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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
1 INTRODUCTION
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, 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.
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withdrawn at the bottom.
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the oil chamber, where it is withdrawn under level control.
The water layer remains on the left-hand side of the weir and is withdrawn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.
3 SEPARATOR INTERNALS
4 PRINCIPLES OF SEPARATION
(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.
The separation of oil, gas and water from each other is largely achieved by
one or both of the following:
Physical separation
Flash separation
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 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)
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.
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.
7 SEPARATOR INSTRUMENTATION
Within the limits of design and construction all separators have the same
basic instruments and controls as follows:
(10) Drains
This gives the facility to manually drain down the separator through
the closed drain system.
8 SEPARATOR CONTROL
Where crude cooling is installed prior to the final-stage separator this can
be fitted with:
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.
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.
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
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.
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.
In line block valves are in the correct position as per the valve position
schedule in the operating manual
At least one main oil line booster pump and one main oil line are
ready for startup
Commence wellhead fluid flow into the first stage of separation from
the wellheads and manifold section
Continuous visual checks for leaks are obviously most important at this
critical stage as pressure and temperatures increase to their normal
operating conditions
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
Figure 3.2
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