Production Engineering II

Separation Process

Potential Operational Problems

The following are the potential operating problems which
can apply to two-phase and three-phase separators
(i) Foamy Crude
(ii) Paraffin
(iii) Sand
(iv) Liquid Carryover
(v) Gas Bolwby
(vi) Liquid Slugs

Potential Operational Problems

i.

Foamy Crude
Foam is caused by the impurities in the crude oil which is impractical to
remove before the stream reaches the separator.
Foaming in a separator results in :
Aggravated Mechanical control of liquid level because the control
device must deal with essentially three phases instead of two.
Reduced space for liquid collection or gravity settling as foam has a
large volume-to-weight ratio (it occupies a large amount of the vessel
space)
Difficulties in removing separated gas or degassed oil from the vessel
without entraining some of the foamy material in either the liquid or gas
outlets.

Potential Operational Problems

Foaming tendencies of an incoming stream can be determined via laboratory
tests.
Foaming cannot be predicted ahead of time without laboratory tests.
By comparing the foaming tendencies of a known oil to a new one, the
operational problems which may be expected with the new oil can be analyzed.
Foaming can be expected where CO2 is present, even in small quantities. (one
percent to two percent).
The amount of foam is dependent on :
(i) Pressure drop to which the inlet liquid is subjected.
(ii) Characteristics of the liquid at the separator conditions.

Potential Operational Problems

Changing the temperature at which a foamy oil is separated has two effects on
the foam.
a) Change is viscosity
b) Change in oil-gas equilibrium
It is difficult to predict the effects of temperature on foaming tendencies, but
some general trends can be identified.
) For heavy oils with a low GOR, an increase in temperature will typically
decrease foaming tendencies.
) Similarly, for light oils with a high GOR, temperature increases typically
decrease foaming tendencies.
) However, for light oils with a low GOR, a temperature increase may
increase foaming tendencies. (because its rich in intermediated which
have tendency to evolve to the gas phase as temperature is increased)

Potential Operational Problems

Foam-depressant chemicals can be utilized to increase the capacity of a given
separator.
In sizing a separator to handle a specific crude, the use of an effective
depressant may not be of the same type as characteristics of the crude and of
the foam may change during the life of the field.
The cost of foam depressants for high-rate production may not be cost
economical.
During the design phase, sufficient capacity should be provided in the separator
to handle the anticipated production without use of a foam depressant or
inhibitor.
Once the foam depressants are used in the operation, it may allow more
throughput than the design capacity.

Potential Operational Problems

ii. Paraffin
The accumulation of paraffin in the separator can adversely affects its
operation.
Coalescing plates in the liquid section and mesh-pad mist extractors in the
gas section are particularly prone to plugging by accumulations of paraffin.
Vane-type or centrifugal mist extractors should be used in events where it is
determined that paraffin is an actual or potential problem.
Manways, handholes and nozzles should be provided to allow steam,
solvent or other types of cleaning of the separator internals.

Potential Operational Problems

iii. Sand
Sand causes cutout of valve trim, plugging of separator internals and
accumulation in the bottom of the separator.
Accumulations of sand can be minimized by periodically injecting
water/steam in the bottom of the vessel to suspend the sand during
draining.
Plugging of the separator internals is a problem that must be considered
during the design stages of the separator.
A design that will promote good separation and have minimum traps for
sand accumulation may be difficult to attain.
This is because the design that provides the best mechanism for separating
the gas, oil, and water phases probably will also provide areas for sand
accumulation.

Potential Operational Problems

iv. Liquid Carryover
Occurs when free liquid escapes the gas phase which results in :

Indication of high liquid level

Damage to vessel internals
Foam
Plugged liquid outlets
Flowrates which exceeds the vessels design rate

Can usually be prevented by installing a level safety high (LSH) sensor that
shuts in the inlet flow to the separator when liquid level exceeds the normal
maximum liquid level by 10-15% (usually).

Potential Operational Problems

v. Gas Blowby
)Gas Blowby occurs when free gas escapes with the liquid phase which can be an
indication of :
Low liquid level
Vortexing
Level control failure
)If there is a level control failure and the level dump valve is open, the gas will exit
the liquid line and will have to be handled by the next equipment in the process.
)Unless the next equipment is designed for gas blowby conditions, it can be over
pressured.
)Can be prevented by installing a level safety sensor (LSL) tat shuts the inflow when
the liquid level drops 10-15% below the lowest operating level.
)Downstream equipment should be equipped with PSH sensor/ PSVs sized for gas
blowby

Potential Operational Problems

vi. Liquid Slugs
)Two phase flow lines tend to accumulate liquids in low spots in the lines.
)When the level of liquid in these low spots rises high enough to block the gas
flow then the gas will push the liquid along the line as a slug.
)Depending on the flow rates, flow properties, length and diameter of the flow
line, and the elevation change involved, these liquid slugs may contain large
liquid volumes.
)Situations in which liquid slugs may occur should be identified prior to the
design of a separator.
)The normal operating level and the high-level shutdown on the vessel must be
spaced far enough apart to accommodate the anticipated slug volume.

Potential Operational Problems

If sufficient vessel volume is not provided, then the liquid slugs will trip the highlevel shutdown.
The location of the high-level set point may be established to provide the slug
volume between the normal level and the high level.
The separator size must then be checked to ensure that sufficient gas capacity
is provided even when the liquid is at the high-level set point.
This check of gas capacity is particularly important for horizontal separators
because, as the liquid level rises, the gas capacity is decreased.
For vertical separators, sizing is easier as sufficient height for the slug volume
may be added to the vessel seam-to-seam length.

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2013 INSTITUTE OF TECHNOLOGY PETRONAS SDN BHD
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