Table of Contents

i. Three-phase separators .............................................................................................................. 2

 Function .......................................................................................................................................... 2
 Applications (Advantages & Disadvantages) .................................................................................. 2
 Associated Meters (rate of all 3 phases, water cut, pressure, temperature) ................................. 3
 Design criteria, including equations................................................................................................ 3
 Associated Safety Devices ............................................................................................................... 3
ii. Wash tanks .................................................................................................................................. 4
 Function .......................................................................................................................................... 4
 Applications (Advantages & Disadvantages) .................................................................................. 4
 Associated Meters (rate of all 3 phases, water cut, pressure, temperature) ................................. 4
 Design criteria, including equations................................................................................................ 4
 Associated Safety Devices ............................................................................................................... 4
iii. Heater Treater............................................................................................................................. 5
 Function .......................................................................................................................................... 5
 Applications (Advantages & Disadvantages) .................................................................................. 5
 Associated Meters (rate of all 3 phases, water cut, pressure, temperature) ................................. 5
 Design criteria, including equations................................................................................................ 5
 Associated Safety Devices ............................................................................................................... 5
iv. Slug Catcher ................................................................................................................................ 5
 Function .......................................................................................................................................... 5
 Applications (Advantages & Disadvantages) .................................................................................. 5
 Associated Meters (rate of all 3 phases, water cut, pressure, temperature) ................................. 5
 Design criteria, including equations................................................................................................ 5
 Associated Safety Devices ............................................................................................................... 5

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 i. Three-phase separators
 Function
The 3-phase separator is usually the first processing vessel that the well stream flows through
after it exits the producing well. When this fluid stream contains 3 separate fluid phases (i.e. oil, gas,
water), a 3-phase separator is necessary. A three-phase separator can be horizontal, vertical or
spherical. This type of separator is commonly called a free-water knockout because its main use is to
remove any free water that can cause problems such as corrosion and formation of hydrates or tight
emulsions, which are difficult to break. The separator accomplished 5 functions:

1. Separation of oil from gas

2. Separation of gas from oil
3. Separation of water from oil
4. Separation of oil from water
5. Separation of solids from fluids
However, the most important function of a separator is to provide oil and gas streams that meet
specifications that allow for the oil to be sold and disposed of safely. For example, for oil to be sold,
it must consist of less than 1% water and gas must contain less than 5lbm of water per 1 MMscf.
Also, in the Gulf of Mexico, water streams must have less than 20 ppm of oil to be discharged
overboard.

 Applications (Advantages & Disadvantages)

Horizontal separators are almost always used for high GOR wells and for foaming well streams. A
vertical separator can handle relatively large liquid slugs without carryover into the gas outlet.
Conversely, vertical separators are often used on low-intermediate GOR wells and where ever large
liquid slugs and more sand production is expected. The table below summarizes the advantages and
disadvantages of the two separator orientations. Another big advantage is that vertical separators
make a relatively small footprint when compared to the large land surface area a horizontal
separator will required.

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  Associated Meters (rate of all 3 phases, water cut, pressure, temperature)

 Design criteria, including equations

Once a separator orientation is decided upon based on the nature of the produced fluids (i.e.
vertical or horizontal), it must be designed to allow for the 3 fluids (and solids) to be separated
efficiently to achieve saleable and disposal specifications as required by the buyer. The basic steps
for designing a separator include:

1. Estimate diameter and length on basis of liquid requirements. Considerations of design include
drop size removal, retention time, coalescers (e.g., plate packs), surge volume, levels and alarms.

2. Calculate the gas cross-sectional area and vessel length. Considerations of design include drop
size, removal, mist eliminator requirements, and velocity requirements.

3. Select vessel diameter and length to satisfy Steps 1 and 2.

4. Select inlet device

Vertical Separator Design Sizing

Step 1: Calculate vessel diameter based on water drop removal.

Step 2: Calculate liquid levels (Ho & Hw) based on retention time. Liquid levels can be retrieved from
tables once diameter is known.

Step 3: Calculate vessel height.

Step 4: Select a vessel size that satisfies gas capacity, water-drop removal, and liquid-retention

time requirements.

 Associated Safety Devices

There are several critical safety devices installed in separator systems to prevent:

1. overpressure and possible rupture of equipment

2. leaks

3. pollution

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 4. fire

5. injury to personnel

6. damage to equipment

7. financial loss

The main components of the safety system include control systems and valves. The controls
required for oil and gas separators are primarily liquid level controllers for oil and oil/water interface
and gas back-pressure control valve with a pressure controller. Pressure controls and temperature
controls are also usually employed in separator systems. High and low liquid level controls are float
operated pilots that actuate inlet valves into the separator, open a bypass around the separator or
sound a warning alarm with liquid levels are too high or too low. This aids in preventing damage that
may result caused by these levels. High- and low pressure controls are installed on separators to
prevent excessively high or low pressures from interfering with normal operations. High and low-
pressure controls can be mechanical, pneumatic, or electric and can sound a warning, actuate a
shut-in valve, open a bypass, or perform other pertinent functions to protect personnel, the
separator, and surrounding equipment.

Safety relief valves and safety heads (rupture disks) are vital parts of the safety system. A spring-
loaded safety relief valve is usually installed on all oil and gas separators. These valves normally are
set at the design pressure of the vessel. Safety relief valves serve primarily as a warning, and in most
instances are too small to handle the full rated fluid capacity of the separator. To compensate for
this, rupture disks are used in conjunction with relief valves. This contains a thin metal membrane
that is designed to rupture when the pressure in the separator exceeds 1.25% of the design pressure
limit value. The disk is selected so that it will not rupture until the safety relief valve has been
activated and is not capable of controlling excessive pressure buildup. If a rupture disk is not used,
then full capacity safety relief valves must be installed.

Safety grounding floats are necessary to ground switches inside the electrostatic treating vessel.
They ensure that no electrically energized components are exposed to the gas phase and that the
electrodes are not energized accidentally during personnel entry into the vessel which can result in
deadly explosions and electrocution respectively.

ii. Wash tanks

 Function

 Applications (Advantages & Disadvantages)

 Associated Meters (rate of all 3 phases, water cut, pressure, temperature)

 Design criteria, including equations

 Associated Safety Devices

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iii. Heater Treater
 Function

 Applications (Advantages & Disadvantages)

 Associated Meters (rate of all 3 phases, water cut, pressure, temperature)

 Design criteria, including equations

 Associated Safety Devices

iv. Slug Catcher

 Function

 Applications (Advantages & Disadvantages)

 Associated Meters (rate of all 3 phases, water cut, pressure, temperature)

 Design criteria, including equations

 Associated Safety Devices

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