3 Phase Separator Process Description - Column Internals ® STRUCTURES PVT.LTD REG.OFFICE & WORKS: - J-25, S Block MIDC, Bhosari, Pune 411026 W-54,T Block MIDC, Bhosari,Pune 411026

FINEPAC ® STRUCTURES PVT.LTD REG.OFFICE & WORKS: - J-25, S Block MIDC, Bhosari, Pune 411026

W-54,T Block MIDC, Bhosari,Pune 411026

TELE No. :-( 020)66120661, 66120665, TELE FAX :-( 020)27119512 Email: - [email protected] ; [email protected]

• Structured Packings & Column Internals For Chemical Distillation • Industrial Fabrication in SS, Copper, Special Metals • Pusher Centrifuges for Solid-Liquid Separation • Random Packings & Trays (Bubble Cap, Valve) for Distillation • Static Mixers • Internals for Oil & Gas Industry

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3 Phase Separator Process Description

The purpose of the Separator is to divide the 3 phase inlet oil-water-gas stream into 3

separate phases. A gas phase free of liquid carry-over droplets, an oil phase free of gas

carry-under and water droplets, and a water phase free of gas carry-under and oil

droplets. Test Separator units usually provide metering of the gas, oil and water phases

to measure the production from individual wells.

The effectiveness of gas/liquid and liquid/liquid separation in Separators is a function of

many factors. Physical properties such as individual phase density and viscosity are

directly related to separation efficiency

Various design features and internal devices are employed to enhance, accelerate or

otherwise improve the efficiency of the separation process from knowledge of the above

factors.





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Inlet Devices

The Inlet Device has the purpose of dissipating the momentum of the incoming fluid,

aiding initial separation without increasing turbulence

The inlet stream entering through the inlet nozzle is smoothly divided into a number of

equal streams each of which is deflected through approximately 90o to create a

centrifugal gas/liquid separation effect. The streams then impinge against the vessel

walls and enter the bulk fluid phases to absorb the momentum.

Bi-Vane Inlet Distributor (Low inlet momentum device)

The inlet stream entering through the inlet nozzle is smoothly divided into two equal

streams each of which is deflected through 90o to create a centrifugal gas/liquid

separation effect. The streams then impinge against the vessel walls and enter the bulk

fluid phases to absorb the momentum. This may be a top or end entry design.

Vane Inlet Diffuser (Medium-High inlet momentum device)





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The inlet stream entering through the inlet nozzle is smoothly divided into a number of

equal streams each of which is deflected through approximately 90o to create a

centrifugal gas/liquid separation effect. The streams then impinge against the vessel

walls and enter the bulk fluid phases to absorb the momentum. This may be a top or end

entry design.

Cyclone Inlet Defoamer (High inlet momentum device for foam).

The inlet stream entering through the inlet nozzle is introduced tangentially into a

vertical cyclone tube to create a centrifugal gas/liquid separation effect. The liquid

stream impinges against the cyclone walls and falls, entering the bulk fluid phase via a

cross baffle to absorb the momentum. Gas exits the cyclone via a top exit. The CID is

also very effective as a foam eliminator. This is normally an end entry design.





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Inlet Distribution Baffles

Immediately after the inlet device the liquid passes through a distribution baffle which

may be a single or matched pair of transverse perforated plate baffles in the liquid zone.

Its primary purpose is to provide a barrier and distribute the liquid evenly from the

turbulent inlet zone into the calm separation zone.

The distributor also acts to dampen adverse liquid waves and surges which may be caused

by incoming slugs. Occasionally, for long separators and/or where the gas velocity is high,

additional baffle plates (wave breakers) are installed at the gas/liquid interface along the

vessel to prevent wave build-up.

In some applications where the liquid velocity is high or where the oil height above the

weir is not large, a second perforated baffle may be located just upstream of the weir to

ensure flow is evenly distributed at this point too.

1. Single Perforated Baffle Plate (Standard design) This is a perforated baffle with typically 25-30% open area extending from the base of

the vessel to the HLL or HHLL. It is used in standard separator applications.

2. Dual Perforated Baffle Plate (Enhanced design)

This is a pair of perforated baffles with typically 15% / 30% open area extending from

the base of the vessel to the HLL or HHLL. It is used in more difficult separator

applications or where the liquid velocity is excessive





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Oil/Water Coalescing Internals( Coalescer pack)

After leaving the initial distribution baffle the liquid enters a settling zone in which

gravity separation causes entrained gas bubbles to rise to the oil/gas interface and join

the continuous gas phase. Oil and water droplets rise or fall to join their respective

continuous phases.

To meet the process guarantees it is sometimes necessary to fit coalescing media which

maximise the liquid/liquid separation by reducing the effective distance that the

dispersed phase droplets need to travel before encountering a coalescing surface.

Flat Plate Pack (Fouling service design)

Flat plate packs achieve good coalescing performance whilst being resistant to fouling and

so are the normal first choice for coarse separation performance in production

separators. Packs are constructed in modular units up to 1m long and bolted together to

provide a large flow face area. Various styles are available to suit the service including a

special fouling resistant style.

Matrix /Coalescer Pack (Standard high performance design)

The packing is manufactured in corrugated sheets making it strong and light and well

suited for this application. Liquid droplets directly impinge on the irregular surfaces

allowing coalescence to take place. The larger droplets then flow either up or down

through the packing and separate out into their respective phases. Packs are typically

210mm deep and 2 to 5 packs are used.





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Dual Media Mesh (High performance polishing service)

The coalescer is manufactured from either a co-knit metal/plastic filament weave, or

from combining layers of different mesh properties. Liquid droplets directly impinge on

the fine wire surfaces allowing coalescence to take place. It is usually used in clean

service for polishing applications down to low levels of contamination.





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Mist Eliminator (Mesh(Demister) Pad/ Vane pack/Cyclones)

Coalescence of the remaining liquid droplets in the gas phase takes place in a demister

just upstream of the gas outlet.

The larger coalesced droplets either drop down into the liquid phase or they are blown

free through the mist extractor into the second quiescent gravity settling zone where

the larger droplets are easily separated.

Wire Mesh Pad

These industry standard devices are the first choice for most applications due to their

high separation performance over a wide operating envelope. However, their limited

capacity (gas and liquid) and susceptibility to fouling mean that other types of mist

eliminator are frequently employed.

Plain Vane Pack (Medium liquid loading)

This vane pack uses plain corrugated vanes on suitable spacing to match the gas velocity

and predicted liquid load and type. It is a robust device suitable for fouling service. Vane

pitch can be adjusted to suit the application although depth is normally 200mm.





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Hooked Vane Pack (Medium to high liquid loading)

This is a higher performance / capacity vane pack with hooked vanes to capture more of

the mist and liquid film under higher velocity conditions.

Pocketed (Double Hooked) Vane Pack (Medium to high liquid loading)

Where the liquid is particularly light (and thus the velocity would otherwise tend to strip

away and re-entrain the liquid film) this pocketed style is used

KSME Axial Cyclones (Specialist design)( By Kirk Process Solution Ltd)

Our Highspeed™ Swirltube Axial Cyclones are used for high capacity mist elimination in a

range of gas treating applications. Their high capacity and wide operating pressure range

mean they are particularly useful for vessel size reduction or retrofit applications





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Weir

The submerged weir is the most effective method of ensuring minimum contamination of

the produced water and oil. The heavier water layer is held behind the weir and only the

upper and cleanest part of the oil layer flows over to the oil outlet compartment.

Correctly designed, they ensure that the oil flow path is evenly distributed across the

separator, with minimum ‘channelling’ or short-circuiting.

This arrangement allows maximum oil/gas residence time to aid degassing and improve

level control stability. On larger separators it may be possible to have an overflow weir

arrangement where the separation level is fixed and the control is achieved in the weir

outlet section

These devices are normally manufactured by the vessel fabricator

Vortex Breakers

The separated liquids are drawn from the bottom of the vessel at the furthermost

position from the inlet as possible. Effective vortex breakers ensure that the oil is not

contaminated with gas or the water with oil.

These devices are normally manufactured by the vessel fabricator.





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Sand Jets

A sand jet pipe system can be fitted along the bottom of the vessel running up to a sand

retention baffle or the weir plate. High pressure water will fluidise any solids settled in

the base of the vessel so that they can be flushed away into the sand removal nozzles. A

sand pan to prevent clogging and blockage of the removal nozzles is also usually supplied.

Sand Jet ‘H’ Header with spray nozzles

One or more ‘H’ header systems can be fitted so that the two parallel headers run along

the base of the separator in the solids settling zone. A single inlet header feeds these

spray headers. Each spray header is normally fitted with an array of flat spray nozzles to

fluidise and sweep the solids towards the sand pan and exit.

Documents

3 Phase Separator Process Description - Column Internals ® STRUCTURES PVT.LTD REG.OFFICE & WORKS: - J-25, S Block MIDC, Bhosari, Pune 411026 W-54,T Block MIDC, Bhosari,Pune 411026