2007-Separators - 2

EQUIPMENT
SEPARATORS
TRAINING MANUAL
COURSE PC-2007
Revision
01
Document Title : SEPARATORS
Doc. Code: OS‐KOSPM‐PC2007
Rev. No.: 00 Rev. Date: 10th May 2015 Page 2 of 132
Document Chapter/Section: Advance Training Course
EQUIPMENT
SEPARATORS
CONTENTS
1. OBJECTIVES ....................................................................................... Error! Bookmark not defined.
2. THE FUNCTIONS OF A SEPARATOR ................................................. Error! Bookmark not defined.
2.1. INTRODUCTION ........................................................................... Error! Bookmark not defined.
2.2. WHY IS THE EFFLUENT PROCESSED? ..................................................................................... 8
2.3. DEFINITIONS OF A SEPARATOR .............................................................................................. 11
2.4. THE FINISHED PRODUCT ........................................................... Error! Bookmark not defined.
2.4.1. Definition of the vapour pressure (TVP) ................................................................................ 15
2.4.2. Definition of the REID vapour pressure (RVP) ...................................................................... 15
2.4.3. H2S specification ..................................................................... Error! Bookmark not defined.
2.4.4. Water and salt content ............................................................ Error! Bookmark not defined.
2.5. EXAMPLE OF A SEPARATOR.................................................................................................... 20
2.6. EXERCISES ................................................................................................................................ 21
3. OPERATION OF SEPARATORS ................................................................................................. 25
3.1. THE SECTIONS OF A SEPARATOR .......................................................................................... 25
3.1.1. The primary separation section ............................................... Error! Bookmark not defined.
3.1.2. The secondary separation section .......................................... Error! Bookmark not defined.
3.1.3. The coalescence section ......................................................... Error! Bookmark not defined.
3.1.4. The collecting section .............................................................. Error! Bookmark not defined.
3.2. THE INTERNAL PARTS OF A SEPARATOR ................................ Error! Bookmark not defined.
Prepared By: Najem Sakor Reviewed By: Approved By:

Rev. No.: 00 Issued Date:
3.3. EXERCISES .................................................................................. Error! Bookmark not defined.
4. THE DIFFERENT TYPES OF SEPARATORS .................................................................................... 32
4.1. VERTICAL SEPARATORS .......................................................................................................... 32
4.1.1. Two-phase vertical separators .............................................................................................. 33
4.1.2. Three-phase separators ....................................................................................................... 35
4.2. HORIZONTAL SEPARATORS .................................................................................................... 36
4.2.1. Two-phase horizontal separators .......................................................................................... 42
4.2.2. Three-phase horizontal separators ....................................................................................... 43
4.2.3. High-pressure horizontal separator with liquid retention capacity ......................................... 46
4.3. SPHERICAL SEPARATOR ............................................................ Error! Bookmark not defined.
4.4. DROPLET SEPARATOR FOR ANTI-FOAM TREATMENT ........... Error! Bookmark not defined.
4.5. DECANTATION TANKS AND WASH TANKS.............................................................................. 51
4.5.1. Wash tank accessories ......................................................................................................... 52
4.6. FWKO (Free Water Knock Out) ..................................................... Error! Bookmark not defined.
4.7. "CENTRIFUGAL" SEPARATOR .................................................................................................. 56
4.7.1. Cyclone effect separator ....................................................................................................... 56
4.7.2. Vortex effect separators ........................................................................................................ 60
4.8. DROPLET ELIMINATORS ("DEMISTERS") ................................................................................ 60
4.9. SLUG CATCHERS ....................................................................... Error! Bookmark not defined.
4.10. ADVANTAGES AND DISADVANTAGES OF THE DIFFERENT TYPES ................................... 62
4.11. EXERCISES .............................................................................................................................. 63
5. SEPARATOR REPRESENTATION AND DATA ................................................................................... 69
5.1. PROCESS FLOW DIAGRAM (PFD) ............................................................................................ 69
5.2. PIPING & INSTRUMENTATION DIAGRAM (PID) ....................................................................... 72

5.3.2. Slug catcher .......................................................................................................................... 69
5.4. SEPARATOR SIZING .................................................................................................................. 70
5.4.1. Typical example .................................................................................................................... 70
5.4.2. Sizing..................................................................................................................................... 71
5.5. EXERCISES .................................................................................. Error! Bookmark not defined.
6. SEPARATORS AND THE PROCESS ................................................... Error! Bookmark not defined.
6.1. LOCATION AND CRITICALITY ..................................................... Error! Bookmark not defined.
6.2. RELATED PROCESSES ............................................................................................................. 78
6.3. EXERCISES ................................................................................................................................ 78
7. AUXILIARIES ....................................................................................... Error! Bookmark not defined.
7.1. LEVEL CONTROL DEVICES ......................................................... Error! Bookmark not defined.
7.2. PRESSURE CONTROL DEVICES .............................................................................................. 80
7.3. TEMPERATURE CONTROL DEVICES ....................................................................................... 83
7.4. VALVES ....................................................................................................................................... 83
7.5. FLOWMETERS ............................................................................................................................ 84
7.6. EXERCICES ................................................................................................................................ 85
8. OPERATING PARAMETERS ............................................................................................................. 87
8.1. NORMAL OPERATION ................................................................................................................ 87
8.1.1. Separation parameters .......................................................................................................... 87
8.1.2. Controls to be carried out or monitoring during operation ....... Error! Bookmark not defined.
8.1.3. Positioning of the valves in normal operation ........................................................................ 89
8.2. SAFE OPERATION ..................................................................................................................... 90
8.2.1. Alarms and safety.................................................................................................................. 91
8.2.2. Valves in Emergency Shut Down position ............................................................................. 93

8.3. MAX / MIN CAPACITIES ............................................................................................................. 94
8.4. EXERCISES ................................................................................................................................ 95
9. SEPARATOR OPERATION .................................................................. Error! Bookmark not defined.
9.1. COMMISSIONING AND SHUTTING DOWN A SEPARATOR ....... Error! Bookmark not defined.
9.1.1. Commissioning a separator ................................................................................................... 97
9.1.2. Shutting down a separator .................................................................................................... 98
9.2. PROVISION ................................................................................................................................. 98
ST
9.3. 1 LEVEL MAINTENANCE ......................................................... Error! Bookmark not defined.
10. TROUBLESHOOTING ................................................................................................................... 100
10.1. WHAT TO DO IF ...................................................................................................................... 100
10.1.1. Troubleshooting procedure for liquid entrainment to the outlet ......................................... 101
10.1.2. Troubleshooting procedure where maintaining a constant liquid level is impossible ........ 102
10.2. EXPERIENCE FEEDBACK ...................................................................................................... 103
11. GLOSSARY ........................................................................................ Error! Bookmark not defined.
12. FIGURES:....................................................................................................................................... 107
13. TABLES .......................................................................................................................................... 109
14. CORRECTIONS FOR EXERCISES ............................................................................................... 110

1. OBJECTIVES
2. THE FUNCTIONS OF A SEPARATOR
2.1. INTRODUCTION
Figure 1: Situation of the separation in a processing of oil

A separator is a device used for separating oil, gases and water contained in the effluent
leaving a production well, by using the differences in their densities.
Generally, the crude oil which leaves a well is a 3-phase combination comprising:
A gaseous phase
A hydrocarbon liquid phase (the

crude itself)
An aqueous phase (formation water)
This effluent may also convey solid particles

in suspension, such as sands resulting from
the formation, corrosive products, paraffin-
base or asphalt-base components that have
precipitated out.
Figure 2: Example of a separator
This well crude effluent cannot be commercialised as is. It has to be processed to conform
to the commercial specifications required by the customer.
This processing may require the implementation of several processes in order to obtain
crude conform to specifications.

2.2. WHY IS THE EFFLUENT PROCESSED?
Figure 3: General diagram of the processing of well effluents
For safety reasons:
o To monitor H2S: H2S is hazardous to human life
o To stabilise the effluent: limit degassing and reduce the risks of explosion
For technical reasons:
o Stable products (vapour pressure specification to be observed, therefore

the crude must be stabilised). A product is stable if it does not change with
time. The sooner it is stabilised, the less gas it will release.
o Measurable products (this means that can it be metered, without water,

without sediment, without gas, to know exactly the quantities sold)

o Pumpable products (the crude needs to be transported from the terminal to

the tanker, and from the tanker to the refinery)
o Non-scaling products (this means that they do not cover the barrels, pipes,
or tanks with a mineral layer (paraffins), for example, sulphate, carbonate
deposits etc…)
For commercial reasons:
o Anhydrous products (customers do no want to transport water)
o Non corrosive products (protection of the tanker, refineries and customers:

salts-H2S)
To guarantee:
o Safe transport (so as to limit the risk of degassing in the tankers with
subsequent risks of explosion)
o A regular supply of produced hydrocarbons (by, for example, correct

processing of foaming and emulsions in order to prevent having to stop the
processing chain.)
To discharge components without commercial value into the immediate

environment, without polluting:
Example: production waters have no value, they can therefore be discharged (or
reinjected if there are no legal restrictions), provided they are processed to
preserve the environment.
Stabilisation eliminates part of the gas but also part of the H2S. However, sometimes this
is not enough. Gas sweetening (acid removal) must also be planned. This treatment
process will be covered in another course.
As indicated above, stabilising a crude produced from a reservoir consists in meeting

certain specifications, particularly RVP (Reid Vapour Pressure) and an H2S specification if
the crude contains a significant quantity of it.
The RVP (Reid Vapour Pressure) is linked to the concentration of gas dissolved in the
crude. The higher the dissolved gas concentration, the higher the RVP. To meet an RVP
specification, it is necessary to implement a process that will, at the least cost, release the
dissolved gas in the crude leaving the well.

The simplest means of stabilising a crude is to subject it to a certain number of separations

at decreasing pressures (multi-stage separation) and to separate the gas obtained at each
one of the separation stages. This process can only be applied for natural flowing
reservoirs whose wellhead pressure is higher than the atmospheric pressure. However,
these well activation methods, whether pumping or gas lift, help increase the wellhead
pressure and use this process in this type of well.
Very often, this simple physical separation is not sufficient. Additional processing must be
therefore performed, consisting in heating the crude to improve gas removal. Distillation
may be added to the heating (often by H2S stripping) to limit loss of "semi-light" or "semi-
heavy" components, such as the C5, and even C6 in the gas phase extracted from the
crude. However, it may also be necessary to cool the crude as it is too hot and losses may
therefore occur.
As for the H2S, if required, simple multi-stage separation will not be sufficient in most
cases. "Stripping" of the crude may be installed in addition to separation.
This course deals with the separation process and more specifically the element used for
this process: the separator. This piece of equipment is one of the most important and,
often, the most used in a plant.
In the following chapters, we will study the operation of a separator, its component parts and
its operation. You will also learn which substances can be separated and why they must be
separated one from the other
Figure 4: Separation principle

2.3. DEFINITIONS OF A SEPARATOR

Separators are installed at the head of the processing chain, in which they are the
essential elements. They receive, directly from the inlet manifold, the production brought
from the collecting pipes.
A separator is a capacity under pressure incorporated into a circuit, in which it slows the
flow velocity of the effluent.
A separator is a cylinder positioned either vertically or horizontally.
There are also spherical separators, but they are not used so commonly. Branch
connections with valves and measuring devices are used to control the operation.
According to the specific use, separators can be classified into:
Flash separators used for condensate gas processing
Gas/oil separators
Free water separators
Test separators
Scrubbers (e.g. a flare drum) and filters
The different types will be described in a chapter below.
2.4. THE FINISHED PRODUCT
As is indicated above, the problem consists in separating a complex effluent into a

gaseous phase and one or several liquid phases.
The role of a separation unit, and therefore a separator is to eliminate the formation water,
to process the oil so that there is almost no release of gas at atmospheric pressure, and to
ensure that the gas released is as dry as possible.
The figure below illustrates the path and changes undergone by the effluent between the
reservoir and the processing centre:

Figure 5: Path of the effluent between the reservoir and the processing centre

These same changes can be followed on a P-T diagram representative of the reservoir
fluid-(Figure 14).
Figure 6: P-T diagram representative of the changes of the fluid during its transit
The fluid in place in a reservoir is a mixture of liquid and/or gaseous hydrocarbons and
water. This mixture is originally in a state of equilibrium that depends on its composition
and on the pressure and temperature conditions in the formation.
Figure 7: Wellhead effluent composition

The production process destroys this equilibrium.
Subjected to pressure drops in the host rock, in the borehole and in the collecting pipes,
the effluent undergoes successive decompressions until it enters the processing centre.
These decompressions are also followed by temperature drops.
Consequently, gases are released from the oil; hydrocarbons and water condense from
the gas.
The processing Centre therefore generally receives alternating slugs of wet gas, free water
and oil still charged with dissolved gas.
The densities of crude oils range between 0.780 and 1.04 (50° at 6° API) and the
viscosities between 5 and 75 000 cP.
The processes involved in extracting the crude oil and conveying it to the surface
sometimes cause emulsions and foaming to form. These particular phenomena require the
installation of specific additional equipment in the processing centre. These terms as well
as the equipment will be defined later.
Whatever the type of crude oil to be processed, the specifications of the product remain
approximately the same, i.e.:
R.V.P. 7-10 PSI
H2S
Mediterranean 30-40 ppm mass
Middle East 70-80 ppm mass
Water content
Departure 0.1% vol.
Arrival 0.2% vol.
Salt content
Departure 40-60 mg/l.NaCl
Arrival <100

2.4.1. Definition of the vapour pressure (TVP)
The vapour pressure of a crude or "True Vapour Pressure" (TVP) under storage conditions
(atmospheric pressure and ambient temperature) is difficult to measure rapidly: it requires
laboratory equipment. However, it characterises the stable quality of the crude and
therefore its gas-release potential.
Too high a vapour pressure of the crude will cause, therefore, some risks for storage and
transport.
2.4.2. Definition of the REID vapour pressure (RVP)
An easily measurable value has been used

instead of TPV, so long as there is access
to samples of the crude, which is always
possible on the production site and even
on an oil carrier or at the refinery. This
value is the REID vapour pressure (RVP).
The RVP of a crude oil is always measured

at 100°F (37.8°C)
Figure 8: RVP measuring instrument
The RVP measuring instrument (Figure 8)

includes 2 chambers: one (1/3 of the total
volume of both chambers) receiving the
crude collected at sampling tap where the
device is connected, and the other (2/3 of
the total volume of both chambers) filled
with air.
Once the collecting operation has been done, the tap is opened and the 2 chambers
communicate with each other. The assembly is then vigorously shaken and put at a
temperature of 100°F.
The pressure indicated on the manometer connected to the device is then read. The
pressure shown is the RVP. The RVP is an effective pressure and is normally expressed
in PSI ("pounds per square inch") which is the Anglo-American measuring unit for
pressure.

The RVP specification of a crude oil depends on the climatic conditions on the production
site (for crude storage) and on the route taken by the oil carrier (in case of carriage by sea)
to the consumer market. Usually, the RVP is between 7 and 10 psi.A.
2.4.3. H2S specification
The well effluent very often contains, in more or less large quantities, a toxic contaminant:
H2S. This component preferentially migrates to the gaseous phase, but a non negligible
quantity remains in the released crude.
An H2S-concentration of 100 ppm in the ambient air (following degassing in the storage,
related to a temperature rise, for example) may lead to very serious consequences on the
personnel brought in to work around the location of the crude.
Let us remember that in the presence of water, H2S results in corrosion problems (H2S +
liquid water = sulphuric acid).
H2S extraction from the crude oil may require the implementation of a so-called "stripping"
process.
Generally, the H2S-concentration in stored crude should not exceed a weight of 100 ppm.
2.4.4. Water and salt content
2.4.4.1. Transport
The field-processed crude is generally sent to refineries.
The usual transport means are:
Pipeline
Rail
Carriage by river
Carriage by sea (by Tanker)

Pipeline
For pipeline transport, the water content is much more important for the carrier than the
salt content. In this case, the water is paid at the crude price and unnecessarily overloads
the pipeline. It may also result in corrosion problems increased by the presence of salt.
Consequently, the water content of a crude transported by pipeline should normally not
exceed 0.1% (vol.).
The salt content (chlorine expressed as NaCl ) should not exceed 60 g/l.
Other transport means
Where transport is other than by pipeline, there really are no constraints set by the carrier.
For all other means, carriage by sea causes the most contamination due to use of
seawater as ballast.
Statistics show that the additional salinity owing to carriage by sea varies between 8 and
37 mg/l and may even reach 50 mg/l.
2.4.4.2. Refining
The salt content of the crude at the refinery, before entering the preheating string towards
the distillation column ("topping"), must decrease to 5 to 10 mg/l of salt, so as to avoid
problems such as:
Fouled heat exchangers
Corroded equipment
Degraded quality of the refined products
With a desalting stage as found in European refineries, the crude salinity value of 5 mg/l
downstream of desalting corresponds to a maximum salinity of 100 mg/l in the crude at the
refinery inlet.
Thus, the maximum salinity of a crude delivered to a refinery should not exceed 100 to 110
mg/l and 0.2% of water.

With a desalting stage as found in European refineries, the crude salinity value of 5 mg/l
downstream of desalting corresponds to a maximum salinity of 100 mg/l in the crude at the
refinery inlet.
Thus, the maximum salinity of a crude delivered to a refinery should not exceed 100 to 110
mg/l and 0.2% of water.
Consequently , in view of the pollution brought by carriage by sea (when carried by

tanker), the salinity of the crude leaving the site should not exceed 60 mg/l and have a
water content less then 0.1%.
Better control of loading procedures, the widespread use of washing of the tanker vessels
with crude for example, should help decrease the pollution due to carriage by sea and
therefore slightly extend the salt specification of the crude leaving the production site (up
to 80 mg/l).
After this digression into explaining specifications required for the finished product, let us
return to the device that we were describing and mainly to the importance it plays in the
process part

In Table 1, the importance of the separator (whether there are two, one or none at all) can
clearly be seen, in the final product quality. (In particular on the gas/oil ratio).
However, do not assume that the more separators there are, the greater the amount of
gas recovered.
Total
Separator Separator Stock
Reservoir GOR
1 2 tank
Sm3/Sm3
Pressure b.eff 245 - - 0 -
Temperature °C 127 - - 15 -
GOR Sm3/Sm3 - - - 234.1 234.1
Pressure b.eff 245 22 - 0 -
Temperature °C 127 22 - 15 -
GOR Sm3/Sm3 - 159.8 - 34.9 194.7
Pressure b.eff 245 69 14 0 -
Temperature °C 127 54 40 15 -
GOR Sm3/Sm3 - 115.5 52.5 24.3 192.3
Table 1: Reservoir fluid separation tests

2.5. EXAMPLE OF A SEPARATOR

When speaking about a separator, one usually thinks about production separator(s)
located upstream of the processing chain.
However, there are different types of separators depending on the fluids which are
circulating in these drums. These will be detailed in the following chapter.
Figure 9: View of a three-phase separator (Girassol test separator)
The production separators are designed to receive a continuous flow from the wells.
This type of capacity separates the gases from the liquids. As this separator is a three-
Phase device, it will also separate the water from the oil.

2.6. EXERCISES
1. What are the three elements of the effluent that a three-phase separator
dissociates?
2. The separator acts on the density of the effluent components in order to separate
them.
‰ True
‰ False
3. Crude oil does not need to be processed in order to be commercialised.
‰ True
‰ False
4. Give two technical reasons why the effluent must be processed.
5. Give one commercial reason why the effluent must be processed.
6. Give one environmental reason why the effluent must be processed.

7. What do the initials R.V.P. mean?
8. The RVP (vapour pressure) specification is linked to the gas content dissolved in
the crude.
‰ True
‰ False
9. The more the dissolved gas content decreases the more the RVP of the crude will
increase.
‰ True
‰ False
10. On natural flowing reservoirs with a wellhead pressure higher than the atmospheric
pressure, what is the simplest method used for stabilising a crude?
11. Complete the diagram of the separating principle

12. Where are the separators located on the oil processing chain?
‰ At the beginning
‰ At the end
13. What are the two main types of separator?
14. By using the definitions of the diagram below, find the location of the correct
pressures.

15. In this P-T diagram showing the changes of the fluid during its transit path (red line),
find the location of the correct
pres sures.
16. Usually, the RVP specifications of the finished product are between:
and psi.
17. Usually, the water content from the installation is:
% vol.
18. Usually, the H2S content from the installation is between:
Mediterranean: and ppm mass
Middle East: and ppm mass
19. Usually, the salt content from the installation is:
mg/l NaCl

3. OPERATION OF SEPARATORS
3.1. THE SECTIONS OF A SEPARATOR
Figure 10: View of the equipment in a separator
Apart from the shape, separators usually consist of four main sections in addition to the
commands and controls required.
Primary separation section
Secondary separation section
Coalescence section
Collection section

The locations of these sections, whatever the type of separator, are shown in the figure
above.
3.1.1. The primary separation section
Section A is the primary separation
It is used for separating the main part of free liquid from the inlet fluid. It contains the inlet
nozzle (also called the intake or feed nozzle) which is generally tangential, or a deflector
(also called a diverter plate) to take advantage of the inertia effects of the centrifugal force
or a sudden directional change in order to separate most of the liquid or gas.
3.1.2. The secondary separation section
The secondary separator or gravity section, B, is designed for using the gravitational
force so as to increase separation of the entrained (carried over by the liquid) droplets.
In this separator section, the gas moves at a relatively low velocity and with little
turbulence
Figure 11: The different sections in a spherical separator

In some cases, straightening vanes are used to reduce the turbulence. These vanes also
act as droplet collectors and thus facilitate the separation of the droplets and the gas.
3.1.3. The coalescence section
The coalescence section, C,

uses a coalescer or a demister
which may consist of a series of
vanes (labyrinth), a braided wire
mesh mat or even a series of
cyclones.
Figure 12: The different sections

in a vertical
separator
This section extracts the very

small liquid droplets from the
gas by collision on a surface
where they coalesce.
Typical liquid entrainment (or

carryover) in a demister is less
than 0.013 ml per m3.
3.1.4. The collecting section
The manifold or liquid

collecting section, D, acts as
the receiver for all the liquids
extracted from the gas in the
primary, secondary and
coalescence sections.
Depending on the requirements

(conditions), the liquid section
should have a certain volume for
gas releasing or appearance of
liquid slugs.

In addition, a minimum liquid level is required for a correct operation.
Gas removal may require a horizontal separator with a shallow liquid level whilst the
separation of emulsion may call for a higher liquid level, higher temperatures, and/or the
addition of a surfactant.
3.2. THE INTERNAL PARTS OF A SEPARATOR
The most common internal parts used for improving the efficiency of a separator are:
The Deflector (Deflector or

diverter plate): When the fluid
hits the plate, the velocity slows
and the liquid droplets fall to the
bottom of the separator. The
gas continues its path around
the plate.
Figure 14: Inlet deflector
The Coalescer (Demister pad/Coalescing pack): Used so that tiny droplets

combine with larger droplets.
A device equipped with a filler,-multiple baffles, wire

mesh, various fibres – so as the liquid particles can be
gathered into droplets and be separated from
gas or vapour as well as from non-miscible liquids.
Figure 15: Wire Mesh

he Weir or Weir plate: Used for

increasing the liquid residence (also
called retention) time as, depending on
where it is located, it increases the
volume offered to the liquid.
Figure 16: Perforated weir plate
The Vortex breaker or anti-Vortex: Installed to prevent the formation of

whirlpools in the
liquid, which would
entrain (or carry
over) the gas with
the liquid being

evacuated from the
separator.
Figure 17: Vortex breaker
he Straightening vanes: used for eliminating turbulence in the gas current after
the initial separation of the inlet deflector.

3.3. EXERCISES
20. Complete the following diagram:
21. In the following diagram, indicate, by using the letters (A-B-C-D), the main sections
of a horizontal separator.

of a vertical separator.
of a spherical separator.

4. THE DIFFERENT TYPES OF SEPARATORS
4.1. VERTICAL SEPARATORS
The main advantage of this separator is that it can accept larger liquid slugs without
causing excessive entrainment in the gas. Considering the great distance there usually is
between the liquid level and the gas outlet, this reduces the entrainment of liquid droplets.
However, it has a larger diameter for any given gas capacity.
Vertical separators are therefore well suited to large quantities of liquid (low GORs) or, on
the other hand when there is only gas (the minimum liquid space in a horizontal drum is
too great).
Typical applications
are scrubbers,
compressor suction,
heating gas drums
and certain oil
separators containing
sediments.
They are also used

for wells with solid
deposits (easy to
clean).
Figure 18:
External view of
a vertical
separator

4.1.1. Two-phase vertical separators
Figure 19: Detailed view of a 2 phase vertical oil/gas separator

Another type of vertical separator is

the gas scrubber. Generally, it is
installed at the compressor suction.
The name "scrubber" comes from the
oil fields.
It simply means that the gaseous

hydrocarbons which enter the drum
are "scrubbed" (cleaned) of liquids
(generally called condensates) which
the gas has entrained.
The gases arriving in this type of

separator are "wet gases".
Figure 20: Typical example of a

scrubber
They still contain liquids. If these liquids are not separated and enter the gas compressor,
they then will cause major damage to the compressor.
A scrubber uses gravity to separate the liquids from the gas. The gas entering the
separator is diverted to the bottom by a deflector installed on the drum inlet line. This
directional change reduces the velocity of the gas and thus causes the liquid droplets to
fall to the bottom of the separator.
In the scrubber, the liquid outlet is equipped with an

"anti-vortex". This is installed so that the gas cannot
leave the separator with the liquids.
Any liquid entrained towards the top of the separator is

separated by a demister placed close to the top of the
drum.
Figure 21: Detailed view of a scrubber

4.1.2. Three-phase separators
As for the three-phase vertical separator, the internal elements are nearly the same.
Just a water outlet and a regulator are added.
Figure 22: Detailed view of a three-phase separator

Production Equipment
Document Title: Separators
Doc. Code: OS‐KOSPM‐M001
Rev. No.: C00 Rev. Date: 10th May 2015 Page 3 of 120
4.2. HORIZONTAL SEPARATORS
They are often used for wells with high GORs. They have a very high exchange
surface. These separators generally have a smaller diameter than vertical separators
for the same

quantity of gas and offer a larger gas/liquid
interface. They are also easier to mount on skids.
The following figure shows the typical arrangement of a field separator drum for which
the following comments can be made:

Figure 23: Detailed view of a two-phase

horizontal separator
The main purpose of the inlet diffuser is to absorb the

kinetic energy of the entering fluid, particularly for an oil well. It can be centrifugal in vertical
drums.
The diffuser also ensures a first liquid/gas

separation.
Figure 24: Photo of an inlet diffuser
Figure 25: View of the separator inlet diffuser process
The straightening section is often composed of parallel plates that may or may
not be slightly inclined to ensure the coalescence of the liquid droplets.
The secondary chamber performs most of

the separation.
The demister which ensures the

coalescence of the smallest droplets of
entrained liquid, can be of different types,
either braided ("wire mesh") or very closely
spaced plates.
Figure 26: Demister

Figure 27: View of a "Wire

Mesh"
The separation wall mainly prevents the gas from by-passing the straightening
section, and also to avoid the gas from forming waves at the surface of the liquid.
Note that certain manufacturers partially flood the straightening section to avoid
the by-passing.
The separation wall mainly prevents the gas from by-passing the straightening
section, and also to avoid the gas from forming waves at the surface of the liquid.
Note that certain manufacturers partially flood the straightening section to avoid
the by-passing.

The prime function of the wave breakers is to prevent waves located at the
liquid/vapour contact in the separator from propagating. Moreover, this is
particularly interesting for test separators mounted on a floating rig.
Also note that the

walls reduce the
lengths required for
liquid decantation.
The opposite diagram

shows the significance
of these wave
breakers.
Figure 28: View of

"internal baffles" in
a horizontal
separator
These plates can be perforated. They provide

even better stability as shown in the diagrams
below.
Figure 29: View of a perforated plate

Figure 30: Diagram showing the significance of the perforated plates
The anti-vortex device breaks the whirlpool generated by the tubular orifice of the
oil outlet.

Figure 31: View of an anti-vortex device
The liquid guard must be high enough to compensate for the pressure drop of the
demister; otherwise the liquid can rise and be re-entrained by the gas.
The sand jet: In order to remove the sand

built up with the liquids, this type of internal
device is installed at the bottom of the
separator. The water or chemicals are sent
under pressure through this equipment. Sand
jetting is often used before inspecting the
vessel.
Note that these separators are generally mounted on complete skids with their pipes and
adjustment, regulation and safety instruments.

4.2.1. Two-phase horizontal separators
A two-phase horizontal separator performs a primary separation close to the separator

inlet. The second separation and the demister are located in the upper part of the capacity.
There is a section which collects the liquid in the bottom of the separator.
The effluent coming from the well enters the separator and hits a water breaker walls.
Figure 33: Cutaway view of a two-phase horizontal separator
Most of the liquid is separated, then the heaviest liquids fall to the bottom of the separator.
The gas and liquid vapour continue their path across the straightening sections (see figure
23).
These sections cause oil droplets to be formed.

These droplets fall into the liquid collector. The water breaker walls limit the
turbulence
Most of the liquid is separated, then the heaviest liquids fall to the bottom of the separator.
The gas and liquid vapour continue their path across the straightening sections (see figure
23).

These sections cause oil droplets to be formed.
These droplets fall into the liquid collector. The water breaker walls limit the turbulence.
The gas continues its path horizontally across the demisters. Here, almost all the
remaining liquid is extracted by this mesh (except certain small droplets). The gas leaves
the separator through the gas outlet at the top of the drum. The collection of liquid is
located in the lower part of the separator. This liquid is separated from the gas by plates
(also called trays).
When the liquid reaches the required level, the liquid level controller opens the level valve.
The liquid leaves the separator through the liquid outlet.
4.2.2. Three-phase horizontal separators
The three-phase horizontal separator design is similar to a two-phase horizontal separator.
Figure 34: Cutaway view of a three-phase horizontal separator

The major difference is in the liquid

collecting section. In a three-phase
separator, the upper part of the
liquid collecting section contains
the oil whereas the water is found
in the lower part.
Each of the liquid sections has its

own controller for their relevant
valve.
Figure 35: Simple diagram of a

three-phase separator
When the liquid reaches the

required level, the controllers open their respective level valve. The separated liquids leave
the separator through the various liquid outlets.
Figure 36: Detailed view of a three-phase horizontal separator

Figure 37: Cutaway view of a three-phase horizontal separator
Figure 38: Exploded view of a three-phase separator (floating separator with flow dividing)

4.2.3. High-pressure horizontal separator with liquid retention capacity
The two tube horizontal separator has an upper tube and a lower tube linked by vertical
tubing called "downcomers".
The upper tube is the separating section of the gas and the lower tube is the collecting
section of the liquids.
The two-tube separator separates better than the single tube separator when there are a
lot of slugs occurring in the well effluent. Also, the two tube separator has the advantage of
avoiding potential re-entrainment.
The upper tube, which is the gas separator, contains the fluid inlet, the inlet diffuser, the
transition section and the demister. This section also has a safety valve or a burst disk.
Figure 39: High pressure two-phase horizontal separator with liquid retention capacity
The fluid from the well enters the upper tube through the inlet nozzle. The flow is diverted
to change its direction and velocity. The liquid falls to the bottom of the upper tube. The
gas and liquid vapour continue their path across the straightening sections. These sections

cause the formation of oil droplets, which fall to the bottom of the upper drum.
The gas passes over a vertical plate and then across the demister. Here most of the liquid
droplets are removed from the gas. The gas leaves the upper tube through the outlet
nozzle.
The lower tube has a liquid level controller, a liquid outlet nozzle and a drain. The
vertical tubes let the liquids flow in from the upper drum to the lower drum. They spread
out over the surface of the liquid contained in the lower separator. Controlled by the
liquid level controller, the liquids leave the lower tube through the liquid outlet nozzle.

The two-tube separator can also be a three-phase separator. The gas still comes out the
upper tube and the oil leaves at the top of the lower tube, with the water at the bottom of
the lower tube.
Figure 40: Cutaway view of a two-tube three-phase horizontal separator
4.3. SPHERICAL SEPARATOR
These type of separators are not very common and are reserved for wells with very high
GORs (gas + condensate wells).
They are relatively low-cost and compact, but with a limited liquid retention time and
decantation section. Use in three-phase separation is, therefore, very difficult if not
impossible.
Their advantage is their compact size but they offer small capacities. They are very easy
to handle. Another interesting point of importance is that owing to their spherical shape,
they can support all pressure ranges.

Figure 41: Two-phase spherical separator

4.4. DROPLET SEPARATOR FOR ANTI-FOAM TREATMENT
These droplet separators are used for anti-foam treatment. They can be vertical or
horizontal as shown below.
They use Dixon plates which are inclined at 45° with a large contact surface. Dixon plates
require anti-foaming products to operate efficiently
Figure 43: Detailed view of a horizontal droplet separator

4.5. DECANTATION TANKS AND WASH TANKS
Simple decantation (also termed settling) in tanks has been a very popular process, in
particular in America. Although not acceptable by engineering & design offices, it is,
nevertheless, an interesting solution when a sufficiently fast additive cannot be selected.
Actually, the main difference with the other separators is that the retention (or residence)
time, and therefore the decantation, is very high (several hours).
Despite all the advantages of simplicity, the interest in tank decantation has waned due to
safety and environmental regulatory constraints.
The wash tank concept is linked to the principle of bubbling the production through the
water kept at the bottom of the tank. When the emulsion is not very solid, the bubbling can
break it due to the fatigue of the emulsifying film.
Wash tanks can also be used for solving the problem of potentially crystallised salt in
suspension in the oil.
Figure 44: Detailed view of a traditional Wash Tank

4.5.1. Wash tank accessories

The effectiveness of the process is obviously linked to the closeness of the water/emulsion
contact. Thus the production inlet must be equipped with a device divides the flow into
several streams through the water. The figure above shows such a device.
A network of screened pipes can also be used.
The oil surface level is kept constant by overflowing into the line which feeds the storage
tanks (also called stock tanks). The water height in retention is often controlled by an
external device composed of an overflow stack located in a barrel tube.
When the oil is not fully degassed, the wash tank can be equipped with an integrated
atmospheric separator called a "boot" or "gun barrel". The released gas is piped to a Low
Pressure flare and several possibilities are available for pressure equilibrium in the
system. Sometimes, "integrated" level control valves are used to prevent gas migration.
figure 45: Diagram of a Gun Barrel principle
Finally, "swing pipes" should be mentioned. These are oil outlet pipes mounted on a swivel

joint at the foot of the tank. They allow a tank to operate as a wash tank in its lower part
and as a storage tank above. When the swing pipe separates these two sections, it is
suspended by a chain.
Sometimes the swing pipe is suspended from a float and is a "floating suction". It is,
therefore, always the surface oil that is sucked in, and therefore, the oil which is best
dehydrated.
4.6. FWKO (Free Water Knock Out)
Equipment called under the name, boiler

separators, in this document, is used for
extracting free water. Let us remember
that, arbitrarily, water which separates in
5 minutes qualifies as free water. The
thermodynamic definition of free water is
as follows: free water is that which forms
a liquid phase (including the droplets) but
does not take into account humidity. The
retention time sometimes exceeds this
but rarely 20 minutes.
They, therefore, they are not really

dehydration devices but are auxiliaries for
preliminary separation. They are
particularly useful when the percentage of
associated water is high as they allow the
size of downstream installations to be
smaller. Furthermore, if heating is
required during the process, they provide
ways of saving energy.

Figure 46: Deflector

Figure 47: FWKO-Free Water Knock

Out

This term will be used to designate separators that use centrifugal force as the main
separating force. They are now available from several manufacturers.
4.7. "CENTRIFUGAL" SEPARATOR

For the purpose of this presentation, the effects of centrifugal force can be classified into
two main types:
Cyclone effect
Vortex effect
4.7.1. Cyclone effect separator
The vertical cyclone effect separator is used mainly in gas processing systems. It can
remove solid particles and liquids which might have been entrained with the gas.
This type of separator removes

solid particles and liquids using
centrifugal force.
The gas enters at the top of the

separator and is forced into a
whirlpool movement. Both the
solid particles and the liquid are
projected onto the walls of the
separator.
The solid particles and the

liquid fall to the bottom of the
separator. They leave the
separator through a level
control.
The whirlpool creates a vortex

inside the separator. The gas is
displaced from this vortex (or
cyclone) to the top of the
separator. Figure 48: Vertical cyclone separator

Some liquids are entrained with the gas in the flow at the top of the separator. There is a
dead space at the outlet which collects the entrained liquids. These are then recycled in
the separator.
The fluid enters the drum tangentially, along an

axis perpendicular to that at which it leaves the
device.
The simplest example is that of a tangential inlet

tube which is horizontal in a vertical drum. The
droplets projected onto the walls of the separator
flow by gravity. Manufacturers often use, in this
type of equipment, cylinders with pierced cones
and orifices oriented so as to give a cyclone
movement to the fluid.
Figure 49: Operating principle of a cyclone effect

separator
Other manufacturers use a series of

small cyclones such as those used
for dust removal.
Figure 50: Cross section view of a

cyclone

Figure 51: View of an internal

multicyclone

Figure 52: Example of a Multicyclone separator

4.7.2. Vortex effect separators
The fluid enters the separator axis, starts to rotate (vortex) due to small blades located
in the inlet. The liquid is then projected on the walls and is evacuated by meticulously
calibrated orifices. These tubes can be used alone or in parallel.
The first advantage of this type of separator is its efficiency: 99.9 to 99.9% of all droplets
are greater than 5 to 10 microns.
However, usually the quantity of liquid at the inlet should not exceed 5% of the weight, and
special precautions, notably those for the primary decantation chambers, must be provided
if there is a possibility of slug occurrence.
The second advantage is the compact size of the equipment which is especially
appreciated on a platform.
4.8. DROPLET ELIMINATORS ("DEMISTERS")

These are recommended for services where there must be a minimum droplet
entrainment, for example in compressor suction and commercial gas deliveries.
There are two main types: braided and plated. Both use an agglomeration effect and the
second also uses a centrifugal effect, resulting from the directional changes.
Their main characteristics are:
Mesh diameter:
0.008-0.03 cm,
Mesh mat thickness:

100 m-150 mm.
According to the manufacturers,

these systems remove 98 to 99% of
particles larger than 10–20 microns.
However, these mist eliminators must
be used with caution as they can
easily become fouled up or even
clogged, for example, with sediments,
paraffin, or corrosion products.

Figure 53: Cross section view of a demister
4.9. SLUG CATCHERS
A slug catcher is a device that is used as a buffer on the outlet line. Its function is to
absorb the “liquid slugs” that form in the pipes or three-phase separators. It therefore
absorbs the flow irregularities of each phase (liquid or vapour) so as to supply a regular
fluid flow to the installations downstream of it.
This is accomplished by fluctuating the level of This separation
element is located
upstream of the processing and
stabilises the entire regulation of
the separation.
Figure 54: Slug Catcher
liquid in the installation

4.10. ADVANTAGES AND DISADVANTAGES OF THE DIFFERENT TYPES

As indicated above, there are three main types of separators. The table below shows a
comparative performance of these different types.
Horizontal Vertical Spherical
Separation efficiency 1 2 3
Stabilisation of separated fluids 1 2 3
Flexibility (slug production) 1 2 3
Ease of setting (level) 2 1 3
Capacity with same diameter 1 2 3
Price per unit 1 2 3
Tendency to admit foreign bodies 3 1 2
Foam treatment capability 1 2 3
Ease of transport 1 3 2
Vertical sizing 1 3 2
Horizontal sizing 3 1 2
Ease of installation 2 3 1
Ease of inspection and maintenance 1 3 2
1 : Good 2 : Fair 3 : Unsatisfactory
Table 2: Comparative performance of the different types of separators

4.11. EXERCISES
24. Water which is usually qualified as free water is the one which is separated in:
‰ 5 seconds
‰ 5 minutes
‰ 5 hours
25. The main advantage of the vertical separator is that it can accept larger size liquid
slugs without excessive carry over in the gas.
‰ True
‰ False
26. The compressor suction drums (scrubbers) are typical examples of drums
‰ True
‰ False
27. What type of fluid is processed in a scrubber:
‰ Wet gases
‰ Oil
‰ Water
28. In the separator, the deflector is located at the liquid outlet and its function is to
collect these same liquids.
‰ True
‰ False

29. Complete the following diagram which represents the internal elements of an oil/gas
two-phase vertical separator:
30. The anti-vortex prevents the gas from leaving the separator with the liquids.
‰ True
‰ False
31. The demister prevents liquids from coming out through the gas outlet.
‰ True
‰ False

32. Complete the following diagram which shows the external elements of a scrubber:
33. Complete the following diagram which shows the internal elements of a horizontal
separator:

34. The straightening section is often composed of parallel plates that may or may not
be inclined and whose function is to ensure the coalescence of liquid droplets.
‰ True
‰ False
35. The main objective of the separation wall is to allow the gas to by-pass the
straightening section.
‰ True
‰ False
36. This internal element is a:
‰ Diffuser
‰ Sand Jet
37. The two-tube horizontal separator has the advantage of avoiding re-entrainment.
‰ True
‰ False
38. The two-tube horizontal separator produces better effluent separation when there
are many slugs.
‰ True
‰ False

39. Spherical separators are designed for wells with very high GOR.
‰ True
‰ False
40. Spherical separators often operate as three-phase separators.
‰ True
‰ False
41. The wash tank design is based on the principle of bubbling the production through
water kept at the bottom of the tank.
‰ True
‰ False
42. Retention times in wash tanks are short
‰ True
‰ False
43. The cyclone-effect vertical separator is more often used in gas processing systems
‰ True
‰ False
44. In a cyclone-effect separator, the fluid enters tangentially into the device.
‰ True

‰ False
45. In a Vortex-effect separator, the fluid enters tangentially into the device.
‰ True
‰ False
46. Where is the Slug Catcher located on separation?
‰ Upstream
‰ Downstream
47. The role of the Slug Catcher is to absorb the entry flow differences so as to supply a
fluid with regular flow to the installations downstream of it.
‰ True
‰ False
48. Of the three main types of separators (horizontal, vertical, spherical), with same
diameter, which one has the best capacity?
‰ The horizontal separator
‰ The spherical separator
‰ The vertical separator

5. SEPARATOR REPRESENTATION AND DATA

This chapter describes how a separator is represented in the main documents available to
the user:
Process Flow Diagram (PFD)
Piping and Instrumentation Diagram (P&ID)
5.1. PROCESS FLOW DIAGRAM (PFD)
This document published during the project phase presents the main process lines and
capacities together with their main operating parameters in a simplified format.
The PFD example shows 3 three-phase horizontal separators on one separation unit.
PFD description:
The DS301 separator is located at the head of the oil processing chain. It receives the
production effluents from the production collector. It is an oil/gas/water three-phase
separator.
The separated oil feeds the

following production separator
(DS302). The gas is sent to
the High Pressure compressor
where it is dehydrated and
then re-injected into the
reservoir whereas water is
sent to oily water processing
for discharge into the sea.
Figure 55: DS301 three-phase

horizontal separator at
transport

The DS302 separator is located downstream of the DS301 separator and upstream of the
EC 301 A/B heater.
As well as other secondary effluents, it receives the oil from the 1st stage separator. This is an oil/gas/water three-phase separator. The
separated oil feeds the following production separator (DS303). The gas is then sent to the Mean Pressure compressor where it is
recompressed to High Pressure whereas water is sent to oily water processing for discharge into the sea.
The DS303 separator is located downstream of the

DS302.
As well as other secondary effluents, it receives the oil from the 2nd stage separator.
The separated oil is drawn off by the GX301 A/B/C pumps that feed the desalters and then the
stock tanks. At the end of this processing chain, the oil (T°<45°C) has now reached the commercial
specifications: BSW=0.5%, RVP<10psi, NaCl<60mg/l.
The gas is sent to the Low Pressure compressor to be recompressed to Mean pressure whereas water is
sent to oily water processing for discharge into the sea.
Figure 56: Illustration of the DS303 three-phase horizontal separator at

Figure 57: PFD of a separation

Production
Equipment
5.2. PIPING & INSTRUMENTATION DIAGRAM (PID)
This document published during the project phase present the main process lines and capacities together with their operating
parameters in a much more complex format than the PFD. It also comprises the instrumentation, safety devices and start-up lines. It
is a comprehensive document.
The example below reiterates the previous example but in a much more detailed format: The PID.
Production
Equipment
5.3. SEPARATOR DATASHEET
5.3.1. Compressor suction scrubber
Figure 59: Diagram of a compressor suction scrubber
Training course: EXP-PR-EQ080-EN

Last revised: 23/04/2007 Page 68 / 120
Production
Equipment
5.3.2. Slug catcher
Figure 60: Diagram of a slug catcher

Production
Equipment
5.4. SEPARATOR SIZING
5.4.1. Typical example

The gas outlet is located at the top of the
separator. There is a pressure control valve
on the gas exhaust line.
There is also a safety valve or a burst disk.
Figure 61: Typical example of horizontal

separato
r
The gas outlet is located at the top of the separator. There is a pressure control valve
on the gas exhaust line. There is also a safety valve or a burst disk.
Certain separators have both a burst disk and a pressure safety valve (PSV).
Figure 62: Typical example of a production separator

Production
Equipment
There is a liquid level control valve (the discharge valve) and a liquid level controller near
the bottom of the drum.
A drain valve (discharge) is installed at the bottom. It is used for cleaning out the solids
that build up over time. The gauges and visual level indicators are located outside the
separator.
5.4.2. Sizing
The basic component of all gas or crude production installations is of course, the field
separator, i.e. the equipment in which the different liquid and gas phases are separated.
However, the increasing complexity of field installations, in particular offshore ones, along
with the aim to maximise recovery and optimise all of the production units, mean that these
installations include other static separation equipment which also conduct liquid-gas
separations.
The aim of this chapter is therefore to introduce the general principles and methods of
sizing as well as the typical values for a certain number of services.
Note that these methods do not cover some specific types of equipment (heater-treaters,
separators, cyclonic separators...) whose sizing methods are determined by their
manufacturers.
5.4.2.1. Vertical separators
Calculation principle
The required sizes for ensuring the set gas and liquid flowrates are calculated separately.
A – For gas flowrates, the gas velocity is limited in the separator so as to prevent
droplets of liquid being entrained by the gas. This non-entrainment condition
requires a small pipe cross section for the gas, therefore the smallest possible
diameter.
B – For liquid flowrates (oil + water), the calculation must ensure that the liquid
stays in the separator long enough for it to release the gas completely. A retention
time is set to be long enough (from 1 to several minutes, depending on the
separation difficulty) to determine the volume needed by the liquid, i.e. the
separator diameter and length.

Production
Equipment
Minimum Decantation time
This is the time required for a gas bubble to pass through a liquid layer (two-phase
separation) or through oil droplets or for water to pass through layers of water and oil
(three-phase combinations). It is based on the hypothesis that the interfaces are clear cut,
i.e. without foaming and that coalescence time is nil.
The drawing below schematically illustrates, for a separator, the different transit paths of
the droplets in the most unfavourable conditions for decantation i.e.:
Gas bubble at the bottom
Oil droplets at the bottom
Water droplets in oil/gas contact.
In practice, however, only the decantation of the water and oil droplets are calculated or
taken into account.
Figure 63: The different paths of the droplets in the most unfavourable conditions for
decantation
Production
Equipment
Retention time
The real retention or residence time must be greater than the minimum decantation time.
This corresponds to the value obtained by taking the volume measured between the mean
level and the low level, where the mean level is usually located in the middle of the drum.
A minimum buffer volume must remain for subsequent processing of liquid phases.
However, these times are not usually added to the minimum decantation times.
The retention time values, given for a few typical services, are mean values and must be
corrected by experience, where possible, notably for slug catchers, wellhead separators,
and tendency to foaming…
5.4.2.2. Horizontal separators
Gas capacity of a horizontal separator
The non-entrainment condition is set as for a vertical separator. However, when the
balance of forces applied to a droplet is calculated, it is seen that the force said to be
"aerodynamic" R is perpendicular to forces P and A.
The particle follows a path in the separator and the non-entrainment condition is
expressed by writing that the path reaches the liquid level inside the separator. The length
L of the separator must, therefore, be taken into account.
Moreover, using flowrate instead of velocity, the cross section for the gas to be taken in
consideration is no longer the total separator section but a fraction of it, from which the
surface occupied by the liquid must be deducted.
Figure 64: Path of a droplet in a horizontal separator

Production
Equipment
In a horizontal drum, the droplet is subjected to the entire gravitational force, whereas in a
vertical drum, the force of gravity must be corrected for the effect of vertical entrainment by
the gas; decantation therefore requires an additional length, which is not always available.
Figure 65: Comparative resultants for both types of separators
The calculation also shows that if no precautions are taken at the fluid inlet (distributor,
centrifuge inlet...), liquid splatters on the opposite site and pulverisation occurs.
Retention time
Same definition as for vertical separators.

Example of several retention times (vertical and horizontal separators). The values, given
for a few typical services, are mean values and must be corrected by experience, where
possible, notably for slug catchers, wellhead separators, tendency to foaming…
Oil/gas separator drum
This time often varies with the crude, from 2’ (horizontal cylinders) to 5’ in the most cases,
but can reach 10 or even 30 minutes on particularly viscous or foaming crudes without an
anti-foaming agent.
FRICK (Petroleum Production Handbook p.11.31) gives the minimum retention

times versus pressure, as follows:

Production
Equipment
Retention times:
o 0-40 bars : 1 minute

o 40-74 bars : 50 seconds
o + above : 30 seconds.
Compressor suction drum (SCRUBBER)
10’ for maximum production of condensate or 5' of lean oil circulation for a gas
from an absorber.
5.5. EXERCISES
49. What do the initials PFD signify?
50. What do the initials PID signify?
51. Decantation time is the time needed for a gas bubble to cross through the liquid
layer in a two-phase separation.
‰ True
‰ False
52. Decantation time is the time needed for oil or water droplets to cross through the
water and oil layers in a three-phase separation.
‰ True
‰ False

Production
Equipment
6. SEPARATORS AND THE PROCESS
6.1. LOCATION AND CRITICALITY
As is indicated above, the separator is a device used for separating the crude oil, the
gases and the water contained in the effluent leaving the production wells.
There will often be several separators arranged in series (as shown in the example below)
which allow us to reach the desired specifications.
All the functions are essential to production if they are seen as being necessary for
meeting the required specifications at the end.
Nevertheless, one function is more or less critical depending on the need to stop
production if this function is lost or to carry on operating for a short time in downgraded
mode.
The criticality of this equipment is thus high because as it will result in a production shut
down. As the separators are arranged generally in series, the interruption of one separator
will result in the whole installation stopping. There is no backup device because these
drums are very large.
Finally, there is no by-pass because each separator must be used with a certain volume of
oil, water and gas at a required temperature and pressure.

Production
Equipment
Figure 66: PFD – Three-phase separators DS301/DS302/DS303 on Girassol

Production
Equipment
6.2. RELATED PROCESSES
To enhance the process, chemical products such as anti-foaming and de-emulsifying

agents, are injected upstream of the separation.
For the same reason, anti-corrosion products are injected, but as far upstream as possible
(on the wells).
These products will be dealt with in course on "Separation" as they are more linked to the
separation process than to the equipment itself.
6.3. EXERCISES
53. Is shutting-down of a separator critical to the correct operating of the installation?
‰ Yes
‰ No
7. AUXILIARIES
Various elements are required to

guarantee the proper operation
of a separator.
The following chapter details

the accessories and process
lines surrounding a separator
in a unit.
Figure 67: Diagram of the

separator
operating
principle

Production
Equipment
7.1. LEVEL CONTROL DEVICES
The liquid levels in the separator must be controlled so that the separator can carry out
its task.
Transmitter and level controller
The liquid level control valves

(discharge valves) are actuated
(operated) by liquid level
controllers.
Figure 68: Level sensor and transmitter

Production
Equipment
Sight glass
Separators also have visual level indicators for

controlling the liquid levels.
These devices allow the operator to check the level,

the correct operation of the discharge valves and the
appropriate level controllers.
Figure 69: Sight glass
7.2. PRESSURE CONTROL DEVICES
Gas pressure must also be controlled.
Pressure regulators
Pressure is controlled by pressure regulators installed

at the gas outlet.
They maintain the separator pressure by acting on the

pressure control valve.
Figure 70: Automatic regulation valve (1)

Production
Equipment
Figure 71: Automatic regulation valve (2)
Pressure transmitters
The separators also have pressure
transmitters. They ensure the correct working
of the pressure
control valve and its regulator.
Figure 72: Pressure Transmitter

Production
Equipment
Safety Valves
Pressure Safety Valve (PSV): The safety valves evacuate the

potential energy surplus from the system. This system must
be protected to limit the maximum pressure in the equipment.
The valves protect the device with an admissible pressure.
A safety valve is a safety device which operates in

particular situations. Its normal position is the closed
position.
This valve is designed to evacuate, in general, a gaseous

flow since, at equal volume, more energy (pneumatic) is
evacuated in the gas phase than in the liquid phase.
Figure 73: Safety valve
Two valves are usually installed so that when one is

in use, the other can be serviced.
Manometers
Often, the separators also have manometers (also

called pressure gauges.
Figure 74: Manometer

Production
Equipment
7.3. TEMPERATURE CONTROL DEVICES
Temperature transmitters and thermometers are also often installed for controlling the
temperature.
Figure 75: Thermometer
Figure 76: Temperature

sensor and transmitter
7.4. VALVES
Manual valves are installed on water and oil outlets for

carrying out maintenance operations and thus
increasing the number of safety barriers.
Figure 77: Manual valve

Production
Equipment
7.5. FLOWMETERS
Gas or Water or Oil flowmeters:
These devices are often installed on separators, at the

oil/water/gas outlets for controlling the respective
flowrates and the underlying efficiency of the separator.
Figure 78: Flowmeter
There are different types of

flowmeters, depending where they are installed, the product
they are metering and the accuracy needed for metering the
effluent.
Figure 79: Vortex flowmeter

Production
Equipment
7.6. EXERCICES
54. Name the devices below:

Production
Equipment

Production
Equipment
8. OPERATING PARAMETERS
8.1. NORMAL OPERATION

Separator operation consists in ensuring that it provides the desired flow for the longest
possible time.
8.1.1. Separation parameters

Parameters of separation, pressure, temperature and level allow the Reid vapour pressure
(R.V.P.) specification to be satisfied and in certain cases, the H2S content as well.
Figure 80: View of the parameters to be monitored
Pressure
The separating pressure is set by the process. It must be maintained constant (it is
not an operating variable). This parameter optimises the recovery. Moreover, it
determines the liquid flowrate during separation. A decrease in this would result in
a very sensitive variation in gas velocity, thereby risking liquid entrainment.

Production
Equipment
Temperature
Temperature is an operating variable when there is a heater or cooler. This, also,

is an optimisation parameter. It is usually less sensitive than the pressure on gas
removal behaviour.
When the fluid is heated, degassing increases (RVP decreases).
When the fluid is cooled, degassing decreases.
Level
It, alone guarantees the time the liquids remain in the separator.
8.1.2. Controls to be carried out or monitoring during operation
With a separator in normal service, the following checks must be carried out:
Observe variations in level, pressure, temperature and flow control instruments in

order to see if these devices are effectively controlling within the required ranges.
The control valve positioning diaphragm must be in proper working condition. To

do this, the operator, in contact with the control room, and depending on the site
facilities, will have to ensure this, from time to time, by performing a full,
unrestricted opening or closing manoeuvre.
From time to time, the visual level indicators will have to be purged and cleaned to
avoid erroneous readings (bal valves tested, taps not clogged).
Make sure there are no leaks.

Production
Equipment
8.1.3. Positioning of the valves in normal operation
8.1.3.1. Safety valves
All Shut Down Valves are open:
Fluid inlet
Oil outlet
Water outlet
The BDV is closed:
BDV gas outlet to flare
8.1.3.2. Regulating valves
The LCVs are in automatic regulating mode:
Oil outlet
Water outlet
The PCV is on automatic regulating mode:
PCV gas outlet
All the equipment is in service, the manual by-passes are closed. All the controllers
are operating

Production
Equipment
8.2. SAFE OPERATION
Figure 81: View of a three-phase horizontal separator with its safety elements

Production
Equipment
8.2.1. Alarms and safety
Different sensors ensure two levels of protection (1 sensor for regulation and 1
sensor for safety)
The sensors and valves which ensure a safety function are separate from the
process control devices
The valves for isolating the separator are independent and distinct
The safety systems can be tested without stopping the production
There is a protection system against overpressures and underpressures
The decompression system is connected to the flare or a vent
The valves cannot be isolated except by means of coupled valves (interlock type)
or a valve locked in the open position.
Separator monitoring mainly consists in checking that the liquid levels (oil and contact or
interface) are correctly maintained and that the low and high alarms are not triggered.
The thresholds have the following meaning:
LSH very high level (initiation) for OIL phase
LAH high level (alarm) “
NLL normal liquid level “
LAL low alarm level “
LSLL very low level (initiation) «
LDAH high level (alarm) for WATER phase

Production
Equipment
There is a protection system against overpressures and underpressures
The decompression system is connected to the flare or a vent
The valves cannot be isolated except by means of coupled valves (interlock type)
or a valve locked in the open position.
Separator monitoring mainly consists in checking that the liquid levels (oil and contact or
interface) are correctly maintained and that the low and high alarms are not triggered.
The thresholds have the following meaning:
LSH very high level (initiation) for OIL phase
LAH high level (alarm) “
NLL normal liquid level “
LAL low alarm level “
LSLL very low level (initiation) «
LDAH high level (alarm) for WATER phase
NLDL normal contact level “
LDAL low level (alarm) “
LDSL very low level (initiation) «
PSH very high pressure (initiation)
PAH high pressure (alarm)

Production
Equipment
8.2.2. Valves in Emergency Shut Down position
8.2.2.1. Safety valves
All SDVs are closed:
Fluid inlet
Oil outlet
Water outlet
The BDV is:
Closed (if a pressurised stop)
Open (if a depressurised stop)
BDV gas outlet towards flare
8.2.2.2. Regulating valves
The LCVs are closed:
Oil outlet
Water outlet
The gas outlet PCV is locked:
All the equipment is in service, the manual by-passes are closed.
All the controllers are operating.

Production
Equipment
8.3. MAX / MIN CAPACITIES
The separators are designed for separating a certain flowrate per day. At this nominal
flowrate, the separation process will be carried out correctly.
However, the separators are also designed for receiving max / min flowrates, but at these
rates, separation is less and less efficient. Thus it would be more difficult to reach the
commercial specifications.
The difficulty lies in the field evolution study (daily flowrates, fluid modifications: GOR,
BSW...).
This study results will be used to size the separators so as to operate closest to their
nominal flowrate, for as long as possible.
However, separator operation can always be modified by acting on the internal elements,
when possible. (E.g. modifying the weir so as to increase or decrease the time the fluid to
be treated remains in the separator).

Production
Equipment
8.4. EXERCISES
55. What are the separating parameters for meeting the R.V.P. vapour pressure
specification?
56. Give three checks to be carried out when inspecting the "separator" equipment.
57. In normal operation, the SDVs are closed and the BDV is open:
‰ True
‰ False
58. The sensors and valves which ensure a safety function are separate and distinct
from the process control devices:
‰ True
‰ False
59. There is no protection system for overpressures/underpressures
‰ True
‰ False

Production
Equipment
60. Valves cannot be isolated except by means of coupled valves (interlock type) or a
valve locked in the open position.
‰ True
‰ False
61. After an emergency shut down, all the SDVs are closed.
‰ True
‰ False
9. SEPARATOR OPERATION
9.1. COMMISSIONING AND SHUTTING DOWN A SEPARATOR
All manufacturers have slightly different production procedures but the basics are common
to all.
The initial start-up and shut-down of production separators will be covered in this chapter.

Production
Equipment
9.1.1. Commissioning a separator
Check the gas and liquid evacuation lines are correctly arranged.
If the drum is empty, close an isolating valve on each liquid outlet of the separator.
This prevents the gas from passing through leaking liquid level control valves.
Set the pressure controller to about 75% of normal working pressure. It will then
adjust to normal operating pressure once the capacity is in service. This prevents
the protection devices against equipment overpressures (valves) from opening if
the pressure controller is out of adjustment (badly calibrated).
If the low level safety devices have initiated, they must be inhibited (upon
Superintendent request) until they are disabled. Caution: During this operation,
inspection should be intensified and the inhibition should notably be cancelled as
soon as possible.
Start up injection of all the chemical products (anti-foam, de-emulsifying) required

for a correct separation operation.
Slowly open the separator inlet.
WARNING: Always open the valves slowly. This prevents water hammer and slugs of
liquid which can damage the equipment and generate a danger for the personnel as well
as their installation.
When the pressures and liquid levels are within the scale of the level controllers, put the
level controllers in service and in automatic and open the valves that were isolated.
Adjust the level and pressure to normal operating values in order to stabilise the
operations.
NB: All start-up, filling operations, etc…, must be carried out in agreement with the control
room and in keeping with the OPERGUIDE procedures of the subsidiary, if any, or the site
instructions.

Production
Equipment
9.1.2. Shutting down a separator

With regard to shutting down a separator, the operator must control the correct position of
the valves according to the degree of shut-down.
9.2. PROVISION
For provisioning a separator, the following steps must be carried out:
Drain the separator if required.
Adjust the level controllers so that the level control valves stay open until the low
safety level (LSL) initiates.
Inhibit the low safety level (LSL) in agreement with the Superintendent. Now, the
operator must be sure liquid is present by checking the visual level indicators
during separator drainage. Before performing this operation, make sure the eye
levels are working properly.
Before no liquid is left in the separator, decrease the pressure in the drum that is
being drained to around one Delta P + 2 bars (Delta P to be adjusted according to
on-site experience) using the drum into which the liquid is being purged. This is
done to ensure there is no pressure surges in the drum receiving the purged liquid.
Once the drainage operation is finished, close the isolating valves at the liquid
outlets.
Even if the separator must not be drained, close the isolating valves on the liquid
outlets to prevent any gas passing through the level control valves; even when
100% closed, these are not sealed.
If the drum must be depressurised, close one isolating valve on the gas exhaust
line.
Depressurise the separator by opening a valve to the flare line (vent /blowdown
isolation system).

Production
Equipment
Leave a slight positive pressure in the capacity to prevent air introducing the
separator. Clearing the drum with an inert gas, before being next put into service,
would not then be needed.
NB: All start-up, filling operations, etc…, must be carried out in agreement with the control
room and in keeping with the OPERGUIDE procedures of the subsidiary if any, or the site
instructions.
9.3. 1ST LEVEL MAINTENANCE
In separator first level maintenance, the operator does an inspection tour of the
installation, checking the correct operation of the auxiliary equipment and recording the
installation operating parameters.
This parameter recording must be compared with the parameters retransmitted to the
control room. This allows checking their proper operation.
And to provide any maintenance work if necessary.
He should, for example, check if the manometers (pressure gauges) read within the scale
and if their value matches that retransmitted to the control room.
Similarly, he must check the different levels (oil, water) by ensuring that the visual level
indicators are clean. (Clean them according to the instructions if required).
He must also ensure the correct layout and installation of the valves (seal in place,
correctly positioned valve, valve leaks…) and leakage from the packing assembly.
Moreover, he should inspect the tightness of the packing assembly.

Production
Equipment
10. TROUBLESHOOTING
10.1. WHAT TO DO IF
The cause of an operating problem is found through a fault-elimination process.
Each event that can give rise to a problem is checked until the cause is found. Whatever
the cause, the best way to find it is to start by eliminating the most likely causes first.
The most likely causes are instrument-related problems (pressure gauges, valve position
control, pressure controllers, reliability of the visual level indicators, flowmeters, etc…).
By carrying out these inspections, it is necessary to ensure that the instruments are
working properly and are not giving false readings.
Once the likely causes are checked and eliminated, the more difficult ones should be
checked.
Another important part of troubleshooting is to have a complete view of the entire

separating process and not just of the equipment.
The problems encountered at the installation inlet can often only be seen at the outlet.
However, it is necessary to find the origin of the problems before too much damage occurs
in the downstream processing phases.

Production
Equipment
10.1.1. Troubleshooting procedure for liquid entrainment to the outlet
CAUSE OF CARRYOVER TROUBLESHOOTING PROCEDURE
High inlet gas flow rate Check gas flow rate and cut back to design rate.
Check liquid level.

High liquid level which cuts down vapor
Blow down gauge glass.
disengaging space
Lower level to design point.
Check temperature and pressure to determine if

hydrate has formed.
Measure pressure drop across device. It should

be less than 10 kPa (2 psi). If pressure drop
Coalescing plates, mist pad, or centrifugal device
across mist pad is 0, pad may have torn or come
is plugged
loose from its mounting. Pressure drop
measurement should be made at design gas flow
rate. High pressure drop indicates plugging.
Internally inspect and clean if necessary.
Excessive wave action in liquid. Install horizontal baffles
Check pressure and raise to design.

Operating pressure is below because degassing
increases Lower gas rate in proportion to reduction in
pressure.
Liquid density is less than design because the Check liquid density. If it is less than design, gas
difference between the gas and liquid densities is rate will have to be cut in proportion to reduction
smaller. in density
Table 3: Troubleshooting procedure for liquid entrainment to the outlet

Production
Equipment
10.1.2. Troubleshooting procedure where maintaining a constant liquid level is

impossible
CAUSE OF CHANGING LEVEL TROUBLESHOOTING PROCEDURE
Clean gauge glass to get accurate level reading

It a float cage is external, drain it to be sure pipes
between cage and vessel are not plugged.
When gauge glass and float care are clean,

Float is totally covered with liquid. check to see if float is covered with liquid.
Manually drain enough liquid from vessel so that

½ of float is immersed.
Put level controller in service
Perform steps a and b above.
If level is below float, close valve in liquid outlet

Liquid level is below float.
line to allow level to rise until float is ½ covered
Put level controller in service
If level controller does not have reset, the level

controller will have to be changed each time the
liquid flow rate makes a significant change
Liquid flow rate has changed.
If the controller has reset, it can be adjusted to
take care of changes in liquid flow rate.
Lower set point in level controller.

Liquid enters vessel in slugs.
In some cases it may be helpful to install a valve
Level controller does not react fast enough to
positioner on the level control valve in order for it
drain liquid
to open rapidly
Wave action is causing internal float to move. Install float shield

Table 4: Troubleshooting procedure where maintaing a constant liquid level is impossible

Production
Equipment
10.2. EXPERIENCE FEEDBACK
11. GLOSSARY
Anhydrous
A term literally meaning "without water"; it describes a substance in which no water is
present in the form of a hydrate or water of crystallization.
Asphaltenes
Constituents of petroleum products having a high molecular mass and dark colour, free
from wax, insoluble in n-heptane and soluble in hot benzene.
Complicated hydrocarbons with molecular skeletons of the graphite type linked together by
long carbon chains. Asphaltenes or "asphaltic matter" are present in almost all crude oils,
but being effectively non-volatile they appear only in the heavier fractions, heavy oils and
bitumen.
Ballast
One of the tanks in the hold of a ship that can be pumped full of or free from water or fuel
ballasts. Larger vessels either use water as ballast by flooding tanks on board.
BDV
Blowdown Valve
By-pass
A valved piping loop to permit flow around a valve closure.
Coalescence
The action by which liquid particles in suspension unite to form particles of greater volume.
Colloidal clay
Clay whose particles are so minute and of such nature that when mixed with a suitable
liquid, it remains in stable suspension.
Colloidal
Composed of particles that are very small hut larger than most molecules.
Condensate

Production
Equipment
A natural gas liquid consisting of a mixture of hydrocarbons (C_5 and upwards) occurring
along side lighter fractions in high pressure and temperature gas reservoirs. It condenses
out of the gaseous mixture as the result of pressure and temperature drop on extraction
from the reservoir.
Deflector
A tray or partition placed in process equipment to direct or change the direction of flow.
Kinetic energy
The energy which a body has because it is in motion.
LCV
Level Control Valve
Manifold
A pipe fitting with several lateral outlets for connecting flowlines from one or more wells.
This connection directs flow to heater-treaters, separators or other devices.
Miscible
Capable of mixing or dissolving in all proportions to give a homogeneous mixture (i.e. a
solution).
A term describing the extent to which liquids or gases can be mixed or blended.
Substances in the gaseous phase can blend in any proportion; this may or may not be true
of liquids. Some, such as ethyl alcohol and water, will blend uniformly in all proportions;
others have limited miscibility that is they will blend only until a certain concentration is
reached.
Packing assembly
A device to seal the flow between the surface of a fixed element (e.g. a bearing shell) and
a mobile elemnt (e.g. a valve spindle, a shaft or a piston rod). - Stuffing-box consists of a
sealing space, a gland and sealing-material to fill the gland space.
PCV
Pressure Control Valve
Retention time
The period that a liquid will be retained in a vessel.

Production
Equipment
Screened pipes
Perforated lining tube
Scrubbers
A device for the removal, or washing out, of entrained liquid droplets or dust, or for the
removal of an undesired gas component from process gas streams.
SDV
Shut Down Valves
Skid
A load carrying platform supported from the floor by two parallel stringers or supports.
Lifting device enters between the stringers.
Stripping
Removal of the light components from a petroleum product by injection of inert gas or
water vapour.
Surfactant
A substance that even though present in small amounts, exerts a marked effect on the
surface behavior of a system.
These agents are essentially responsible for producing great changes in the surface
energy of liquid or solid surfaces, and their ability to cause these changes is associated
with their tendency to migrate to the interface between two phases. Consequently,
surfactants are of potential interest wherever there are solid-solid, solid-liquid, solid-gas,
liquid-liquid, or liquid-gas interfaces at which the surfactant is a solute whose presence
makes the surface properties of the solution greatly different from those of the solvent.
Tubular orifice
An opening of construction in a passage to regulate the flow of a fluid, having the form of a
tube, or containing, or provided with tubes

Production
Equipment
Surfactant
A substance that even though present in small amounts, exerts a marked effect on the
surface behavior of a system.
These agents are essentially responsible for producing great changes in the surface
energy of liquid or solid surfaces, and their ability to cause these changes is associated
with their tendency to migrate to the interface between two phases. Consequently,
surfactants are of potential interest wherever there are solid-solid, solid-liquid, solid-gas,
liquid-liquid, or liquid-gas interfaces at which the surfactant is a solute whose presence
makes the surface properties of the solution greatly different from those of the solvent.
Tubular orifice
An opening of construction in a passage to regulate the flow of a fluid, having the form of a
tube, or containing, or provided with tubes
Vent
An opening or hole for the escape or passage of something (as of a gas or liquid)..

Production
Equipment
12. FIGURES:
Figure 1: Situation of the separation in a processing of oil ..................................................6
Figure 2: Example of a separator.........................................................................................6
Figure 3: General diagram of the processing of well effluents .............................................7
Figure 4: Separation principle ..............................................................................................9
Figure 5: Path of the effluent between the reservoir and the processing centre ................11
Figure 6: P-T diagram representative of the changes of the fluid during its transit ............12
Figure 7: Wellhead effluent composition ............................................................................12
Figure 8: RVP measuring instrument .................................................................................14
Figure 9: View of a three-phase separator (Girassol test separator) .................................18
Figure 10: View of the equipment in a separator ...............................................................23
Figure 11: The different sections in a spherical separator .................................................24
Figure 12: The different sections in a vertical separator ....................................................25
Figure 13: The different sections in a horizontal separator ................................................25
Figure 14: Inlet deflector ....................................................................................................26
Figure 15: Wire Mesh ........................................................................................................26
Figure 16: Perforated weir plate.........................................................................................26
Figure 17: Vortex breaker ..................................................................................................27
Figure 18: External view of a vertical separator .................................................................30
Figure 19: Detailed view of a 2 phase vertical oil/gas separator ........................................31
Figure 20: Typical example of a scrubber ..........................................................................32
Figure 21: Detailed view of a scrubber ..............................................................................32
Figure 22: Detailed view of a three-phase separator .........................................................33
Figure 23: Detailed view of a two-phase horizontal separator ...........................................34
Figure 24: Photo of an inlet diffuser ...................................................................................35
Figure 25: View of the separator inlet diffuser process ......................................................35
Figure 26: Demister ...........................................................................................................35
Figure 27: View of a "Wire Mesh" ......................................................................................35
Figure 28: View of "internal baffles" in a horizontal separator ............................................36
Figure 29: View of a perforated plate .................................................................................36
Figure 30: Diagram showing the significance of the perforated plates...............................37
Figure 31: View of an anti-vortex device ............................................................................37
Figure 32: Sand Jet ...........................................................................................................38
Figure 33: Cutaway view of a two-phase horizontal separator...........................................38
Figure 34: Cutaway view of a three-phase horizontal separator ........................................39
Figure 35: Simple diagram of a three-phase separator......................................................40

Production
Equipment
Figure 36: Detailed view of a three-phase horizontal separator.........................................40

Figure 37: Cutaway view of a three-phase horizontal separator ........................................41
Figure 38: Exploded view of a three-phase separator (floating separator with flow dividing)
...................................................................................................................................41
Figure 39: High pressure two-phase horizontal separator with liquid retention capacity....42
Figure 40: Cutaway view of a two-tube three-phase horizontal separator .........................43
Figure 41: Two-phase spherical separator.........................................................................44
Figure 42: Detailed view of a vertical droplet separator .....................................................45
Figure 43: Detailed view of a horizontal droplet separator .................................................46
Figure 44: Detailed view of a traditional Wash Tank ..........................................................47
Figure 45: Diagram of a Gun Barrel principle.....................................................................48
Figure 46: Deflector ...........................................................................................................50
Figure 47: FWKO-Free Water Knock Out ..........................................................................50
Figure 48: Vertical cyclone separator ................................................................................51
Figure 49: Operating principle of a cyclone effect separator..............................................52
Figure 50: Cross section view of a cyclone ........................................................................52
Figure 51: View of an internal multicyclone........................................................................52
Figure 52: Example of a Multicyclone separator ................................................................53
Figure 53: Cross section view of a demister ......................................................................54
Figure 54: Slug Catcher .....................................................................................................55
Figure 55: DS301 three-phase horizontal separator at transport .......................................63
Figure 56: Illustration of the DS303 three-phase horizontal separator at installation .........64
Figure 57: PFD of a separation ..........................................................................................65
Figure 58: A PID example of a separation .........................................................................67
Figure 59: Diagram of a compressor suction scrubber ......................................................68
Figure 60: Diagram of a slug catcher .................................................................................69
Figure 61: Typical example of a horizontal separator ........................................................70
Figure 62: Typical example of a production separator .......................................................70
Figure 63: The different paths of the droplets in the most unfavourable conditions for
decantation
.................................................................................................................72
Figure 64: Path of a droplet in a horizontal separator ........................................................73
Figure 65: Comparative resultants for both types of separators ........................................74
Figure 66: PFD – Three-phase separators DS301/DS302/DS303 on Girassol..................77
Figure 67: Diagram of the separator operating principle ....................................................79
Figure 68: Level sensor and transmitter.............................................................................79
Figure 69: Sight glass ........................................................................................................80
Figure 70: Automatic regulation valve (1) ..........................................................................80
Figure 71: Automatic regulation valve (2) ..........................................................................80

Production
Equipment
Figure 72: Pressure Transmitter ........................................................................................81

Figure 73: Safety valve ......................................................................................................81
Figure 74: Manometer........................................................................................................81
Figure 75: Thermometer ....................................................................................................82
Figure 76: Temperature sensor and transmitter.................................................................82
Figure 77: Manual valve.....................................................................................................82
Figure 78: Flowmeter .........................................................................................................83
Figure 79: Vortex flowmeter ...............................................................................................83
Figure 80: View of the parameters to be monitored ...........................................................85
Figure 81: View of a three-phase horizontal separator with its safety elements ................88
13. TABLES
Table 1: Reservoir fluid separation tests............................................................................17

Table 2: Comparative performance of the different types of separators ............................56
Table 3: Troubleshooting procedure for liquid entrainment to the outlet ............................98
Table 4: Troubleshooting procedure where maintaing a constant liquid level is impossible
...................................................................................................................................99

Production
Equipment
14. CORRECTIONS FOR EXERCISES
1. What are the three elements of the effluent that a three-phase separator
dissociates?
Gas – Oil - Water
2. The separator acts on the density of the effluent components in order to separate
them.
; True
3. Crude oil does not need to be processed in order to be commercialised.
; False
4. Give two technical reasons why the effluent must be processed.
Stable products (vapour pressure specification to be observed, therefore

the crude must be stabilised).
Measurable products (this means that can it be metered, without water,

without sediment, without gas, to know exactly the quantities sold)
Pumpable products (the crude needs to be transported from the terminal to

the tanker and from the tanker to the refinery)
Non-scaling products (this means that they do not cover the barrels, pipes,
or tanks with a mineral layer (paraffins), for example, sulphate, carbonate
deposits etc…)

Production
Equipment
5. Give one commercial reason why the effluent must be processed.
Anhydrous products (customers do no want to transport water)
Non corrosive products (protection of the tanker, refineries and customers:

salts-H2S)
6. Give one environmental reason why the effluent must be processed.
To discharge components without commercial value into the immediate

environment, without polluting
7. What do the initials R.V.P. mean?
Reid Vapour Pressure
8. The RVP (vapour pressure) specification is linked to the gas content dissolved in
the crude.
; True
9. The more the dissolved gas content decreases the more the RVP of the crude will
increase.
; False
The higher the dissolved gas concentration, the higher the RVP.
10. On natural flowing reservoirs with a wellhead pressure higher than the atmospheric
pressure, what is the simplest method used for stabilising a crude?
The simplest means of stabilising a crude oil is to subject it to a certain

number of separations at decreasing pressures (multi-stage separation) and
to separate the gas obtained at each one of the separation stages.

Production
Equipment
11. Complete the diagram of the separating principle
12. Where are the separators located on the oil processing chain?
; At the beginning
13. What are the two main types of separator?
Horizontal – Vertical
14. By using the definitions of the diagram below, find the location of the correct
pressures.

Production
Equipment
15. In this P-T diagram showing the changes of the fluid during its transit path (red line),
find the location of the correct pressures.
16. Usually, the RVP specifications of the finished product are between:
7 and 10 psi.
17. Usually, the water content from the installation is:
0,1 % vol
18. Usually, the H2S content from the installation is between:
Mediterranean: 30 and 40 ppm mass
Middle East: 70 and 80 ppm mass

Production
Equipment
19. Usually, the salt content from the installation is:
40 - 60 mg/l NaCl
20. Complete the following diagram:

Production
Equipment
of a horizontal separator.
of a vertical separator.

Production
Equipment
of a spherical separator.
24. Water which is usually qualified as free water is the one which is separated in:
; 5 minutes
25. The main advantage of the vertical separator is that it can accept larger size liquid
slugs without excessive carry over in the gas.
; True
26. The compressor suction drums (scrubbers) are typical examples of drums
; True
27. What type of fluid is processed in a scrubber:
; Wet gases

Production
Equipment
; False
The deflector plates are located at the inlet of the separator

Production
Equipment
; False
The deflector plates are located at the inlet of the separator

Production
Equipment
30. The anti-vortex prevents the gas from leaving the separator with the liquids.
; True
31. The demister prevents liquids from coming out through the gas outlet.
; True
32. Complete the following diagram which shows the external elements of a scrubber:

Production
Equipment
33. Complete the following diagram which shows the internal elements of a horizontal
separator:
34. The straightening section is often composed of parallel plates that may or may not
be inclined and whose function is to ensure the coalescence of liquid droplets.
; True
35. The main objective of the separation wall is to allow the gas to by-pass the
straightening section.
; False
The separation wall mainly prevents the gas from by-passing the
straightening section, and also to avoid the gas from forming waves at the
surface of the liquid.

Production
Equipment
36. This internal element is a:
; Sand Jet
37. The two-tube horizontal separator has the advantage of avoiding re-entrainment.
; True
38. The two-tube horizontal separator produces better effluent separation when there
are many slugs.
; True
39. Spherical separators are designed for wells with very high GOR.
; True
40. Spherical separators often operate as three-phase separators.
; False
They are relatively low-cost and compact, but with a limited liquid retention
time and decantation section. Use in three-phase separation is, therefore,
very difficult if not impossible.

Production
Equipment
41. The wash tank design is based on the principle of bubbling the production through
water kept at the bottom of the tank.
; True
42. Retention times in wash tanks are short
; False
43. The cyclone-effect vertical separator is more often used in gas processing systems
; True
44. In a cyclone-effect separator, the fluid enters tangentially into the device.
; True
45. In a Vortex-effect separator, the fluid enters tangentially into the device.
; False
The fluid enters the separator axis
46. Where is the Slug Catcher located on separation?
; Upstream
A slug catcher is a device that is used as a buffer on the outlet line. Its
function is to absorb the “liquid slugs” that form in the pipes or three-phase
separators
47. The role of the Slug Catcher is to absorb the entry flow differences so as to supply
a fluid with regular flow to the installations downstream of it.
; True

Production
Equipment
48. Of the three main types of separators (horizontal, vertical, spherical), with same
diameter, which one has the best capacity?
; The horizontal separator
49. What do the initials PFD signify?
Process Flow Diagram
50. What do the initials PID signify?
Piping & Instrumentation Diagram
51. Decantation time is the time needed for a gas bubble to cross through the liquid
layer in a two-phase separation.
; True
52. Decantation time is the time needed for oil or water droplets to cross through the
water and oil layers in a three-phase separation.
; True
53. Is shutting-down of a separator critical to the correct operating of the installation?
; Yes
The interruption of one separator will result in the whole installation stopping.

Production
Equipment
54. Name the devices below:
Level sensor and transmitter
Sight glass
Pressure Transmitter
Safety valve
Manual valve
Automatic regulation valve
Flowmeter

Production
Equipment
Temperature sensor and transmitter
55. What are the separating parameters for meeting the R.V.P. vapour pressure
specification?
Pressure
Temperature
Level
56. Give three checks to be carried out when inspecting the "separator" equipment.
Observe variations in level, pressure, temperature and flow control

instruments in order to see if these devices are effectively controlling within
the required ranges.
The control valve positioning diaphragm must be in proper working condition.

To do this, the operator, in contact with the control room, and depending on
the site facilities, will have to ensure this, from time to time, by performing a
full, unrestricted opening or closing manoeuvre.
From time to time, the visual level indicators will have to be purged and
cleaned to avoid erroneous readings (bal valves tested, taps not clogged).
Make sure there are no leaks.
57. In normal operation, the SDVs are closed and the BDV is open:
; False

Production
Equipment
All Shut Down Valves are open: Fluid inlet, Oil outlet, Water outlet
BDV gas outlet to flare
58. The sensors and valves which ensure a safety function are separate and distinct
from the process control devices:
; True
59. There is no protection system for overpressures/underpressures
; False
Safety valves
60. Valves cannot be isolated except by means of coupled valves (interlock type) or a
valve locked in the open position.
; True
61. After an emergency shut down, all the SDVs are closed.
; True

Production
Equipment

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EQUIPMENT

1. OBJECTIVES ....................................................................................... Error! Bookmark not defined.

2. THE FUNCTIONS OF A SEPARATOR ................................................. Error! Bookmark not defined.

2.1. INTRODUCTION ........................................................................... Error! Bookmark not defined.

2.2. WHY IS THE EFFLUENT PROCESSED? ..................................................................................... 8

2.3. DEFINITIONS OF A SEPARATOR .............................................................................................. 11

2.4. THE FINISHED PRODUCT ........................................................... Error! Bookmark not defined.

2.4.1. Definition of the vapour pressure (TVP) ................................................................................ 15

2.4.2. Definition of the REID vapour pressure (RVP) ...................................................................... 15

2.4.3. H2S specification ..................................................................... Error! Bookmark not defined.

2.5. EXAMPLE OF A SEPARATOR.................................................................................................... 20

2.6. EXERCISES ................................................................................................................................ 21

3. OPERATION OF SEPARATORS ................................................................................................. 25

3.1. THE SECTIONS OF A SEPARATOR .......................................................................................... 25

3.1.3. The coalescence section ......................................................... Error! Bookmark not defined.

3.1.4. The collecting section .............................................................. Error! Bookmark not defined.

Prepared By: Najem Sakor Reviewed By: Approved By:

3.3. EXERCISES .................................................................................. Error! Bookmark not defined.

4. THE DIFFERENT TYPES OF SEPARATORS .................................................................................... 32

4.1. VERTICAL SEPARATORS .......................................................................................................... 32

4.1.1. Two-phase vertical separators .............................................................................................. 33

4.1.2. Three-phase separators ....................................................................................................... 35

4.2. HORIZONTAL SEPARATORS .................................................................................................... 36

4.2.1. Two-phase horizontal separators .......................................................................................... 42

4.2.2. Three-phase horizontal separators ....................................................................................... 43

4.2.3. High-pressure horizontal separator with liquid retention capacity ......................................... 46

4.3. SPHERICAL SEPARATOR ............................................................ Error! Bookmark not defined.

4.5. DECANTATION TANKS AND WASH TANKS.............................................................................. 51

4.5.1. Wash tank accessories ......................................................................................................... 52

4.7. "CENTRIFUGAL" SEPARATOR .................................................................................................. 56

4.7.1. Cyclone effect separator ....................................................................................................... 56

4.7.2. Vortex effect separators ........................................................................................................ 60

4.8. DROPLET ELIMINATORS ("DEMISTERS") ................................................................................ 60

4.9. SLUG CATCHERS ....................................................................... Error! Bookmark not defined.

4.10. ADVANTAGES AND DISADVANTAGES OF THE DIFFERENT TYPES ................................... 62

4.11. EXERCISES .............................................................................................................................. 63

5. SEPARATOR REPRESENTATION AND DATA ................................................................................... 69

5.1. PROCESS FLOW DIAGRAM (PFD) ............................................................................................ 69

5.2. PIPING & INSTRUMENTATION DIAGRAM (PID) ....................................................................... 72

Prepared By: Najem Sakor Reviewed By: Approved By:

5.3.2. Slug catcher .......................................................................................................................... 69

5.4. SEPARATOR SIZING .................................................................................................................. 70

5.4.1. Typical example .................................................................................................................... 70

5.5. EXERCISES .................................................................................. Error! Bookmark not defined.

6. SEPARATORS AND THE PROCESS ................................................... Error! Bookmark not defined.

6.1. LOCATION AND CRITICALITY ..................................................... Error! Bookmark not defined.

6.2. RELATED PROCESSES ............................................................................................................. 78

6.3. EXERCISES ................................................................................................................................ 78

7. AUXILIARIES ....................................................................................... Error! Bookmark not defined.

7.1. LEVEL CONTROL DEVICES ......................................................... Error! Bookmark not defined.

7.2. PRESSURE CONTROL DEVICES .............................................................................................. 80

7.3. TEMPERATURE CONTROL DEVICES ....................................................................................... 83

7.4. VALVES ....................................................................................................................................... 83

7.5. FLOWMETERS ............................................................................................................................ 84

7.6. EXERCICES ................................................................................................................................ 85

8. OPERATING PARAMETERS ............................................................................................................. 87

8.1. NORMAL OPERATION ................................................................................................................ 87

8.1.1. Separation parameters .......................................................................................................... 87

8.1.3. Positioning of the valves in normal operation ........................................................................ 89