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SECTION 3

THREE-PHASE SEPARATION

1 Introduction
1.1 Separator Types
2 Flow Patterns
3 Separator Internals
4 Principles of Separation
5 The Separation Process
5.1 Inlet Separation
6 Separation Systems
6.1 Production Separators
7 Separator Instrumentation
8 Separator Control
8.1 Pressure Control
8.2 Level Control
9 Process Shutdowns
9.1 Planned Shutdown
9.2 Startup Procedure
9.3 Startup After Emergency or Short-term Shutdown
10 High Pressure Relief Valves

Figures

3.1 Three-phase Horizontal Separator

3.2 Vertical Separator Internals
3.3 Three-phase Separator Internals
3.4 The Separation System
3.5 Production Train Separator and Instrumentation
3.6 Separator Pressure Control

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1 INTRODUCTION

A separator is a vessel in which a mixture of fluids, that are not soluble in

each other, can be segregated.

On offshore installations, separators are used to segregate gas from liquid,

or one liquid from another such as water from oil.

1.1 Separator Types

Separators are classified in two ways:

By the position or shape of the vessel

By the number of fluids to be segregated

The following two vessel shapes are commonly used:

Horizontal - as shown in Figure 3.1

Vertical as shown in Figure 3.2

The number of phases refer to the number of streams that leave the vessel,
not the number of phases that are in the inlet stream.

For separation of gas and liquid, the separator is referred to as a two-phase

type.

For separation of gas, oil and water, the separator is referred to as a three-
phase type.

Some wellstreams contain sand or other solid particles which are also
removed in a separator. To achieve this, special internal devices are
provided in order to collect and dispose of these solid materials such as
sand, hence the term sandwashing of the separators.

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2 FLOW PATTERNS

The flow in both horizontal and vertical separators is similar for two-phase
separators whereby the mixture enters at the side or end of the vessel, the
lighter fluid (usually gas) passes out at the top, and the heavier fluid is
withdrawn at the bottom.

Flow in a three-phase separator is shown in Figure 3.1; the fluid entering at

one end of the vessel and the liquids being allowed to settle out at the left-
hand side of the vessel.

The oil layer floats on top of the water layer and spills over the weir into
the oil chamber, where it is withdrawn under level control.

The water layer remains on the left-hand side of the weir and is withdrawn
under separate level control.

Problems can, and do, arise with the interface level control between the oil
and water layers usually due to an emulsion of oil and water at the
interface. This type of problem can normally be overcome by using
demulsifying agents, chemicals that break down emulsions, in order to give
cleaner separation of the fluids.

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3 SEPARATOR INTERNALS

A wide variety of mechanical devices are used inside separators in order to

improve their efficiency and operation (refer to Figure 3.3). Those most
commonly used are as follows:

(1) Deflector Plates or Diverters

A deflector plate is used in gas-liquid separators and placed in front of
the inlet nozzle of the vessel.
The plate can be flat or dished, and as the inlet stream strikes it, the
liquid falls to the bottom and the gas flows around the plate.
In a vertical type vessel, the deflector may divert the stream around
the walls of the vessel in order to create a centrifugal action.

(2) Mist Pads

Mist pads are most frequently used within gas-liquid separators to
remove the vapour mist from the gas.
The pad is made of closely woven wire mesh and is typically 4 to 8in
thick. It is held in place by a sturdy grid frame which prevents it from
being swept out or torn by a sudden surge of gas flow.

(3) Coalescing Plates

There are several configurations of coalescing plates and they are
available from different vendors.
They are used in gas-liquid vessels to remove liquid from the gas by
causing small droplets to combine into larger drops which will
separate more readily.

(4) Straightening Vanes

Typical of those used on Shell installations is the Schoepentoeterl
type. These allow the use of smaller vessels, which are just as
efficient as the larger vessels with longer residence times.
Straightening vanes are installed to reduce turbulence.
They are also used in gas-liquid separation vessels and installed when
hydrate formation or paraffins would prevent the use of mist pads due
to blocking etc.

(5) Filter Elements

Filters are used to remove mist from the gas in oil-water vessels. The
separator usually contains an access hatch in order to allow
replacement of the elements.

(6) Centrifugal Devices

These are used in gas-liquid separators. They impart a swirling action
to the inlet stream that concentrates the flow of the liquid phase onto
the wall of the device.

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(7) Horizontal Baffles

These are used in gas-liquid separators in order to prevent waves
forming within the liquid phase. They are normally located near to the
liquid level in the vessel.

(8) Vortex Breakers

It is normally a good idea to include a simple vortex breaker or liquid
draw-off nozzles in order to prevent a vortex from forming, which
could result in some gas being drawn out through the liquid line.

(9) Water Jets

Water jets are sometimes referred to as sand jets. Their purpose is to
spray the sides and bottom of the vessel with a high pressure stream
of water in order to remove sand and other solid particles from the
walls and base of the vessel.

4 PRINCIPLES OF SEPARATION

Two factors are necessary for separators to function properly:

(1) The fluids that are to be separated must be insoluble with each other ie
they will not dissolve with each other.

(2) The fluids must not be of the same mass, ie they must be different
in density.

Separators depend upon the effect of gravity to segregate the fluids, if the
fluids are soluble in each other, no separation is possible by gravity alone.

For example, a mixture of distillate and crude oil will not separate in a
vessel because they will dissolve together. They must therefore be
segregated in a distillation process.

Since a separator depends upon gravity to separate the fluids, the ease with
which two fluids can be segregated depends upon the difference in the
density or weight per unit volume of the fluids.

Gas weighs far less than oil for the same volume, and will therefore
separate within a matter of seconds.

However, although oil is lighter than water, there is not such a marked
difference in weight and separation of oil and water can take several
minutes. (A typical specific gravity for oil is 0.84, which means that a given
volume of oil would weigh 84% as much as the same as water.)

Therefore the primary factor that affects separation of fluids is that of the
difference between their densities.

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5 THE SEPARATION PROCESS

The separation of oil, gas and water from each other is largely achieved by
one or both of the following:

Physical separation
Flash separation

Physical separation of liquids, solids and gases can be achieved naturally in

a number of ways including:

Settling of solids and layering of liquids through differences in densities

Coalescence
Filtration
Velocity changes
Centrifugal forces
Impingement

Flash separation of gas and water vapour from the liquid phase is achieved
when the well fluids mixture is discharged into a vessel at:

A reduced pressure
A higher temperature
With an enlarged volume

The effect of all of these processes can be optimised by ensuring that:

The equipment design incorporates features to make use of as many as

possible of the above separation processes
The separation equipment has been sized to accommodate the peak
anticipated flowrates
Sufficient time is allowed for the separation process to take place
efficiently

A three-phase separator is illustrated in Figure 3.3. The upper section of the

vessel is designed to separate gas from the liquid, while the lower section is
designed to collect and degas the oil, and to separate oil and water by
gravity separation, so that the three phases can be discharged from the
vessel separately, each in a relatively clean state; it should be appreciated
however that a three-phase separator will seldom produce water-clean oil
and oil-free water.

Normally efficient separation of the oil, gas and water is achieved in a

series of stages:

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5.1 Inlet Separation

The bulk of the liquid-gas separation takes place in this section.

The well fluid entering the vessel is subjected to a rapid and sudden change
of direction and velocity, when it strikes an inlet momentum breaker or
diverter plate.

This redirects the mixture back against the dished end of the vessel which
helps to minimise splatter and prevent the production of a mist of small
particles. With the reduced operating pressure and enlarged space
available, this results in the liberation of flash gas and an oil mist which
rise, while the heavier slugs and large droplets of liquid fall to the bottom
of the tank.

6 SEPARATION SYSTEMS

Separators are located downstream of the wellhead xmas tree, choke and
production/test manifolds and provide the following functions:

Clean-up/test separation
Test separation
Production separation (bulk)

Clean-up/test separators are used in the initial stages of well production

when the flow of oil is likely to be contaminated with mud and sand. Test
separators are used to test the flow of individual wells and are
instrumented to measure flow of oil, water and gas. Production separators
form an integral part of the production train.

As the capacity of a separator is limited, it may be necessary to have a

number of separators to handle the well fluid flow. Also it will be seen that
the most effective form of separation may be in stages so there could be
two, three or even four separators in series; each of these groups of
separators is known as a train.

6.1 Production Separators

Most platforms in the North Sea produce water in varying quantities which
are expressed as a percentage of the liquid to storage. This water
percentage is called the water cut and if a platform is producing oil into
storage with a water cut of 13% then there is 87% oil going into storage.

On gravity platforms, that is, platforms with subsea storage facilities, the
water flows through the train into the storage cells where the water settles
out leaving dry oil to be exported. Provided the separators are not
overloaded and the design throughput of the process train can be
maintained, this is the better mode of operation. However, circumstances
can dictate that three-phase separation is required.

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Figure 3.1 shows a simplified sketch of a typical three-phase separator. The

difference between two and three-phase separators is that on the three-
phase separator:

A weir is fitted
An additional level indicating controller (LIC) and level control valve
(LCV) are fitted

The weir forms a dam which creates a section where the water can separate
out of the oil. The water falls to the bottom of the separator with the drier
oil on top which flows over the top of the weir into the oil section. In this
example the oil level is controlled by the LIC-2 and its associated LCV.

On the upstream side of the weir LIC-1 and its LCV are controlling the level
of the water. The controller is often at the interface level where the oil and
water meet. The interface is not a clear division of oil and water but an
emulsion of the two. Emulsion is one of the main problem areas of three-
phase control in that it makes interface level control difficult.

Two sightglasses are fitted to a three-phase separator; one to show the

interface level and the other the oil level. An example of an oil level gauge
or sightglass is shown in Figure 3.3.

7 SEPARATOR INSTRUMENTATION

Within the limits of design and construction all separators have the same
basic instruments and controls as follows:

(1) Pressure Indicator (PI)

Monitors the pressure in the separator with readout both locally and
remotely, the remote readout being transmitted to a central location
such as the Central control room (CCR) or local equipment room
(LER).

(2) Temperature Indicator (TI)

Monitors the separator temperature, again indicated both locally and
remotely.

(3) Pressure Safety Valve (PSV)

Relief valves are installed on each separator, one in service and the
other isolated. The relieving pressure is set, tested and certified at
an authorised centre. No alteration to this setting is allowed after
the relief valve has been certified.

(4) Manual Blowdown Line

This gives the facility to manually depressurise the separator, the gas
being routed to the flare system.

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(5) Gas Outlet Line

This is split into two streams - the gas to the recompression and
treating section and the gas to flare.

(6) Pressure Indicating Controller (PIC) and PCV

These two instruments control the separator pressure. The PIC
monitors and modulates the PCV as required.

(7) Gas Off-take Flowmeter

This measures the volume of gas flowing from the separator in both
flare or recompression mode. Generally this flow is a remote readout
in the control room on both indicator and recorder.

(8) Level Indicating Controller and Level Control Valve

The LIC monitors the level and modulates the LCV to control the
level at the setpoint. This is another instrument which gives local
and remote readout in the control room.

(9) Oil Outlet Line

This line, which has the LCV in it, leads the oil to the next link in the
process train which could be a lower stage of separation, storage or
transfer pumps.

(10) Drains
This gives the facility to manually drain down the separator through
the closed drain system.

A typical production two-phase crude oil separator is shown in Figure 3.5.

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8 SEPARATOR CONTROL

All separators are fitted with the following protection facilities:

Low level alarm

Low level shutdown

High level alarm

High level shutdown

High pressure alarm

High pressure shutdown

High pressure relief valves

In order to give added safety by preventing gas blowby between

separators, a shut off valve is fitted to the pipework connecting the
vessels. This valve is designed to close on a Low Low level being
detected in the upstream vessel, or a high pressure being detected
in the downstream vessel.

Should either/both of these conditions be detected, then excessive pressure

from an upstream vessel will not be communicated to a lower pressure
rated vessel.

Where crude cooling is installed prior to the final-stage separator this can
be fitted with:

High temperature alarm

High temperature shutdown

High integrity protection system (HIPS) - this provides an alternative

(electronic) means of shutdown as a backup to the high level
shutdown systems on the separators

Regardless of what function is being monitored the sequence for alarm and
shutdown is the same. The first notice is the alarm allowing the operator to
take corrective action.

If no corrective action is taken or the action is ineffective further

deterioration occurs and a shutdown results. All level, pressure or
temperature shutdowns normally result in the closure of all of the producing
wells' upper master gate (surface safety valves) and flow wing valves.

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8.1 Pressure Control

When the gas recompression and treating facilities are operating, the gas
from the separators flows directly to them; separator pressure being
controlled by the backpressure in the downstream gas plant. Figure 3.6 is a
diagram of a four-stage separation system and shows typical operating
pressures at each stage.

Separator pressure control varies depending on the operating mode but the
first-stage separator will always be gas stream flow pressure. Pressure in
the other separators is designed for stable operation of the gas compressors
which compress gas from the second, third and fourth-stage separators.

The PICs on each separator will be set slightly above the pressure the gas
plant is holding on them. If the gas plant fails to take all of the gas from one
or more of the separators, the pressure in those vessels will start to rise. As
soon as it reaches the pressure setpoint the controller opens the PCV to
route the excess gas to the flare.

8.2 Level Control

The control of the oil level in the separator is the same regardless of
whether gas is being recompressed or flared. Each separator has a level
control system which regulates the position of a control valve in the oil
outlet line. If the level rises, the controller opens the control valve;
conversely, the valve closes when the level falls.

9 PROCESS SHUTDOWNS

During startup and shutdown, equipment and pipework are subject to

additional stresses and strains from expansion and contraction. Where
possible, action to prevent an emergency shutdown, for example, cutting
back production to avoid high level trip, is good operating practice. A
shutdown may still be required to cure the fault but it can be planned, as
can the remedial action, so minimising the shutdown time.

9.1 Planned Shutdown

Where a shutdown is planned it should be carried out in a manner which

creates the least disturbance and shocks to the process and also to the
reservoir. Wells should be closed in slowly using the chokes prior to closing
their surface safety valve (SSV).

The reason for shutting down will determine whether the train can be left
pressurised and undrained or if maintenance is to be done. In this case, the
separator train must be depressurised, drained and isolated.

All isolations must be logged to ensure the train is correctly deisolated prior
to startup.

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Prior to restart after an emergency shutdown, not only must the cause of
the shutdown be cured but also the fault which created the cause. For
example, a high pressure trip would require that the high pressure be bled
off and the fault which caused the high pressure cured before restarting.

9.2 Startup Procedure

Before any startup, pre-start checklists will be used by operations to ensure

that all systems are in a state of readiness.

These checklists will include the following:

All utilities, including hydrate inhibitor, chemical injection, flare

systems (HP and LP), closed drains and produced water, are to be
available at the battery limits

Pressure purging with nitrogen up to a pressure of 2 barg at the initial

startup or following maintenance work where the system is air filled
until an oxygen content of 3% is achieved

Locked and interlocked valves are in their normal operating position

Spectacle blinds and spades are in their normal startup position

In line block valves are in the correct position as per the valve position
schedule in the operating manual

All instrumentation is fully commissioned, checked and ready for

service

ESD systems are to be at process level startup status

Power generation and distribution are to be at normal status, with

switchgear racked-in and deisolated

Safety detection and protection systems are to be at normal status

Control valve handwheels are disengaged

At least one main oil line booster pump and one main oil line are
ready for startup

A series of operational checklists for verification of pre-startup

requirements will be available for each system and subsystem

The importance of good communications between all involved sections

must be of the highest quality at all times, particularly at this startup
NB stage.

Commence wellhead fluid flow into the first stage of separation from
the wellheads and manifold section

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Continuous visual checks for leaks are obviously most important at this
critical stage as pressure and temperatures increase to their normal
operating conditions

Separator off-gas will be flared initially. Flares should have been

nitrogen purged and pilots commissioned prior to initial flaring

Gas compression feed valve remains shut until the HP gas system is
brought into operation

When the interface level exceeds the low trip setting, reset the
shutdown valve to commence water treatment by routing produced
water to the water treatment facilities

When the oil level exceeds the low trip setting reset the shutdown
valve thus allowing oil to flow to the next stage of separation

As levels are established throughout the separation train the export

pumping facilities are brought on line and oil flow through the plant
stabilised

As soon as conditions are stable, chemical injections such as scale

inhibitor, corrosion inhibitor, demulsifier etc are commissioned

9.3 Startup After Emergency or Short-term Shutdown

Startup after emergency or short-term shutdown follows the same

procedure as startup after a prolonged shutdown, except for those items
not applicable. For example, after an emergency shutdown all manual block
valves will still be open. The fault which caused the shutdown must be
rectified prior to opening up the well SSV.

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Figure 3.1

Figure 3.2

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 Figure 3.3

1) Inlet Divertor
2) Vapour Mist Pad
3) Coalescing Plates
4) Straitening Vanes
5) Weir Plate
6) Gas Outlet
7) Vertical
8) Vortex Breaker
9) Sand Jetting Facility

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 Figure 3.4

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Figure 3.5

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Figure 3.6

Petrofac Training Services / June 2010