Production Engineering II

Separation Process

Learning Outcomes
At the end of this lecture, students should be able to :

1. Describe the different types of separator and their functions.

2. Understand the basic theory of separation process.
3. Describe the two phase separation process.
4. Describe the three phase separation process.

5. Perform separator sizing calculations.

Introduction

Crude/Gas Separation System-Overview

Introduction

Main Offshore Production Facilities (key components):

Wellhead Equipment

Separation

Waste Handling

Pump/Compressor

Gas utilities, flaring

Introduction
The oil production system begins at the
wellhead, which includes at the least one
choke valve (percentage opening
determines the flowrate from the wells).
Most of the pressure drop between the well
flowing tubing head pressure (FTHP) and
the separator operating pressure occur
across the choke valve.
Whenever there are two or more producing
wells, a production manifold (as well as a
test manifold) is installed to gather fluids
prior to be processed.
The test manifold is provided to allow an
individual well to be tested via a test
separator or a multiphase flowmeter.

Simple wellhead assembly including

casing spools and Christmas tree

Introduction

Manifold / Gathering Station

The Production Process

SEPARATORS form the HEART of the production process
SEPARATION MODULE
wellhead
Wellhead
manifold

Gas to gas scrubber

and gas
compression module

FIRST STAGE

well
SECOND STAGE
reservoir

Water treatment
Oil
Water
Disposal

Storage
tank final
oil treatment

To export

Introduction
Produced wellhead fluids are complex mixtures of different compounds of
hydrogen and carbon, all with different densities, vapor pressures, and other
physical characteristics.
As a well stream flows from the reservoir, it experiences pressure and
temperature reductions.
Gases evolve from the liquids and the well stream changes in character. The
velocity of the gas carries liquid droplets, and the liquid carries gas bubbles.

The physical separation of these phases is one of the basic operations in the
production, processing, and treatment of oil and gas.
In oil and gas separator design, we mechanically separate from a hydrocarbon
stream the liquid and gas components that exist at a specific temperature and
pressure.

Introduction

Phase Diagram of a typical production system

Introduction
Proper separator design is important because a separation vessel is
normally the initial processing vessel in any facility, and improper design
of this process component can bottleneck and reduce the capacity of the
entire facility.
Separators are classified as the following
Two Phase if they separate gas from the total liquid stream
Three Phase if they also separate liquid stream into its crude oil and
water components.

Introduction
What is a separator?
A separator is a pressure vessel designed to separate a combined
liquid-gas system into individual components that are relatively free of
each other for subsequent processing or disposition
Why separators are needed?
Downstream equipment cannot handle gas-liquid mixtures
Pumps require gas-free liquid

Compressor/ dehydration equipment require liquid-free gas

Product specifications has limits on impurities
Measurement devices (metering) for gases/liquids highly

inaccurate when the other phase is present.

Basic Separator Construction

Regardless of the size/shape of a
separator, each gas-liquid
separator contains four major
sections :

Vertical
Separator
Schematic

I.

Inlet Diverter Section

II.

Liquid Collection Section

III. Gravity Settling Section

IV. Mist Extractor Section
Horizontal
Separator
Schematic

Basic Separator Construction

I.

Inlet Diverter Section

The inlet stream to the separator is typically a high-velocity turbulent

mixture of gas and liquid.

Due to the high velocity, the fluids enter the separator with a high
momentum.
Fluid phase at different densities have different momentum.
The Inlet Diverter abruptly changes the direction of flow by absorbing the
momentum of the liquid and allowing the liquid and gas to separate.
Results in the initial gross separation of liquid and gas. Initial separation of
gas phase from the free liquid phase.

Basic Separator Construction

II.

Liquid Collection Section

Located at the bottom of the vessel.

Provides the required retention time necessary for any entrained gas in
the liquid to escape to the gravity settling section.
Also provide a surge volume to handle intermittent slugs.

After a certain period of retention time, phases become equilibrium with

each other and separated naturally due to density differences
Degree of separation is dependent on the retention time available.
Retention time is affected by the amount of liquid the separator can hold,
the rate at which the fluids enter the vessel, and the differential density of
the fluids.

Basic Separator Construction

III. Gravity Settling Section
As the gas stream enters the gravity settling section, its velocity drops.
Small liquid droplets that were entrained in the gas and not separated by
the inlet diverter are separated out by gravity and fall to the gas liquid
interface.
The gravity settling section is sized so that liquid droplets greater than 100
to 140 microns fall to the gas-liquid interface while smaller liquid droplets
remain with the gas.
Liquid droplets greater than 100 to140 microns are undesirable as they
can overload the mist extractor at the separator outlet.

Basic Separator Construction

IV. Mist Extractor Section
Gas leaving the gravity settling section contains small liquid droplets, 100140 microns.

This section uses coalescing elements that provide a large amount of

surface area used to coalesce and remove the small droplets of liquid.
As the gas flows through the coalescing elements, it must make numerous
directional changes.
Due to their greater mass, the liquid droplets cannot follow the rapid
changes in direction of flow. These droplets impinge and collect on the
coalescing elements, where they fall to the liquid collection section.

Factors Affecting Separation

The following factors must be determined before separator design :
Gas and liquid flow rates
Operating & design pressures and temperatures

Surging or slugging tendencies of the feed streams

Fluid physical properties (density, compressibility)
Desired phase separation (gas-liquid or liquid-liquid)

Desired degree of separation

Presence of impurities (paraffin, sand, scale)
Foaming tendencies of the crude oil

Corrosive tendencies of the liquids or gas

Two Phase Separators

The two phase separator is a device used to separate gas and
liquid phases.
In two phase separator design, the gas and liquid phases of a
stream are mechanically separated at a specific temperature and
pressure.

Improper design of this process component can bottleneck and

reduce the capacity of the entire facility.

Separator Design Checklist (2P)

A primary separation section to remove the bulk of the liquid from the gas
Sufficient liquid capacity to handle surges of liquid from the line
Sufficient length of height to allow small droplets to settle out by gravity. Also a
means of reducing turbulence in the main body to ensure proper settling
A mist extractor to capture entrained droplets
Back pressure and liquid level controls

Separators are designed and manufactured in horizontal, vertical, spherical and

various other configurations.
Each configuration has specific advantages and limitations.
Selection is based on obtaining the desired results at lowest life-cycle cost

Separator Types (2P)

Gravity separators
Horizontal
Vertical
Spherical
Centrifugal separators
Venturi Separators

Double-Barrel Horizontal Separators

Horizontal Separator with Water Pot
Filter Separators
Scrubbers

Selection of
separators is based
on obtaining the
desired results at the
lowest cost

Horizontal Separators (2P)

Illustration of a Horizontal Separator

Horizontal Separators (2P)

The fluid enters the separator and
hits an inlet diverter, causing a
sudden change in momentum.
The initial gross separation of liquid
and vapor occurs at the inlet diverter.
The force of gravity causes the liquid
to fall to the bottom of the vessel and
gas to rise to the vapor space.
The liquid collection section provides retention time to let entrained gas evolve
out of the oil and reach a state of equilibrium.
It also provides a surge volume, to handle intermittent slugs of liquid.
The level controller senses changes in liquid levels and controls the dump
valve accordingly.

Horizontal Separators (2P)

Gas flows over the inlet diverter and then
horizontally through the gravity settling
section above the liquid.
Small drops of liquid, which were
entrained in the gas and not separated by
the inlet diverter, are separated by
gravity-settling; they fall to the gas-liquid
interface.
Some small diameter droplets are not easily separated in the gravity-settling
section.

Before the gas leaves the vessel, it passes through a coalescing section, or
mist extractor.
This section uses elements of vanes, wire mesh, or plates to coalesce and
remove the very small droplets of liquid in one final separation step.

Horizontal Separators (2P)

The pressure in the separator is
maintained by a pressure
controller.
The pressure controller senses
changes in the pressure within
the separator and sends a
signal to the pressure control
valve accordingly.

By controlling the rate at which gas leaves the vapor space of the vessel, this
system maintains the pressure in the vessel.
Normally horizontal separators are operated half full of liquid to maximize the
surface area of the gas-liquid interface.

Vertical Separators

Illustration of a Vertical Separator

Vertical Separators
Inlet flow enters the vessel through the side.
The inlet diverter does the initial gross separation.
The liquid flows down to the liquid collection
section of the vessel and continues to the liquid
outlet.
As the liquid reaches equilibrium, gas bubbles flow
counter to the direction of the liquid flow and
eventually migrate to the vapor space.
The level controller and liquid dump valve operate in the same manner as in a
horizontal separator.
The gas flows over the inlet diverter and then vertically upward toward the gas
outlet.

Vertical Separators
In the gravity settling section, the liquid drops fall
vertically downward counter-current to the upward
gas flow.
Gas goes through the mist extractor section before
it leaves the vessel to capture smaller liquid
droplets.
Pressure and level are maintained as in a
horizontal separators using pressure and level
controllers respectively.

Spherical Separators

Illustration of a Spherical Separator

Spherical Separators
The same four sections can be found in
this separator too. (Inlet Diverter, Liquid
Collection, Gravity Settling and Mist
Extractor)

Fluid enters through the inlet diverter

where flow stream is split into two.
Liquid falls to the liquid collection section.
Gases rising out of the liquids pass through the mist extractor and out of the
separator through the gas outlet.
Liquid level and pressure are maintained by liquid dump valve and back
pressure control valve respectively.
Not widely used because they have limited liquid surge capability and exhibit
fabrication difficulties.

Centrifugal Separators

Illustration of a Centrifugal Separator

Centrifugal Separators
Work on the principle that droplet separation can be
enhanced by the imposition of a radial or centrifugal force.
Consists of three sections ( inclined tangential inlet,
tangential liquid outlet and axial gas outlet).
Fluids are introduced tangentially into the separator via
inclined feed pipe.
The high-velocity swirling flow creates a radial acceleration field that causes the gas
to flow to the axial core region due to differences in gas and liquid density.

The gas exits through an axial outlet located at the top of the separator, and the
liquid leaves through a tangential outlet at the bottom.
Control can be achieved by a control valve on either liquid or the gas outlet lines.
Not suitable for widely varying flow rates since separation efficiency decreases as
velocity decreases.

Centrifugal Separators
The major benefits of using centrifugal separators are :
(i)
(ii)
(iii)
(iv)
(v)

No moving parts
Low maintenance
Compact (space and weight)
Insensitive to motion
Lower cost

Not commonly used in production operations because :

(i) Too sensitive to flowrates
(ii) Require greater pressure drop than other conventional separators.

Venturi Separators
Like the centrifugal, the venturi separator
increases droplet coalescence by
introducing additional forces into the
system.
Motive Fluid

The venturi principle involves

sending a motive stream horizontally
through a constricting nozzle.
This movement creates an area of low
pressure at the expanding side of the
nozzle which pulls gas molecules into
the flow from an attached inlet.

Instead of centrifugal forces the venturi

acts on the principle of accelerating the
gas linearly through a restricted flow path
with a motive fluid to promote the
coalescence of droplets.
Best suited for applications that contain a
mixture of solids and liquids.
Not cost-effective for removing liquid
entrainment alone, because of the highpressure drop and need for a motive fluid.

Double-Barrel Separators

Illustration of a Double-Barrel Separator

Double-Barrel Separators
The flow-stream strikes the inlet diverter and the free
liquids fall to the lower barrel through a flow pipe.
The gas flows through the gravity settling section
and encounters a mist extractor en route to the gas
outlet.
Small amounts of gas entrained in the liquid are
liberated in the liquid collection barrel and flow up
through the flow pipes.
Commonly used in applications where high gas flowrate and/or large liquid slugs are
encountered
Single barrel horizontal separators can handle large flowrates but offer poor liquid surge
capabilities compared to the double barrel separators.
Two-barrel separators are typically used as gas scrubbers on the inlet to compressors,
glycol contact towers and gas treating systems in which the liquid flow rate is extremely
low relative to the gas flow rate.

Horizontal Separator with a Water Pot

Single barrel separator with a
liquid water pot at the outlet
end.

Small amounts of liquid in the

bottom flow to the boot end
which serves as a liquid
collection section.

Illustration of a Horizontal Separator with a Water Pot

Less expensive than double

barrel separators but has less
liquid handling capacity.

Used for productions with very low liquid flowrates

When liquid flowrates are minimal, the boot section can serve as a liquid-liquid
separator as well.

Filter Separators

Illustration of a Horizontal Double Barrel Filter Separator

Filter Separators
Commonly used in high-gas/low liquid flow streams. Can be either horizontal
or vertical in configuration.
Designed to remove small liquid and solid particles from the gas stream.

Typically used when conventional separators employing gravitational or

centrifugal force are ineffective.
Filter tubes in the initial separation section cause coalescence of any liquid
mist into larger droplets as the gas passes through the tubes.
A secondary section of vanes or other mist extractor elements removes these
coalesced droplets.

The design of filter separators is dependent on the type of filter element

employed. Some filter elements can remove 100% of 1-micron particles and
99% of 1/2-micron particles when they are operated at rated capacity and
recommended filter-change intervals.

Scrubbers
Is a two-phase separator that is designed to recover liquids carried over from
the gas outlets of production separators or to catch liquids condensed due to
cooling or pressure drops.
Lower liquid loading compared to a conventional separator.
Typical applications :
Mechanical equipment (such as compressors) that could be damaged by
free liquid
Equipment (such as coolers) that can cause liquids to condense from a
gas stream.
Gas dehydration equipment that would lose efficiency if contaminated with
liquid hydrocarbons

Selection Criteria
The geometry, physical and operating attributes give each separator type its
own advantages and disadvantages.
Horizontal separators are normally more efficient at handling large volumes of
gas than vertical separators ; less expensive compared to vertical separator for
a given gas capacity.
Since the interface area is larger in a horizontal separator than a vertical
separator, it is easier for the gas bubbles, which come out of solution as the
liquid approaches equilibrium, to reach the vapor space.
Thus, from a pure gas/liquid separation viewpoint, horizontal separators would
be preferred.

Selection Criteria
The following are the limitations of a horizontal separator which would require
the usage of a vertical separator :
(i)

Horizontal separators cannot handle solids as good as vertical separators.

The liquid dump of a vertical separator can be placed at the center of the
bottom head so that, solids will not build up in the separator but continue to
the next vessel in the process.
(ii) Necessary to place several drains along the length of the horizontal separator.
In a horizontal vessel, it is necessary to place several drains along the
length of the vessel.
Solids have an angle of repose of 45-60 O , which requires the drains to be
spaced at very close intervals.
The distance between the drains can be increased by using sand jets but is
not cost effective.

Selection Criteria
(iii) Horizontal separators require more area to perform the same separation as
vertical separators.
Not critical for onshore development but very critical consideration for
offshore development due to space constraint.
(iv) Lower liquid surge capacity compared to vertical separators.
Surge capacity of a separator is defend as the ability to absorb a slug of
liquid.
The liquid level change is larger in liquid volume for horizontal separator
compared to the vertical separator which is sized for the same flowrate.
Surges in horizontal vessels could create internal waves which can activate
the high level sensor prematurely.

Selection Criteria
Vertical separators also have some drawbacks which are not process-related
and must be considered in making a selection :
The location of the relief valves and other controls which would be difficult
to access without scaffolding for maintenance activities.

More expensive than an equally sized horizontal separator.

Taller vertical separators are
subjected to larger wind loads which
requires the wall thickness to be
increased
Vertical Separators are supported
by bottom skirt, which requires the
walls of the vertical separator to be
much thicker than a horizontal
separator which is supported by
support saddles.

Illustration of a the support structures of

vertical and horizontal separators.

Selection Criteria
Overall, horizontal separators are most economical for normal oil-gas
separation, particularly where there may be problems with emulsions, foam, or
high gas-oil ratios (GOR).
Vertical separators work most effectively in low-GOR applications.
Vertical separators are used in some very high-GOR applications, such as
scrubbers in which only fluid mists is removed from the gas and where extra
surge capacity is needed (particularly for compressor suction scrubbers)

Comparison Summary of Different Gravity Separators

Advantages
Horizontal

Vertical

Spherical

1.Can handle much higher gasoil ratio well streams because

the design permits much higher
gas velocities
2.Cheaper than the vertical
separator
3.Easier and cheaper to ship
and assemble
4.Requires less piping for field
connections
5.Reduces turbulence and
reduces foaming (thus, it can
handle foaming crude)
6.Several separators may be
stacked, minimizing space
requirements

1.Easier to clean
2.Saves space
3.Provides better surge control
4.Liquid level control is not
critical
5.Less tendency for reevaporation of liquid into the
gas phase due to the relatively
greater vertical distance
between liquid level and gas
outlet

1.Good for low or

intermediate gas-oil ratio
2.Very compact and easy
to ship and install
3.Better clean-out.
Comparison of different
gravity separator types

Comparison Summary of Different Gravity Separators

Disadvantages
Horizontal

Vertical

Spherical

1.Greater space requirements

generally
2.Liquid level control more
critical
3.Surge space is somewhat
limited
4.Much harder to clean (hence
a bad choice in any sand
producing area

1.It takes a longer diameter

separator for a given gas
capacity as compared to
horizontal separator
2.More expensive to
fabricate
3.Difficult and more
expensive to ship
(transport)

1.Very limited liquid

settling section and rather
difficult to use for three
phase separation
2.Liquid level control is
very critical
3.Very limited surge space

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Q&A
Session