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3 Phase Separators (Separators)
ASCOM designed separators guarantee a very high performance because of:
Application of state-of-the-art design rules based on in-house expertise using CFD and
empirically verified by testing.
1.
Use of the proprietary range of high performance ASCOM HiPer internals. 2.
Design philosophy: 4 sections of a separator
Generally, in horizontal orientated gas/liquid separators, the incoming multiphase mixture
flows into the vessel through an inlet device.
The inlet section (1) ensures preliminary gas/liquid(s) separation and a good flow
distribution across the vessel. The design of separators generally includes a gas/liquid
gravity separation section (2), that ensures the creation and fall out of large liquid
droplets. The gravity separation section can include a coalescer stage (either a mesh type
or vane type coalescer). After the fall out of the bulk liquids, the demisting section (3)
ensures the removal of finer mist particles. In the liquid separation section (4) liquids are
degassed and the light and heavy liquid phases are separated. Designed based on the
fluid properties and liquid-liquid separation requirements, this section is large enough to
provide sufficient residence time for gas bubbles to escape from the liquids and oil and
water droplets to reach the oil-water interface.
For separators located on FPSOs or moving facilities it is essential to be thoroughly
evaluated by Computational Fluid Dynamics and where necessary by finite element analysis
strength calculations. ASCOM has these capabilities and this will ensure the end user of a
robust design under a wide range of operating conditions.
Inlet section
In horizontal three phase gas/liquid separators (separators), the incoming multiphase
mixture flows into the vessel through an inlet device. In the processing industry many
types of inlet devices are used ranging from inlet baffles, half open pipes to more
elaborate vane type and cyclonic inlet devices. Irrespective of the service, only vane type
inlet devices and properly designed cyclonic inlet devices will handle the fluids at the inlet
nozzle adequately and will maximise the separation performance. All other inlet devices will
result in a very poor gas distribution AND in an increase of the liquid content entrained in
the gas due to the high shear forces exerted by these devices.
A poorly designed or wrongly chosen inlet device can result in a poor gas and liquid
distribution, increase the liquid content entrained in the gas and create smaller water in oil
and oil in water droplets due to the high shear forces exerted by these devices. This will
result in a poor liquid-liquid separation performance and potentially to liquid control issues.
With ASCOM HiPer internals these problems will be avoided!
Gravity separation of liquids entrained in the gas phase
Downstream of the inlet device the gas section of the separator ensures the pre-separation
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of entrained liquids. The gravity separation section of the separator is basically an open
volume in which larger liquid droplets will fall out by gravity. This effect will be stronger
when the gas is well distributed over de cross section of the vessel. The gas distribution
can be improved by the application of well-designed distribution baffles.
In this case the fluids are introduced into the vessel by means of a battery of HiPer Inlet
Cyclones whereby the bulk of the liquid is introduced through the bottom of the cyclone
tubes and the gas will enter the vessel through the top. As the gas jets from the cyclones
it will need to be evenly distributed as to maximise the liquid drop out in the gravity
separation section (2) from the perforated distributor plates to the mist eliminating
equipment (3).
Coalescence aids in the gravity separation section
In clean services, i.e. no presence of wax or fouling tendencies, a HiPer Mesh Coalescer
can be used to increase the liquid handling capacity of the gravity separation section. The
wire mesh structure is designed to coalesce small liquid droplets into larger ones. The
specific arrangement of the HiPer Mesh Coalescer ensures very good drainage of the liquid
accumulated within the mesh. This device will increase the turndown properties of the
scrubber as the mode of operation changes from a flooded mode to a demisting mode once
the gas velocity is reduced to below the transition point. In situations where the fluids do
have a fouling tendency, alternatively a HiPer Vane Coalescer can be considered.
Mist elimination
After the gas has travelled through the gravity separation section, it will only contain fine
mist droplets. The third section is the mist eliminating section (3) which ensures the
separation of these fine mist particles. Essentially, the overall gas-liquid separation
efficiency of a separator depends on the fraction of liquid entrained as mist in the gas, the
droplet size distribution, the volumetric amount of the liquid in mist form and the
efficiency of the mist eliminating equipment under those conditions.
Again the gas distribution is of significant importance to maximise the gas-liquid separation
efficiency. In particular mist eliminating equipment with a low pressure drop (e.g. mesh or
vane mist eliminator) is prone to mal-performance as the result of gas mal-distribution on
the face of the equipment. Therefore the orientation in the gas flow is a critical design
parameter. Mist eliminating cyclones typically having a slightly higher pressure drop
positively contribute to an overall improved gas distribution in the entire vessel.
Oil / water separation
The liquid introduced into the vessel by either a HiPer Vane Diffuser or HiPer Inlet
Cyclones is very turbulent in the inlet section. Maximising the liquid/liquid separation
efficiency, the flow of liquids needs to be evenly distributed over the entire cross-sectional
area of the vessels liquid section. For this reason, perforated baffles need to be installed
in three-phase separators.
In order to further enhance the liquid/liquid separation, a HiPer Plate Coalescer can be
considered. This can either reduce the vessel size required in a new built situation, or
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increase the throughput or improve the oil in water or water in oil outlet performance in
retrofit situations. Between each of the flat parallel plates oil-water interfaces are being
established which significantly reduce the distance oil or water droplets need to travel to
their respective continuous phase. This directly impacts the time and distance required for
liquid/liquid separation to occur, which therewith improves the minimum Tan/Tan length
requirement of the separator.
When applied during the initial design stages of a new built facility, the space, weight and
overall cost savings can be quite substantial due to the knock-on effects on the overall
facility.
Sand removal
Fields where a large amount of sand is produced, sand will accumulate in process
equipment. Horizontal and vertical separators can be equipped with a HiPer Sand Fluidising
System. This will allow solid particles that have settled in the separator to temporarily
being fluidised by the injection water and the slurry simultaneously being drained off to
the sand handling / produced water system for physical removal from the process. This can
be done both whilst the separator is offline as well as online.
Separators on floating installations
Separators that are installed on moving facilities such as FPSOs deserve special attention
for separation as well as mechanical reasons. The movement of the facility as a result of
the local weather conditions / waves induces the liquid in the separator to move backward
and forward, eventually leading to sloshing under the more severe weather/motion
conditions. In case liquid sloshing is not adequately suppressed by wave suppression
baffles, the separation process in the separator will be affected.
Effect as result of motion vs Operational consequence(s)
Inlet device to become submerged Obliteration of liquid, overloading of mist
elimination equipment
1.
Bottom of inlet cyclones to become exposed , Obliteration of liquid, overloading of
mist elimination equipment, liquid level control difficulties, oil water interface
disruption
2.
Mist elimination overloaded with liquid Leading to excessive liquid carryover 3.
Mist elimination equipment to become submerged Leading to excessive liquid
carryover
4.
Oil exiting water outlet nozzle Leading to excessive OIW carryover 5.
Water sloshing over weir Leading to excessive WIO carryover 6.
Liquid level & interface control difficulties Leading to level trips and consequential
shut-down
7.
Reducing mechanical loads on distribution baffles Leading to excessive forces and
potential mechanical failure
8.
During the entire design process, ASCOM takes effects and their operational consequences
into consideration. This applies to both the process and the mechanical aspects. To verify
the robustness of the design, the separator is subjected to a Computational Fluid Dynamics
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(CFD) study. The movement of the liquid will be visualised and the mechanical forces on
the wave mitigation baffles will be calculated. This information is used to properly design
baffles and their welded supports in the vessel and to ensure that the design and material
thicknesses are adequate to handle the loads. Finite element analysis will be performed if
necessary.
Summary
ASCOM posseses expertise and CFD capabilities as well as the possibilitiy to test equipment
under model and real life conditions which results in ASCOM having a very powerful design
expertise. In combination with the range of proprietary HiPer separator internals, this
guarantees that ASCOM separators and scrubbers will provide:
Maximum liquid droplet coalescence and separation from gas
Maximum oil from water and water from oil separation efficiency
Excellent turndown characteristics
Insensitivity to sand presence
Insensitivity to wave induced motion
Low pressure drop
Insensitivity to fouling service
No maintenance requirements due to robust design
Removable through Man Way
No welding requirements for installation
Easily replaces existing older internals
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