Production and Test Separators

Principles of separation
There are two necessary factors for separators to function which are:
1) The fluids to be separated must be insoluble in each other.
2) One fluid must be lighter than the other.
Separators depend on the effects of gravity to separate fluids. If they are
soluble in each other, no separation is possible with gravity alone.
In the process of separating gas from liquid, we actually have two
separation stages:
1) Separate liquid mist from gas.
2) Separate foamy gas from liquid.

Basic considerations
Separators are mechanical devices used for removing and collecting
liquids from natural gas or gas stream.
A properly designed separator will also provide the release of entrained
gases from the accumulated hydrocarbon liquids.
The objective of ideal separator selection design is to separate the
hydrocarbon stream into, liquid free of gas, and gas free of liquid.
Ideally, gas and liquid reach a state of equilibrium at the existing
conditions of pressure and temperature within the vessel.

Factors affecting separation

Fluids stream composition, operating pressure, and operating temperature
are the factors controlling separation.
Changes of any of them will change the amount of gas and liquid leaving
the separator.

Production and Test Separators

1.2 Classification of Separators:

Separators are Classified According to:
1) The configuration of the separator.
2) The number of fluids to be separated.
1.2.1 Separator Configuration:
It is manufactured in three basic types:
a. Horizontal type.
b. Vertical type
c. Spherical type
Each configuration has specific advantages and the selection is based on which will
accomplish the desired results at the lowest cost.

Horizontal Separators
This type of vessel has a large interface area between liquid and gas, therefore results
in more separation. When the gas capacity is a design criterion, the horizontal vessel
is more economical in highpressure separation. However liquid level control is more
critical than that of vertical separator.

Vertical Separators
This type of vessel is capable of handling larger slugs of liquid without carrying over
to gas outlet. In this configuration, the action of level control is not critical. Due to
greater distance between liquid level and gas outlet, there are less tendencies to
evaporate. This type is most often used with fluid streams having more liquid than
gas. The vertical separator is more difficult and expensive to fabricate than a
horizontal separator.

Production and Test Separators

Spherical Separators
This type of vessel is cheap and compact. It has a limited surge space and liquid
settling section.
The placement of liquid level control is very critical in this type. This type of
separators are not popular today because of their limitations.

1.2.2 Classification According to the Number of Fluids to be

Separated
If the fluid stream inside the separator is separated into two fluids (gas and oil), the
separator is two phase.
If the fluid stream inside the separator is separated into three fluids (gas, oil, and
water), the separator is three phase separator.
Some well streams contain sand and other solid particles, which are removed in the
separator. Special internal devices are provided to collect and dispose of the solid
materials. See Fig. 7. Solids are not considered as a phase of fluid in the
classification of separators.

1.3 Flow Patterns

1- Two Phase Separator
Flow patterns in horizontal or vertical separators are the same. The crude oil stream
enters to the separator, the lighter fluid (gas) passes out to the top, and the heavier
fluid (oil) drops out to the bottom.

Production and Test Separators

Figure 1 Two Phase Horizontal Separator

Figure 2 Three Phase Horizontal Separator with Weir

Production and Test Separators

Figure 3 Three Phase Horizontal Separator with Bucket

Figure 4 Two Phase Vertical Separator

Production and Test Separators

Figure 5 Three Phase Vertical Separator

Production and Test Separators

Figure 6 Two Phase Vertical Centrifugal Separator

Production and Test Separators

Figure 7 Three Phase Vertical Separator with Sand Cone

2- Three Phase Separator
These type of separators are shown in fig. 2, 3, 5, 7.
In Horizontal separator, liquid flow is shown in fig. 2, 3.
In fig 2, oil and water settle down to the bottom in the left side of weir. Oil floats on
water and spills to the right side over the weir into oil chamber.
Oil is withdrawn using level controller.
Water at the left side of the weir is withdrawn using level controller.
The float of a level controller has a problem due to emulsion at the water oil interface.

Production and Test Separators

Fig. 3 shows the flow pattern with no interface.
withdrawn using a level controller.

Oil spills in the bucket are

Water flows along the bottom of separator, where using a level controller.
Flow in the centrifugal separator Fig. 6 is somewhat different than that in the
conventional type.
The centrifugal separator is vertical and depends on centrifugal action for separation
of fluids. The inlet stream is forced to flow around the wall of the separator in a
swirling motion. The liquid reaches the outside wall and drops down to the bottom.
Gas collects in the middle of the separator and flows up to the outlet pipe.

1.4 Separator Internals

Production equipment involving the separation of oil and gas usually have a wide
variety of mechanical devices that should be present in some of all separators,
regardless of the overall shape or configuration of the vessel. These mechanical
devices improve the separators efficiency and simplify its operation. The most
commonly used devices are:

Inlet configuration
Intermediate configuration
Outlet configuration

1.4.1 Inlet Configurations

In horizontal separators the internal configuration can take many shapes as shown in
the Figures ( 8 and 9). The most commonly used are:
-

Structural channel iron

Angle iron
Flat plates
Dished heads
Schopentoeter

The latter three shapes have been considered optimum for certain
applications. These shapes are used in gas liquid separators in front of
the inlet nozzle of the vessel, which serve two purposes:
1. To aid in the separation of entrained gas from the liquid.
2. To divert the fluid flow downstream.

Production and Test Separators

In vertical separators, there is a centrifugal inlet device, it causes the primary
separation of the liquid and gas to take place. Here, the incoming stream is subject to
a centrifugal force as much as 500 times the force of gravity. This action stops the
horizontal motion of the liquid droplets together, where they will fall to the bottom in
the settling section.

Figure 8 Inlet Momentum Absorber Designs (All Views

Taken In Plan)

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Production and Test Separators

Schoepentoeter
The Schoepentoeter (vane-type) is a Shell-proprietary inlet device and is commonly
used for introducing gas/ liquid mixtures into a vessel or column
It is used to absorb the initial momentum as the well fluid enters the separator. It tends
to deflect the direction of flow causing gas to rise and free liquid to drop that the flow
encounters. A drop in velocity as well as reduction in pressure.
Figure 9 shows schematically the typical outline of a Schoepentoter in a vertical
vessel together with its design parameters (for simplicity not all the vanes are shown).
The geometry of the Schoepentoter is largely standardised so that the choice of
dimensions to be made by the designer is limited to the following:

The number of vanes per side nv.

The vane angle, a which is 8 degrees o less.

The length of the straight part of the vanes, Lv , which shall be 75,
100, 150 or 200 mm. The choice of Lv is also used to fix the vane
spacing.

The radius of the vanes, Rv, which shall be 50 or 100 mm.

With a Schoepentoeter, it is normal to specify a protruded nozzle, although this is not

essential.

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Production and Test Separators

a
B.
D.
d1.
E
Lv
nv
Rv
t

= vane angle, angle made by straight part of vanes with centre line.
= edge angle, angle made by edge of the row of vanes with centre line.
= vessel inside diameter, mm.
= inlet nozzle inner diameter, mm.
= available space, mm.
= length of straight part of vanes (normally 75, 100, 150 or 200 mm)
= number of vanes per side.
= vane radius, mm (normally 50 or 100 mm)
= vane material thickness, mm (normally 3 mm, but typically 5 mm for heavy
duty, e.g slugs)
W1/0 = width of vane entrance opening, mm.

Figure 9 Schematic Outline of the Schoepentoeter

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Production and Test Separators

1.4.2 Intermediate Configuration
The most commonly used of these intermediate devices are:

Coalescing plates
Straightening vanes
Weir
Horizontal baffles

These are commonly used in gravity separation sections and are as follows:

- Coalescing plates
Several configurations are available. They are used in gas-liquid vessels to remove
liquid from the gas and is not used where hydrate or paraffins are present.
- Straightening vanes
These are used to separate liquid mist from gas and used where hydrate or paraffins
are present. They are used when hydrate or paraffins prevent the use of pads.

- Weir
As illustrated in figures, it is a dam-like structure, which is controlling the liquid
level and keeps it at a given level. Maybe one or two weirs are used in one
separator, where one maintains the oil level and the other the water level.

- Horizontal Baffles
These are used in large gas liquid separators to prevent waves in the liquid phase.
1.4.3 Outlet Configuration
These mechanical outlet devices are sometimes used in horizontal and vertical
separators, and the most commonly used are the following.
- Mist pad or extractor (Figure 10 and 11)

Most frequently used in gas - liquid separators and normally

located near the gas outlet that will coalesce small particles (mist)
of liquid that will not settle out by gravity. It breaks oil-water
emulsion to help in segregating the two liquids. Not used where
hydrate or paraffin may be present. The stainless steel woven wire
mesh mist-eliminator of thickness 10 20 cm (4-8 inch) is
considered to be the most efficient type.

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Production and Test Separators

It is held in place by a sturdy grid which prevents it from being swept out or torn by a
sudden surge of gas, and has been proven by removing up to 99.5% or ore of the
entrained liquids from the gas stream.
This type offers the greatest area for the collection of liquid droplets per unit volume
as compared to vane type.

Figure 10 Types of Mist Extractors

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Production and Test Separators

Figure 11 Mist Extractors in Varius Types Vessels

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Production and Test Separators

- Vane Type (Figure 12)
It consists of a labyrinth formed with parallel metal sheets with suitable liquid
collection pockets.
The gas passing between plates is agitated and has to change direction a number of
times. Vane type mist eliminators have their applications in areas where there are
entrained solid materials in the gas phase.

Figure 12 Demister Types

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Production and Test Separators

- Vortex Breakers
The liquid outlet should be equipped with anti-vortex devices to prevent a vortex from
forming, and gas from going out with the liquid. Several types are shown in the
figure.

Figure 13 Outlet Vortex Breaker

The designation of high or low gas-oil ratio is rather arbitrary. The following are
specific instances in which high or low GOR's usually occur:
Low Gas-Oil Ratio

Oil wellstreams.
Flash tanks in dehydration.and sweetening plants.
Fractionator reflux accumulators.

High Gas-Oil Ratio

Gas wellstreams.
Gas pipeline scrubbers.
Compressor suction scrubbers
Fuel gas scrubbers.

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Production and Test Separators

The terms Flash Tank, Accumulator and Scrubber are commonly used for specific
applications of separators. The vessels are gas-liquid separators.

1.5 Inspection & Maintenance

Reasons for Inspection
General:
The basic reasons for inspection are to determine the physical condition of the vessel
and the type, rate, and cause of deterioration.
All data should be recorded.
With such data on hand:

Safety can be maintained

Continuity of operation can be enhanced
Rate of deterioration can be reduced
Future repair and / or replacement can be predicted.

Periodic scheduled maintenance and inspection can reveal conditions that

if not discovered and corrected may result in hazardous leak or vessel
failures and unscheduled shutdowns.
These unnecessary start ups and shutdowns of equipment tend to be more hazard than
routine operation.
Periodic inspection can lead to wellplanned maintenance.
Corrosion rates and remaining corrosion allowance determined by such inspection are
the normal basis for predicting replacement or repair.
These predictions provide the orderly planned maintenance and continuity of
operation.

Causes of Vessel Deterioration

Corrosion
Erosion
Metallurgical and physical changes
Excessive mechanical forces.

Mechanical forces can cause a vessel to fail or to operate inefficiently.

Mechanical Forces Such as:

Thermal shock
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Production and Test Separators

Cyclic temperature changes

Vibration
Excessive pressure surge
External loads
-

Thermal shock is caused by a sudden change in temperature (either

from cold to hot or from hot to cold). The stresses resulting from the
sudden unequal expansion or contraction of the different parts of a
vessel may cause distortion to these parts.

Cyclic temperature changes may cause cracks as a result of thermal

fatigue. Thermal fatigue is often found at locations where metals of
different expansion coefficients are welded together.

Vibration forces may be transmitted to vessels through piping systems.

These forces may cause undue loads on nozzles, internal piping, and
vessel walls.

Pressure surge due to the failure of relief valves to open promptly at

the set pressure may result in internal pressures exceeding the
maximum allowable working pressure. This condition may cause
damage to the internals or bulging of the vessel walls.

Excessive temperature in excess of the design limits during operation

of the vessel (even without high pressure) may cause bulging of vessel
walls.

Methods of Inspection
External Inspection
External inspection can be carried out visually, and using nondestructive testing
methods while vessel is in service.
External inspection of pressure vessels should start with ladders, stairways, platforms,
or walkways connected to or bearing on them.
A careful visual inspection should be made for corroded or broken parts, cracks,
tightness of bolts, condition of paint and wear of external parts.
Foundation and supports should be inspected carefully for any deterioration as
spalling, cracking, and settling.

Internal Inspection
Internal inspection carried out on vessels in out of service conditions. The vessel
should be isolated completely, cleaned, freed of gases, and prepared for internal
inspection.
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Production and Test Separators

All internals should be inspected carefully to detect any damaged or deteriorated
parts.
Vessel wall should be inspected ultrasonically, metallic lining should be inspected
carefully using dye penetrant test.
Non metallic lining should be inspected using holiday detector.
Fig. 14 shows measurements of a vessel.

Bracket

Figure 14 Method of Obtaining Vessel Profile Measurements

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Production and Test Separators

Tools for Inspection of Vessels

-

Portable lights (including a flash light)

Thinbladed knife
Chisel or scraper (to remove scales)
Hammer
Inside calipers and outside calipers.
Tape measuring tape
CRT ultrasonic flow detector
Thickness gauge
Pit depth gauge
Paint or crayon
Straightedge
Wire brush
Magnet
Spirit level
Magneticparticle inspection equipment
Dyepenetrant inspection equipment
Temperatureindicating crayons
Radiographic equipment
Micrometer
Meger ground tester
Magnifying glass
Sandblasting equipment
Metal samplecutting equipment
Portable hardness tester
Camera

Methods of Repair and Maintenance

Before any repairs are made to a vessel, the application code and standards under
which it is to be rated should be studied to ascertain that the method of repair will not
violate the rules.
Most repairs on the shell and heads of a vessel are made to maintain the strength and
safety of the vessel and will therefore require reinspection.
In case of replacement a section of shell plates, the calculated joint efficiency of the
patch should be equal or greater than the calculated efficiency of the original joints in
the shell.

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Production and Test Separators

Heater Treaters

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Production and Test Separators

Heater Treaters
The function of the heater treater is to provide further gas separation, free water
removal and coalescence of entrained water particles to ensure that the crude oil
produced meets pipeline specifications of 0.5% BS&W maximum.
The heater treater consists of the following:
1. Degassing Vessel, which is a two phase separator mounted on top of the main
body of the heater treater.
2. The main body of the Heater Treater, which is divided into three sections:
a. Heating Section. The fire tubes for heating the oil are situated in this section.
This is also where initial separation of free water and oil takes place.
b. Oil Chamber. The oil chamber separates the inlet section from the coalescing
section. It is separated from the inlet section by a weir and also contains the
inlet to the metered orifice distributors which control the flow into the
coalescing section.
c. Coalescing Section. High voltage positive (+) and negative (-) electrodes are
fitted in the coalescing section. Two externally mounted high voltage
transformers provide power to these electrodes.
Pressure and incoming liquid level in the degassing vessel are controlled by:
a. A pressure valve located in the gas discharge to the flare header.
b. A level valve in the clean oil discharge to the crude oil coolers.
The pressure and level controllers work together to maintain a constant level in the
degassing vessel.
A rise in liquid level will increase the pressure in the degassing vessel causing the
pressure valve to open releasing excess pressure to the flare header. The level valve
will also open further to allow more clean oil to be discharged. A falling liquid level
will cause the level valve to close restricting the flow of oil to the coolers.

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Figure 1 Heater Treater Cross Section

Production and Test Separators

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Production and Test Separators

The heating section free water and the coalescing section treated water levels are
maintained by level valves located in the water discharge to the produced water
disposal system.
These level valves are operated according to the interface level of oil on water. As the
level of free or treated water rises the interface controller initiates a signal to open the
level valves. The movement of the valves is proportional to the strength of the signal.
A flow element is fitted in the gas discharge to the flare header. This connects to a
two pen circular flow and pressure chart recorder.
The heater treater is protected from overpressure by a pressure safety valve.
Spectacle blinds are used to positively isolate the vessel.
Drain valves are fitted to allow draining of the heating oil chamber and coalescing
sections of the heater treater. The drains are connected to the closed drain system.
An emergency shutdown will be initiated by a high high pressure or high high level
condition in the degassing vessel.
A low low liquid level in the heating section of the heater treater will cause the inlet
flow valve to shut.
The burner control panel is also fitted with system shutdowns which will be detailed
later in this section.
Alarms and shutdowns will be annunciated at the local shutdown panel and at the
control room annunciator panel.

Firetube Heater
The purpose of the firetube heater is to raise the oil temperature to the dehydration
temperature. This will cause additional gas to be released and aid in the coalescing
process.
The firetubes of the heater treater are heated by dual gas burners supplied from the
fuel gas system.

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Figure 2 Heater Treater (V 206, V 207, V 301, V 401).

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Figure 3.3 Heater Treater Process Flow

Figure .4 Heater Treater Fuel Gas System

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