500 psi.
Low Pressure
Intermediate
Pressure
High Pressure
general
• A separating vessel may be referred to in the following ways:
SEPARATOR
Skimmer
Scrubber
knockout drum
Flash drum, flash
vessel, or flash trap
Stage separator
Filter
Separator
Slug catcher
1. Multi Stage Separator
2. Single Stage Separator
3. knockout drum
A separator used for a bulk separation of gas and liquid.
3. knockout drum
Flare Knockout drum
4. Flash drum
5. Slug catcher ( Finger Type )
A particular separator design able to absorb sustained in-flow of large liquid volumes at
irregular intervals
commonly used in gas gathering pipelines, is a special case of a two-phase gas–liquid
separator that is designed to handle large gas capacities and liquid slugs on a regular
basis
Finger type Slug catcher
5. Slug catcher ( Finger Type )
5. Slug catcher ( Vessel type)
Vessel type Slug catcher
Influent
Flow
Gas
Discharge
5. Slug catcher ( Vessel type)
6. Scrubber
A scrubber is a two-phase separator that is designed to recover liquids carried over
from the gas outlets of production separators or to catch liquids condensed due to
cooling or pressure drops.
Applications:
1. upstream of mechanical equipment such as compressors that could be damaged,
destroyed, or rendered ineffective by free liquid;
2. downstream of equipment that can cause liquids to condense from a gas stream
(such as coolers);
3. upstream of gas dehydration equipment that would lose efficiency, be damaged,
or destroyed if contaminated with liquid hydrocarbons;
Vertical scrubbers are most commonly used. Horizontal scrubbers can be used,
but space limitations usually dictate the use of a vertical configuration.
6. Scrubber
A type of separator which has been designed to handle flow streams with unusually high gas-to liquid
ratios.
6. Scrubber
Compressor suction scrubber
Designed to recover liquids carried
over from production separators or
condenses after initial separation
Liquid loading level much lower than
separator
Applications
Upstream of compressors
Downstream of coolers (liquids can
condense)
Upstream of dehydration
equipment
Upstream of a vent of flare outlet
6. Scrubber
Compressor suction scrubber
7. Filter
7. Skimmer
An oil skimmer is a device that is designed to remove oil floating on a liquid surface. Depending on the
specific design they are used for a variety of applications such as oil spill response, as a part of oily water
treatment systems, removing oil from machine tool coolant and aqueous parts washers, and collecting fats
oils and greases in wastewater treatment in food manufacturing industries.
Separator internals
P r o c e s s p o i n t o f v i e w
Sections of Separator
secondary separation
Section
Liquid Accumulation
Section
Primary Separation
Section
Mist Extraction
Section
91Separator internals
Separator Sections
• Primary Separation (A)
• Gravity Settling (B)
• Liquid Collecting (C)
• Coalescing/Demister (D)
94
Separator Sections
1. Primary Separation section
• As the fluids enter the vessel an initial separation of gas and liquid takes place.
This happens because of:
Reduction in
velocity
95Separator internal
Reduction in
pressure
Change in flow
direction
• Collecting and removing the bulk of the liquid in the inlet stream.
• Exploit the momentum of the inlet stream either by creating centrifugal force or
change of direction (as in horizontal separators) thus separating most of the
incoming liquid.
96Separator internal
The velocity of the inlet stream is reduced as the fluids flow from a
relatively small diameter pipeline into the large volume separator.
The pressure is reduced by maintaining a controlled pressure on the
vessel lower than that of the inlet stream.
The change in flow direction is accomplished by placing some form
of deflector at the inlet to the separator.
1. Primary Separation section
2. Secondary separation section
In the secondary separation process these liquid droplets are removed from the
gas stream.
Liquid droplets which are suspended in the gas stream will tend to fall or 'settle'
towards the bottom of the vessel. This is simply due to the force of gravity.
• The difference in density between liquid and gas and the droplet size will be
determined by the composition of the inlet fluid streams.
• The velocity of the gas stream is determined by the size of the separator and
its throughput.
97Separator internal
Retention Time
Defined as : the average time a molecule of liquid is retained in the vessel
assuming plug flow .
 It is thus the volume of liquid storage in the vessel divided by the liquid flow rate.
 It is affected by composition, foaming tendency, presence of solids & emulsions etc.
For most applications retention times between 30 sec. & 3 minutes have been found to
be sufficient.
For foaming crudes, retention times up to four times this amount may be needed. For
chemical reactors like ‘Water Deoxygenating Towers’ it is kept about 3 to 5 minutes.
Separator internal
Retention Time
3. Mist Extraction Section
• The secondary separation of liquid droplets from the gas by gravity settling
will not usually remove very small particles.
• These particles tend to remain in the gas stream in the form of a mist. In
order that the gas leaving a separator is as free as possible from liquid, a
final mist extraction section is built into the vessel.
• Mist extraction is accomplished using either an impingement or a
centrifugal force mechanism.
10
0
Separator internal
4. Liquid accumulation Section
 The lowermost section of a separator where the liquids from the other three
sections accumulate before being discharged from the vessel.
 Initially, this liquid will have gas bubbles entrained within it which must be
removed. Just as liquid droplets tend to fall through a gas stream, gas bubbles
tend to rise to the surface of liquids due to density differences.
 The time required for the bubbles to reach the surface and re-enter the gas
stream will vary. However, for most oilfield applications it will occur in one to
four minutes. This means that the liquids must stay in the vessel for this period of
time, which is known as the retention time.’
Mechanical Devices
Mechanical Devices
104
Components of Separator
1. Inlet Diverters
• Also Known as Inlet Deflectors & Deflector Plate
 Locate in front of the flow inlet
 Cause a rapid change in direction & velocity of
fluid.
 Forcing the liquids to fall to the bottom of the
vessel.
 Responsible for the initial gross separation of
liquid and gas.
105
Components of Separator
1. Inlet Diverters
• There are several different types of separator inlet devices
• that are commonly used:
 no inlet device
 diverter plate
 half-pipe
 vane-type
 cyclonic
106
Components of Separator
1. Inlet Diverters
107
Components of Separator
1. Inlet Diverters
108
Components of Separator
1. Inlet Diverters
109
Components of Separator
• Cyclonic Inlet Diverters
1. Inlet Diverters
110
Components of Separator
• Half pipe Inlet Diverters
1. Inlet Diverters
111
Components of Separator
• Efficiency
1. Inlet Diverters
112
Components of Separator
2. Straightening Vanes
turbulence in the flowing gas stream can be reduced by incorporating straightening vanes
113
Components of Separator
2. Straightening Vanes
114
Components of Separator
2. Straightening Vanes
Turbulence in the flowing gas stream can be reduced by incorporating straightening vanes
Effluent
Inlet Gas
Outlet
Oil/Condensate
Outlet
Water
Outlet
SDVSDV
SDV LCVSDV
LCV
Deflector Plate
Coalescing Plate
Straightening Vane
Weir
Demister Pad
Vortex Breakers
115
Components of Separator
3. Mist extractor
mist extractors or mist eliminators, designed to remove the liquid droplets and solid
particles from the gas stream.
Before a selection can be made, one must evaluate the following factors:
Size of droplets the separator must remove
 Pressure drop that can be tolerated in achieving the required level of removal
 Susceptibility of the separator to plugging by solids, if solids are present
 Liquid handling capability of the separator
 Whether the mist extractor/eliminator can be installed inside existing equipment, or
if it requires a standalone vessel instead
 Availability of the materials of construction that are comparable with the process
 Cost of the mist extractor/eliminator itself and required vessels, piping,
instrumentation, and utilities
116
Components of Separator
3. Mist extractor
Small liquid droplets present in the gas
stream can be carried along with the gas
stream and contaminate the gas
processing system. Mechanical devices
to capture droplets are used close to gas
outlet.
Droplets are removed by impingement
on solid surface when liquid collects and
eventually drips off from unit.
117
Components of Separator
3. Mist extractor
vane type Mist extractor
parallel metal sheets with suitable liquid collection "pockets," The gas, in passing
between plates, is agitated and has to change direction a number of times.
Obviously, some degree of centrifugation is introduced, for as the gas changes
direction the heavier particles tend to be thrown to the outside and are caught in the
pockets provided.
118
Components of Separator
3. Mist extractor
vane type or knitted wire Mist extractor
119
Components of Separator
3. Mist extractor
knitted wire type Mist extractor
The most common type of mist extractor found in
production operations
a knitted wire mesh supported on a lightweight
support. This material has given generally favorable
results and has a low installed cost
The element consists of wire knitted into a pad
having a number of unaligned, asymmetrical
openings. Although similar in appearance to filter
media, its action is somewhat different. The latter
are rather dense and have small openings. This
knitted wire, on the other hand, has about 97 to 98%
free voids and collects the particles.
120
Components of Separator
3. Mist extractor
Special types
An arch plate-type mist extractor
121
Components of Separator
3. Mist extractor
Special types
A coalescing pack mist extractor.
Centrifugal mist extractor.
122
Components of Separator
3. Mist extractor
123
Components of Separator
4. Foam Breaker
These are flat plates located in the separator just above the liquid accumulation section.
They help to prevent waves in the liquid which might result in liquid re-entrainment in the
gas stream.
124
125
Components of Separator
4. Foam Breaker
127
Components of Separator
Vortex in vessels
VORTEX is a region in fluid in which the flow is rotating around an axis line, which is
influenced by the Earth's rotation. The formation of vortices can entrain vapor in the
liquid stream, leading to;
• Poor separation in process steps such as distillation
• Excessive pressure drop
• Erosion of nozzle and connecting pipe due to two phase flow
• Causing cavitation of downstream pumps.
128
Components of Separator
5. Vortex Breaker
VORTEX BREAKER is a device used to stop formation of a vortex when a liquid is drained
from vessel.
• Installed at bottom outlet/drain nozzle of vessel.
• Many type of vortex breaker are available, e.g.
 Cross Type
 Disc Type (Baffle Plate)
 Cross & Disc Type
129
Components of Separator
5. Vortex Breaker
The formation of vortices can entrain vapor in the liquid stream, leading to poor
separation in process steps such as distillation or excessive pressure drop, or causing
cavitation of downstream pumps. Vortices can also re-entrain solid particles previously
separated from a gas stream in a solid-gas separation device such as a cyclone
130
Components of Separator
5. Vortex Breaker
Figure 11.10 Campbells 7th Edition Volume 2.
131
Components of Separator
6. Sand Jets and Drains
 The Sand Jetting system is commonly used in the
upstream separator to remove solids that settles in
gravity separators.
 It fluidizes the solids with pressurized water
introduced through specially designed nozzles.
 The solids are then discharged through sand drains
located down the length of the vessel
132
Components of Separator
6. Sand Jets and Drains
133
Components of Separator
6. Sand Jets and Drains
134
Components of Separator
7. Weir
 vertical baffles placed in the liquid accumulation section of the separator. In a 3 phase vessel
they separate the oil accumulation area from the water accumulation part.
 They may also be used to isolate a section of the oil accumulation part of the separator. This
will then provide a calm area for level control equipment to operate in.
 Locate at the bottom of the vessel
 Divide the separator into two compartments
 Control the water level
 Permits oil to overflow into the oil compartment
135
Components of Separator
7. Weir
Separation troubleshooting
P r o c e s s p o i n t o f v i e w
Operation problems
Gas Blow-by : Blowby occurs when free gas escapes with liquid phase and indicates
 low liquid level
 Vortexing
 Level control failure
Carryover: occurs when free liquid escapes gas phase
 Can indicate high liquid level
 Damage to vessel internals
 Plugged liquid outlets or exceeding the design rate of vessel (e.g.
foam, improper design).
Amount of liquid carry over coming from droplets larger in size than 10 micron is
generally less than 0.1 gallon / MSCFlow liquid level
Operation problems
Emulsions – Water Carry Through: troublesome in operations
 Over a period of time emulsified materials with other impurities accumulate &
foam at inter-phase of W&O which affect the separation efficiency
 Addition of heat & chemicals often minimizes this difficulty
 To overcome the problem:
 add de-emulsifier upstream of separator
 provide coalescing devices
 when necessary, provide heating coil to improve water settling & break of
emulsion of waxy crudes (e.g. Mumbai High Crude)low liquid level
Operation problems
Solid Deposits : troublesome in operations
• Sand carryover from reservoirs
• Salt deposits from formation water
Troublesome;
 Can cause cut-out of valve trims
 Plugging of internals
 Accumulations at bottom whereby reducing capacity of LAS & causing
corrosion
To overcome:
 provide water-jets to fluidize & prevent accumulation
 Design outlet circuits considering accumulations and corrosion
 Provide anti-deposit additive injection after lab. tests
 Provide soft water injection facilities for water soluble salt deposit
Operation problems
FOAMING : troublesome in operations, Can increase dramatically amount of liquid
carry-over with gas.
Effects of foaming
• Reduces the capacities of oil and gas separators
• Carry over of oil in gas
• Control of liquid levels
When foaming is ‘potential problem:
• Antifoam additives injection be provided upstream of separator (lab. tests)
• Increase retention time within reasonable limits
• Install cyclonic device as fluid inlet distributor
• Provide vane type of mist extractor upstream of gas outlet nozzle
Operation problems
FOAMING : troublesome in operations, Can increase dramatically amount of liquid
carry-over with gas.
Retention Time
Defined as : the average time a molecule of liquid is retained in the vessel
assuming plug flow .
 It is thus the volume of liquid storage in the vessel divided by the liquid flow rate.
 It is affected by composition, foaming tendency, presence of solids & emulsions etc.
For most applications retention times between 30 sec. & 3 minutes have been found to
be sufficient.
For foaming crudes, retention times up to four times this amount may be needed. For
chemical reactors like ‘Water Deoxygenating Towers’ it is kept about 3 to 5 minutes.
Retention Time
Typical retention time Mins.
• Natural gas-oil 2 – 3
• Lean oil - surge tank
10 – 15
• Fractionation feed tanks 8
– 15
• Refrigerant surge tanks 4 –
7
• Refrigerant economizers 2
– 3
Retention Time
Sizes and Capacities :
• Recommended retention time:
Oil gravity Retention time
o API (min.)
2-Phase > 35 1
Separators 20-30 1-2
10-20 2-4
3-Phase >35 3-5
separators Below35
100+o F 5-10
80+o F 10-20
60+o F 20-30
Recommended retention time
Instrumentation and
control system
P r o c e s s p o i n t o f v i e w
Vessel instrumentation
Level controller Radar Level
Transmitter
Radar Level
Transmitter
Pressure control
Level control
Oil Level control
Level control
Level Measurement
Level Measurement
Level Measurement
Level transmitter
Level Indication
Level switches
Level control
Level Control Settings
• Level control positions give a degree of flexibility to separator design
• Response times from control room or outside operation
• Slugging volumes
• Residence times
LZA(HH) - High level trip
0.15m below inlet or 0.05D
LA(H) - High level pre-alarm
LA(L) - Low level pre-alarm
LZA(LL) - Low level trip
0.1m below LZA(HH) or
60 sec flow for control room
5 mins for outside action
0.1m below LA(L) or
60 sec flow for control room
5 mins for outside action
0.36m below LA(H) or
2 - 4 mins of residence time
and allow for slugging
Oil
Water
Gas
Flow control
Process Monitoring
Control valve standard
Liquid Levels Definition
NLL Normal Liquid Level
Liquid level maintained by controls during operation
HLL High Liquid Level
First liquid level above NLL to trigger an alarm
HHLL High High Liquid Level
Second liquid level above NLL to trigger a shutdown
LLL Low Liquid Level
First liquid level below NLL to trigger an alarm
LLLL Low Low Liquid Level
Second liquid level below NLL to trigger a shutdown
Hold-up time
(Residence
Time)
Time to fill separator from empty to NLL at design liquid
feed rate.
Surge Time Time to fill separator from NLL to HLL at design liquid
feed rate.
170
Safety Devices in Separator
• PSHH (Pressure Swich High High)
• PSLL (Pressure Swich Low Low)
• LSHH (Level Swich High High)
• LSLL (Level Swich Low Low)
• BDV (Blowdown Valve)
• PSV (Pressure Safety Valve)
• SDV (Shut Down Valve)
Since vertical separators are supported only by the bottom skirt (Figure
3.16), the walls of vertical separators must be somewhat thicker than a
similarly sized and rated horizontal separator, which may be supported
by saddles.
Comparison of vertical and horizontal support structures
Geometry
1. Normal Operating
Pressure at which equipment operates
1. Maximum operating
Highest operating pressure foreseen for all applicable cases (normal,
turndown, startup shutdown).
1. Design Pressure
Maximum operating pressure plus a safety margin
Process Design Considerations
Pressure Nomenclature
Maximum Operating
Pressure, psig
Design Pressure, psig
Less than 25 50
25 to 250 Oper P + 25
250 to 1000 (Oper P) * (1.1)
More than 1000 (Oper P) * (1.05) (*)
(*) Applicable only if pilot operated relief valves are used,
otherwise use a 10 percent margin
Process Design Conditions
Determine Design Pressure
Sizes and Capacities :
• Liquid levels
• Maximum oil level : < 0.65 I.D.
• Normal oil level : 0.5 I.D. or 1 min.
retention time between max.
and normal liq. Level
• Low oil level : 0.1 I.D. or 12” from bottom
• Water/ inter face level : Water retention time of 1-2 min. or 12”
which ever is greater
Sizes and Capacities :
Level Control Settings
• Level control positions give a degree of flexibility to separator design
• Response times from control room or outside operation
• Slugging volumes
• Residence times
LZA(HH) - High level trip
0.15m below inlet or 0.05D
LA(H) - High level pre-alarm
LA(L) - Low level pre-alarm
LZA(LL) - Low level trip
0.1m below LZA(HH) or
60 sec flow for control room
5 mins for outside action
0.1m below LA(L) or
60 sec flow for control room
5 mins for outside action
0.36m below LA(H) or
2 - 4 mins of residence time
and allow for slugging
Oil
Water
Gas
8. Phase separation

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8. Phase separation

  • 2. Email:Eng20072007@gmail.com https://www.facebook.com/elsayedameer Phone : 01065860658 Very good grade with degree of honor Worked for weatherford drilling for 1.5 years BSC Of petroleum engineering Currently, a Production and process engineer At SUCO and RWE Dea Egypt Petroleum Co. Eng. Elsayed Amer Petroleum and natural gas Engineer
  • 3. SEPARATOR a pressure vessel used for separating well fluids produced from oil and gas wells into gaseous and liquid components. Removal of Oil from Gas Removal of Gas from Oil Separation of Water and solid FUNCTIONS
  • 4. • Downstream equipment cannot handle gas–liquid mixture: SEPARATOR Pumps require gas-free liquid Compressor and dehydration equipment require liquid-free gas Product specification set limits on impurities Oil generally cannot contain more than 1% BS&W Gas sales contracts generally require that the gas contain no free liquids Measurement devices for gases or liquids are highly inaccurate when another phase is present.
  • 5. Fluid from a well can include condensable liquid condensable vapors Liquid water water vapor 01 02 03 04 05 gas crude oil solid debris ( sand, Scale, …)
  • 6. Wells are classified according to the type of fluid they produce in the greatest quantity. A B 1. Crude oil well contains mostly crude oil, but can contain ▪ solid debris ▪ water ▪ gas. 2. Dry gas well ○ contains mostly gas ○ can contain some water ○ does not contain crude or Liquid hydrocarbons . 3. Gas condensate well ○ contains both liquid and gaseous hydrocarbons ○ contains some water ○ does not contain crude oil C
  • 7. Well fluids e x i s t a s e i t h e r A B emulsion layered
  • 8. 01 Gas Solubility The solubility of natural gas in oil is a function of pressure & temperature at reservoir conditions. The gas solubility is defined as the number of cubic feet of gas measured at std. conditions which are in solutions in one barrel of S. T .O. at reservoir temp. & pressure.
  • 9. 9 Separation terminology There are two basic types of gas liberation: Flash & Differential. Flash & Differential liberation of gas: 01 02 flash liberation pressure is reduced by a finite amount and after equilibrium is established the gas is bled off, keeping the pressure constant. differential liberation gas evolved is removed continuously from contact with the oil.
  • 10. Operating pressures and temperatures affect the density and viscosity Gas and liquid flow rates (minimum, average, and peak) Physical properties of the fluids such as density and compressibility factor Presence of impurities (paraffin, sand, scale, etc.) Foaming tendencies of the crude oil Corrosive tendencies of the liquids or gas B A E G C D F Separation Surging or slugging tendencies
  • 11. Density difference provides the least effort
  • 12. 12 SEPARATION MECHANISMS • Separation works on specific temperature & pressure • Employs one or more mechanisms: - Gravity Settling - Centrifugal Force - Baffling / Impingement - Electrostatic / Sonic Precipitation - Filtration - Adhesive Separation - Adsorption - Heat / Thermal - Chemical
  • 13. Separator Classification P r o c e s s p o i n t o f v i e w
  • 14. 14 Separators Configuration ( Shape ) Vertical Horizontal Spherical Function Separator Scrubber K.O.D Flash Drum No of phase separation Two phase Three phase Operating pressure Low ( 20 – 200 Psi) Medium (200-750 Psi) High ( 750 - 1500 Psi Application LTS Test Separator Production separator
  • 15.
  • 16. 16
  • 18.
  • 19. 19
  • 23.
  • 24. 24 Advantages  ideal for high flow rate  Good for surging flows  Work well for high GOR applications  can handle foaming liquids with ease  much more economical as compared to use of horizontal separators.  Takes up less space than a horizontal separator with the same capacity  Can handle more sand, mud, paraffin, wax without plugging.  can be skid-mounted for quick and easy installation 1. Vertical Separators  Difficult for modular systems - transport & installation.  Some of the instruments and safety devices may be difficult to access without ladders or access platforms  Low efficient in high liquid rate Disadvantages
  • 25. 25
  • 26.
  • 27.
  • 28.
  • 29. 2. Horizontal separator A. Horizontal Separator with a Boot or Water Pot
  • 30. 2. Horizontal separator A. Horizontal Separator with a Boot or Water Pot D. Press. = 125 psi 1" Gas outlet 2" Glycol inlet 1" Cond. Outlet 1 1/2" Glycol outlet
  • 31. 31 2. Horizontal separator B. Double barrel Separator
  • 32. 32 2. Horizontal separator c. Double barrel Separator
  • 34. 34 • Horizontal separator Advantage and disadvantage of Advantages • Normally more efficient at handling large amounts of liquid and gas • Cheaper than Vertical separator for same capacity. • Large liquid surface area for foam dispersion generally reduces turbulence Disadvantages • More difficult to clean produced sand, mud, wax, paraffin, etc. • Larger mounting area • Poor solids removal • Lower surge capacity
  • 35. 35
  • 36. 36
  • 37. 37 Advantages and disadvantages They are not widely used They are difficult to fabricate
  • 38. Separator Types Comparing Parameters Vertical Horizontal Spherical Advantages 1. Easier to clean 2. Saves space 3. Provides better surge control 4. Liquid level control is not critical 1. Can handle much higher gas- oil ratio well streams because the design permits much higher gas velocities 2. Cheaper than the vertical separator 3. Easier and cheaper to ship and assemble 4. Requires less piping for field connections 5. Reduces turbulence and reduces foaming (thus, it can handle foaming crude) 1. Very inexpensive 2. Good for low or intermediate gas-oil ratio 3. Very compact and easy to ship and install
  • 39. Separator Types Comparing Parameters Vertical Horizontal Spherical Disadvantages 1.It takes a longer diameter separator for a given gas capacity as compared to horizontal separator 2.More expensive to fabricate 3.Difficult and more expensive to ship (transport) 1.Greater space requirements generally 2.Liquid level control more critical 3.Surge space is somewhat limited Much harder to clean (hence a bad choice in any sand- producing area) 1. Very inexpensive 2. Good for low or intermediate gas-oil ratio 3. Very compact and easy to ship and install
  • 40. Separator Types Comparing Parameters Vertical Horizontal Spherical IdealUsage Low to intermediate gas-oil ratio, and where relatively large slugs of liquid are expected High gas-oil ratio crudes, foaming crudes, or for liquid- liquid separation. Good for a diverse range of situations Intermediate or low gas-oil ratio, preferably two- phase separation
  • 41. Separator Types Comparing Vertical Separator Horizontal Separator Gas flows vertically upwards against liquid settling. Therefore, gas velocity must be less than the liquid droplet terminal velocity for effective separation. Gas flows horizontally and hence perpendicular to droplet setting. Therefore, the gas velocity can be larger than the liquid droplet velocity For the same application, vertical separator is generally less efficient than horizontal separator. Horizontal separator is generally more effective in separating vapour and liquid due to a larger surface area for vapour to be released from liquid. Vapor flow area is constant therefore performance of separator is not sensitive to changing liquid level. Vapour flow area depends on liquid level therefore the performance of horizontal separator can deteriorate as liquid level rises. Vertical separator is generally used when gas is the dominant phase. Horizontal separator is generally used when gas and liquids are of equal proportions or liquid is the dominant phase. Vertical separator generally takes less plot space. generally takes more plot space but less height.
  • 42. 42 • How much solid (sand) is produced: Buildup of solid material can lead to corrosion, reduction in performance. Regular cleaning by jet-wash system or manual removal. • How steady the flow is Slugging and surges cause increases in feed rates causing levels to increase. Control system needs constant adjusting. • How much water is produced • Is any emulsion (dispersion) formed Long residence time unsuited for primary separators. May need to add chemical de-emulsifier or reduce water quality. • Is foaming a problem
  • 43. Elevated separator Stage separator Metering separator Foam Separator Free water Knock out drum Production Separator Test Separator Low temperature separator
  • 44. 1. Test Separator A vessel used to separate and meter relatively small quantities of oil and gas. Test separators can be two-phase or three-phase, or horizontal, vertical or spherical. They can also be permanent or portable.
  • 46. 1. Test Separator  A test separator is used to separate and to meter the well fluids.  They can be permanently installed or portable (skid or trailer mounted).
  • 49. 2. Production Separator pressure vessel used for separating well fluids produced from oil and gas wells into gaseous and liquid components
  • 51.
  • 52. 3. Low temperature separator is an on-site natural gas treatment process aimed at gas condensate recovery. it allows presence of non-hydrocarbon components in gas, ensures compliance of the water dew point and the hydrocarbon dew point of gas with the Industry Standards and the condensate recovery level (C5H12 + higher) up to 97 per cent (hydrocarbon dew point corresponds to separation temperature).
  • 53. 3. Low temperature separator
  • 54. 3. Low temperature separator
  • 55. 3. Low temperature separator
  • 56. 4. Free water Knock out drum Knockouts are also are separators & fall in two categories: - free water & - total liquid knockouts
  • 57. 4. Free water Knock out drum 1. Free water knockout is a vessel used to separate free water from a combined gas, hydrocarbon liquid and water stream. The gas & hydrocarbon liquid usually are allowed to leave the vessel together through the same outlet to be processed by other equipment. The water is removed for disposal. A free water knockout can be utilized at either high or low pressure
  • 58. 4. Free water Knock out drum No Emulsion Treatment
  • 59. 4. Free water Knock out drum Emulsion Treatment by heating
  • 60. 4. Free water Knock out drum 1. Total liquid knockout is normally used to remove liquids from a high pressure gas stream (3,000 psig & above ). This vessel usually is used with a cold separation unit.
  • 62. 6. Filter separator The filter separator is frequently used in some high-gas/low-liquid flow applications. It is designed to remove small liquid and solid particles from the gas stream. 14" Outlet 14" Inlet 2" Liquid outlet 2" Liquid outlet Mist Extractor 38 Filter elements second stage liquid storage First stage liquid storage
  • 64. 7. Cyclone sand separator
  • 65. gas liquid condensate water Gas Two Phase separator Three phase separator
  • 66. Two phase Horizontal separator
  • 67. Two phase Vertical separator
  • 68.
  • 70. 01 02 03 04  operate at pressures ranging from 10 to 20 up to 180 to 225 psi.  operate at pressures ranging from 230 to 250 up to 600 to 700 psi.  operate in the wide pressure range from 750 to 1,500 psi.  Most oil and gas separators operate in the pressure range of 20 to 1 ,500 psi. Low Pressure Intermediate Pressure High Pressure general
  • 71. • A separating vessel may be referred to in the following ways: SEPARATOR Skimmer Scrubber knockout drum Flash drum, flash vessel, or flash trap Stage separator Filter Separator Slug catcher
  • 72. 1. Multi Stage Separator
  • 73. 2. Single Stage Separator
  • 74. 3. knockout drum A separator used for a bulk separation of gas and liquid.
  • 75. 3. knockout drum Flare Knockout drum
  • 77. 5. Slug catcher ( Finger Type ) A particular separator design able to absorb sustained in-flow of large liquid volumes at irregular intervals
  • 78. commonly used in gas gathering pipelines, is a special case of a two-phase gas–liquid separator that is designed to handle large gas capacities and liquid slugs on a regular basis Finger type Slug catcher 5. Slug catcher ( Finger Type )
  • 79.
  • 80. 5. Slug catcher ( Vessel type) Vessel type Slug catcher
  • 82. 6. Scrubber A scrubber is a two-phase separator that is designed to recover liquids carried over from the gas outlets of production separators or to catch liquids condensed due to cooling or pressure drops. Applications: 1. upstream of mechanical equipment such as compressors that could be damaged, destroyed, or rendered ineffective by free liquid; 2. downstream of equipment that can cause liquids to condense from a gas stream (such as coolers); 3. upstream of gas dehydration equipment that would lose efficiency, be damaged, or destroyed if contaminated with liquid hydrocarbons; Vertical scrubbers are most commonly used. Horizontal scrubbers can be used, but space limitations usually dictate the use of a vertical configuration.
  • 83. 6. Scrubber A type of separator which has been designed to handle flow streams with unusually high gas-to liquid ratios.
  • 84. 6. Scrubber Compressor suction scrubber Designed to recover liquids carried over from production separators or condenses after initial separation Liquid loading level much lower than separator Applications Upstream of compressors Downstream of coolers (liquids can condense) Upstream of dehydration equipment Upstream of a vent of flare outlet
  • 85.
  • 88. 7. Skimmer An oil skimmer is a device that is designed to remove oil floating on a liquid surface. Depending on the specific design they are used for a variety of applications such as oil spill response, as a part of oily water treatment systems, removing oil from machine tool coolant and aqueous parts washers, and collecting fats oils and greases in wastewater treatment in food manufacturing industries.
  • 89.
  • 90. Separator internals P r o c e s s p o i n t o f v i e w
  • 91. Sections of Separator secondary separation Section Liquid Accumulation Section Primary Separation Section Mist Extraction Section 91Separator internals
  • 92.
  • 93. Separator Sections • Primary Separation (A) • Gravity Settling (B) • Liquid Collecting (C) • Coalescing/Demister (D)
  • 95. 1. Primary Separation section • As the fluids enter the vessel an initial separation of gas and liquid takes place. This happens because of: Reduction in velocity 95Separator internal Reduction in pressure Change in flow direction • Collecting and removing the bulk of the liquid in the inlet stream. • Exploit the momentum of the inlet stream either by creating centrifugal force or change of direction (as in horizontal separators) thus separating most of the incoming liquid.
  • 96. 96Separator internal The velocity of the inlet stream is reduced as the fluids flow from a relatively small diameter pipeline into the large volume separator. The pressure is reduced by maintaining a controlled pressure on the vessel lower than that of the inlet stream. The change in flow direction is accomplished by placing some form of deflector at the inlet to the separator. 1. Primary Separation section
  • 97. 2. Secondary separation section In the secondary separation process these liquid droplets are removed from the gas stream. Liquid droplets which are suspended in the gas stream will tend to fall or 'settle' towards the bottom of the vessel. This is simply due to the force of gravity. • The difference in density between liquid and gas and the droplet size will be determined by the composition of the inlet fluid streams. • The velocity of the gas stream is determined by the size of the separator and its throughput. 97Separator internal
  • 98. Retention Time Defined as : the average time a molecule of liquid is retained in the vessel assuming plug flow .  It is thus the volume of liquid storage in the vessel divided by the liquid flow rate.  It is affected by composition, foaming tendency, presence of solids & emulsions etc. For most applications retention times between 30 sec. & 3 minutes have been found to be sufficient. For foaming crudes, retention times up to four times this amount may be needed. For chemical reactors like ‘Water Deoxygenating Towers’ it is kept about 3 to 5 minutes.
  • 100. 3. Mist Extraction Section • The secondary separation of liquid droplets from the gas by gravity settling will not usually remove very small particles. • These particles tend to remain in the gas stream in the form of a mist. In order that the gas leaving a separator is as free as possible from liquid, a final mist extraction section is built into the vessel. • Mist extraction is accomplished using either an impingement or a centrifugal force mechanism. 10 0 Separator internal
  • 101. 4. Liquid accumulation Section  The lowermost section of a separator where the liquids from the other three sections accumulate before being discharged from the vessel.  Initially, this liquid will have gas bubbles entrained within it which must be removed. Just as liquid droplets tend to fall through a gas stream, gas bubbles tend to rise to the surface of liquids due to density differences.  The time required for the bubbles to reach the surface and re-enter the gas stream will vary. However, for most oilfield applications it will occur in one to four minutes. This means that the liquids must stay in the vessel for this period of time, which is known as the retention time.’
  • 104. 104 Components of Separator 1. Inlet Diverters • Also Known as Inlet Deflectors & Deflector Plate  Locate in front of the flow inlet  Cause a rapid change in direction & velocity of fluid.  Forcing the liquids to fall to the bottom of the vessel.  Responsible for the initial gross separation of liquid and gas.
  • 105. 105 Components of Separator 1. Inlet Diverters • There are several different types of separator inlet devices • that are commonly used:  no inlet device  diverter plate  half-pipe  vane-type  cyclonic
  • 106. 106 Components of Separator 1. Inlet Diverters
  • 107. 107 Components of Separator 1. Inlet Diverters
  • 108. 108 Components of Separator 1. Inlet Diverters
  • 109. 109 Components of Separator • Cyclonic Inlet Diverters 1. Inlet Diverters
  • 110. 110 Components of Separator • Half pipe Inlet Diverters 1. Inlet Diverters
  • 111. 111 Components of Separator • Efficiency 1. Inlet Diverters
  • 112. 112 Components of Separator 2. Straightening Vanes turbulence in the flowing gas stream can be reduced by incorporating straightening vanes
  • 113. 113 Components of Separator 2. Straightening Vanes
  • 114. 114 Components of Separator 2. Straightening Vanes Turbulence in the flowing gas stream can be reduced by incorporating straightening vanes Effluent Inlet Gas Outlet Oil/Condensate Outlet Water Outlet SDVSDV SDV LCVSDV LCV Deflector Plate Coalescing Plate Straightening Vane Weir Demister Pad Vortex Breakers
  • 115. 115 Components of Separator 3. Mist extractor mist extractors or mist eliminators, designed to remove the liquid droplets and solid particles from the gas stream. Before a selection can be made, one must evaluate the following factors: Size of droplets the separator must remove  Pressure drop that can be tolerated in achieving the required level of removal  Susceptibility of the separator to plugging by solids, if solids are present  Liquid handling capability of the separator  Whether the mist extractor/eliminator can be installed inside existing equipment, or if it requires a standalone vessel instead  Availability of the materials of construction that are comparable with the process  Cost of the mist extractor/eliminator itself and required vessels, piping, instrumentation, and utilities
  • 116. 116 Components of Separator 3. Mist extractor Small liquid droplets present in the gas stream can be carried along with the gas stream and contaminate the gas processing system. Mechanical devices to capture droplets are used close to gas outlet. Droplets are removed by impingement on solid surface when liquid collects and eventually drips off from unit.
  • 117. 117 Components of Separator 3. Mist extractor vane type Mist extractor parallel metal sheets with suitable liquid collection "pockets," The gas, in passing between plates, is agitated and has to change direction a number of times. Obviously, some degree of centrifugation is introduced, for as the gas changes direction the heavier particles tend to be thrown to the outside and are caught in the pockets provided.
  • 118. 118 Components of Separator 3. Mist extractor vane type or knitted wire Mist extractor
  • 119. 119 Components of Separator 3. Mist extractor knitted wire type Mist extractor The most common type of mist extractor found in production operations a knitted wire mesh supported on a lightweight support. This material has given generally favorable results and has a low installed cost The element consists of wire knitted into a pad having a number of unaligned, asymmetrical openings. Although similar in appearance to filter media, its action is somewhat different. The latter are rather dense and have small openings. This knitted wire, on the other hand, has about 97 to 98% free voids and collects the particles.
  • 120. 120 Components of Separator 3. Mist extractor Special types An arch plate-type mist extractor
  • 121. 121 Components of Separator 3. Mist extractor Special types A coalescing pack mist extractor. Centrifugal mist extractor.
  • 123. 123 Components of Separator 4. Foam Breaker These are flat plates located in the separator just above the liquid accumulation section. They help to prevent waves in the liquid which might result in liquid re-entrainment in the gas stream.
  • 124. 124
  • 126.
  • 127. 127 Components of Separator Vortex in vessels VORTEX is a region in fluid in which the flow is rotating around an axis line, which is influenced by the Earth's rotation. The formation of vortices can entrain vapor in the liquid stream, leading to; • Poor separation in process steps such as distillation • Excessive pressure drop • Erosion of nozzle and connecting pipe due to two phase flow • Causing cavitation of downstream pumps.
  • 128. 128 Components of Separator 5. Vortex Breaker VORTEX BREAKER is a device used to stop formation of a vortex when a liquid is drained from vessel. • Installed at bottom outlet/drain nozzle of vessel. • Many type of vortex breaker are available, e.g.  Cross Type  Disc Type (Baffle Plate)  Cross & Disc Type
  • 129. 129 Components of Separator 5. Vortex Breaker The formation of vortices can entrain vapor in the liquid stream, leading to poor separation in process steps such as distillation or excessive pressure drop, or causing cavitation of downstream pumps. Vortices can also re-entrain solid particles previously separated from a gas stream in a solid-gas separation device such as a cyclone
  • 130. 130 Components of Separator 5. Vortex Breaker Figure 11.10 Campbells 7th Edition Volume 2.
  • 131. 131 Components of Separator 6. Sand Jets and Drains  The Sand Jetting system is commonly used in the upstream separator to remove solids that settles in gravity separators.  It fluidizes the solids with pressurized water introduced through specially designed nozzles.  The solids are then discharged through sand drains located down the length of the vessel
  • 132. 132 Components of Separator 6. Sand Jets and Drains
  • 133. 133 Components of Separator 6. Sand Jets and Drains
  • 134. 134 Components of Separator 7. Weir  vertical baffles placed in the liquid accumulation section of the separator. In a 3 phase vessel they separate the oil accumulation area from the water accumulation part.  They may also be used to isolate a section of the oil accumulation part of the separator. This will then provide a calm area for level control equipment to operate in.  Locate at the bottom of the vessel  Divide the separator into two compartments  Control the water level  Permits oil to overflow into the oil compartment
  • 136.
  • 137.
  • 138. Separation troubleshooting P r o c e s s p o i n t o f v i e w
  • 139. Operation problems Gas Blow-by : Blowby occurs when free gas escapes with liquid phase and indicates  low liquid level  Vortexing  Level control failure Carryover: occurs when free liquid escapes gas phase  Can indicate high liquid level  Damage to vessel internals  Plugged liquid outlets or exceeding the design rate of vessel (e.g. foam, improper design). Amount of liquid carry over coming from droplets larger in size than 10 micron is generally less than 0.1 gallon / MSCFlow liquid level
  • 140. Operation problems Emulsions – Water Carry Through: troublesome in operations  Over a period of time emulsified materials with other impurities accumulate & foam at inter-phase of W&O which affect the separation efficiency  Addition of heat & chemicals often minimizes this difficulty  To overcome the problem:  add de-emulsifier upstream of separator  provide coalescing devices  when necessary, provide heating coil to improve water settling & break of emulsion of waxy crudes (e.g. Mumbai High Crude)low liquid level
  • 141. Operation problems Solid Deposits : troublesome in operations • Sand carryover from reservoirs • Salt deposits from formation water Troublesome;  Can cause cut-out of valve trims  Plugging of internals  Accumulations at bottom whereby reducing capacity of LAS & causing corrosion To overcome:  provide water-jets to fluidize & prevent accumulation  Design outlet circuits considering accumulations and corrosion  Provide anti-deposit additive injection after lab. tests  Provide soft water injection facilities for water soluble salt deposit
  • 142. Operation problems FOAMING : troublesome in operations, Can increase dramatically amount of liquid carry-over with gas. Effects of foaming • Reduces the capacities of oil and gas separators • Carry over of oil in gas • Control of liquid levels When foaming is ‘potential problem: • Antifoam additives injection be provided upstream of separator (lab. tests) • Increase retention time within reasonable limits • Install cyclonic device as fluid inlet distributor • Provide vane type of mist extractor upstream of gas outlet nozzle
  • 143. Operation problems FOAMING : troublesome in operations, Can increase dramatically amount of liquid carry-over with gas.
  • 144.
  • 145. Retention Time Defined as : the average time a molecule of liquid is retained in the vessel assuming plug flow .  It is thus the volume of liquid storage in the vessel divided by the liquid flow rate.  It is affected by composition, foaming tendency, presence of solids & emulsions etc. For most applications retention times between 30 sec. & 3 minutes have been found to be sufficient. For foaming crudes, retention times up to four times this amount may be needed. For chemical reactors like ‘Water Deoxygenating Towers’ it is kept about 3 to 5 minutes.
  • 146. Retention Time Typical retention time Mins. • Natural gas-oil 2 – 3 • Lean oil - surge tank 10 – 15 • Fractionation feed tanks 8 – 15 • Refrigerant surge tanks 4 – 7 • Refrigerant economizers 2 – 3
  • 148. Sizes and Capacities : • Recommended retention time: Oil gravity Retention time o API (min.) 2-Phase > 35 1 Separators 20-30 1-2 10-20 2-4 3-Phase >35 3-5 separators Below35 100+o F 5-10 80+o F 10-20 60+o F 20-30 Recommended retention time
  • 149.
  • 150. Instrumentation and control system P r o c e s s p o i n t o f v i e w
  • 151. Vessel instrumentation Level controller Radar Level Transmitter Radar Level Transmitter
  • 163. Level Control Settings • Level control positions give a degree of flexibility to separator design • Response times from control room or outside operation • Slugging volumes • Residence times LZA(HH) - High level trip 0.15m below inlet or 0.05D LA(H) - High level pre-alarm LA(L) - Low level pre-alarm LZA(LL) - Low level trip 0.1m below LZA(HH) or 60 sec flow for control room 5 mins for outside action 0.1m below LA(L) or 60 sec flow for control room 5 mins for outside action 0.36m below LA(H) or 2 - 4 mins of residence time and allow for slugging Oil Water Gas
  • 166.
  • 168. Liquid Levels Definition NLL Normal Liquid Level Liquid level maintained by controls during operation HLL High Liquid Level First liquid level above NLL to trigger an alarm HHLL High High Liquid Level Second liquid level above NLL to trigger a shutdown LLL Low Liquid Level First liquid level below NLL to trigger an alarm LLLL Low Low Liquid Level Second liquid level below NLL to trigger a shutdown Hold-up time (Residence Time) Time to fill separator from empty to NLL at design liquid feed rate. Surge Time Time to fill separator from NLL to HLL at design liquid feed rate.
  • 169.
  • 170. 170
  • 171. Safety Devices in Separator • PSHH (Pressure Swich High High) • PSLL (Pressure Swich Low Low) • LSHH (Level Swich High High) • LSLL (Level Swich Low Low) • BDV (Blowdown Valve) • PSV (Pressure Safety Valve) • SDV (Shut Down Valve)
  • 172. Since vertical separators are supported only by the bottom skirt (Figure 3.16), the walls of vertical separators must be somewhat thicker than a similarly sized and rated horizontal separator, which may be supported by saddles. Comparison of vertical and horizontal support structures
  • 174.
  • 175. 1. Normal Operating Pressure at which equipment operates 1. Maximum operating Highest operating pressure foreseen for all applicable cases (normal, turndown, startup shutdown). 1. Design Pressure Maximum operating pressure plus a safety margin Process Design Considerations Pressure Nomenclature
  • 176. Maximum Operating Pressure, psig Design Pressure, psig Less than 25 50 25 to 250 Oper P + 25 250 to 1000 (Oper P) * (1.1) More than 1000 (Oper P) * (1.05) (*) (*) Applicable only if pilot operated relief valves are used, otherwise use a 10 percent margin Process Design Conditions Determine Design Pressure
  • 177. Sizes and Capacities : • Liquid levels • Maximum oil level : < 0.65 I.D. • Normal oil level : 0.5 I.D. or 1 min. retention time between max. and normal liq. Level • Low oil level : 0.1 I.D. or 12” from bottom • Water/ inter face level : Water retention time of 1-2 min. or 12” which ever is greater Sizes and Capacities :
  • 178. Level Control Settings • Level control positions give a degree of flexibility to separator design • Response times from control room or outside operation • Slugging volumes • Residence times LZA(HH) - High level trip 0.15m below inlet or 0.05D LA(H) - High level pre-alarm LA(L) - Low level pre-alarm LZA(LL) - Low level trip 0.1m below LZA(HH) or 60 sec flow for control room 5 mins for outside action 0.1m below LA(L) or 60 sec flow for control room 5 mins for outside action 0.36m below LA(H) or 2 - 4 mins of residence time and allow for slugging Oil Water Gas