SEPARAT

SEPARATOR OR

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10/30/19
 SEPARAT
OR
Contents:

•Separation principle
•Description & Operation of separator with
all associated equipment
•Data Quality
•References

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 SEPARAT
OR
Lecture Objectives,
by the end of this lecture, YOU
should be able to:

- Explain the separation principle

- Explain the functions of the
Separator and associated equipment
(liquid & gas meters, safety devices)
-List all characteristics of the
separator
-Know about Data Quality
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 SEPARAT
Introduction: OR
•Used to separate, meter and sample all phases of
the effluent.
•They are able to treat effluent as gas, gas
condensate,light oil, heavy oil, foaming oil, oil
containing water impurities such as mud or solid
particles.
•The main element is the vessel, with the
necessary piping, skid and protective frame.
•There are also equipped with a built-in Shrinkage
tester, Barton recorder & sampling point.
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Separator flow SEPARAT
sheet OR

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 SEPARAT
Separator vessel description: OR

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 SEPARAT
Separation principle: OR
•Phase separation in a separator is based on
gravity - Gas is segregated from liquid
- Oil is segregated from
water
•Gravity separation only takes place when:
- Fluids to be segregated are not
soluble in each together - Fluids have different
densities 95% of separation takes
place within a few
•Separation speed is a direct
seconds
function of relative
gravity:
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Separation requires a few
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Gg/Gl = 1/20 = 0.05
Separator SEPARAT
capacity: OR
High liquid
level
(liquid level =
10bbls)

Medium liquid
level

Low liquid
level
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 SEPARAT
Separation Capacity: OR
- Retention
•Liquid capacity is function of: Time
- Separator oil
volume
Volume of oil (design capacity
Retention for 1-mn RT)
Time = Quantity of oil (meter
reading)

- Retention
•Gas capacity is function of: Time
-Separator oil
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volume
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-Separator
Separator SEPARAT
capacity: OR

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 SEPARAT
OR
Pneumatic regulation:
The system is supplied with air under a
constant pressure of 35 psi.
The air
pressure acting on the ACV is adjusted by a
restricted orifice (inside the relay) and a nozzle,
that can be more or less blocked by a flapper,
pivoting at a fixed point and connected at the
other end to the detection mechanism
(Bourdon tube or float).
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Pneumatic SEPARAT
regulation: OR

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 SEPARAT
Air Gas OR
outlet
instrument separator

ation
Gas sampling
supply:
Rig air supply point

Gauge Pressure
regulator to 40
– 50 psi
Air to regulator
67FR and to
Press/Level
controllers

Scrubber
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 SEPARAT
Pressure OR
Regulator:
•The 67FR used to
supply air pressure at a
constant pressure
(35psi) to the
pneumatic controllers.
-it reduces pressure
-It maintains a constant
flow
-It filters impurities
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 SEPARAT
Automatic Control Valves OR
•The ACV for oil, gas, and water controllers are
designed to regulate the rate of flow in a pipe by
varying its cross-sectional area in response to an
air leak signal received from a controller.
•There are two different types of ACV used in a
separator: - normally open (on gas line)
- normally close (on
liquid line)

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 SEPARAT
Automatic Control OR
Valves
Pressure Control Valve
(PCV):
•It is Normally Open (stays
Open if air supply is lost, to
release vessel pressure)
•It is usually a 3” Fisher valve
located on the gas outlet
separator and surge tank.
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 SEPARAT
Automatic Control OR
Valves
Liquid Control Valve
(LCV):
•It is Normally Close (Close if
air supply is lost, to minimize
pollution)
•There are usually 3” and 2”
valves located on the oil
outlet and a 2” on the water
outlet separator.
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 SEPARAT
Pneumatic controllers: OR
•Level Trol (Liquid) & Wizard
(Pressure)
Set point
(5 is
medium level)

Relay Proportional
Band (usually
15% - 25%)
Air supply
(35psi)
Air pressure to
ACV
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Relay: The heart of the SEPARAT
system OR

3
5

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Rela SEPARAT
y:
Position OR is
of free floating assembly when Flapper
CLOSE to Nozzle

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Rela SEPARAT
y:
Position ORis
of free floating assembly when Flapper
AWAY from Nozzle

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Pressure Control Valve SEPARAT
(PCV): OR
When gas line
pressure drops
bourdon tube
contracts closing
nozzle, relay switches
allowing pressure
build up to close
valve.
As gas line pressure
rises bourdon tube
expands opening
relay and releasing
pressure from valve
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allowing it to open.
Pressure Control Valve SEPARAT
(PCV):3 OR
5

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Pressure)
Level Control Valve SEPARAT
(LCV): ORnozzle
With low level flapper
is open to atmosphere.
Pressure cannot build up
and valve remains closed.
As level increases float rises
closing the nozzle with the
float. Pressure builds up and
valve opens.

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evel Control Valve (LCV): SEPARAT
From PBOR
valve

Low
level

Bourdon
Tube
From pilot
relay
(thru liner &
nozzle)
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 SEPARAT
Proportional Band OR
The PB control valve is a three-way valve
connecting: - the proportional action
bellows - the
modulated air supply
- the atmosphere

The extreme positions correspond to either

closure of the modulated air inlet (0%) or to
closure of the bleed to atmosphere (100%)
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 SEPARAT
Proportional Band OR
•Pressure: The PB valve reduces the response
time of the PCV to act as a damper and prevent
oscillation of the PCV, and therefore reducing
pressure
if: oscillation in the Separator.
Full range is 1500 psi (Bourdon tube range)
10% on the PB
75 psi before valve fully Open or Close,
above & below set point.

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 SEPARAT
Proportional Band OR
•Level: The PB valve reduces the response time
of the LCV to act as a damper and prevent
oscillation of the LCV, and therefore reducing
pressure
if: oscillation in the Separator.
Full range is 12 inches
10% on the PB
0.6 in. before valve fully Open or Close,
above & below set point.

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Safety SEPARAT
Devices OR
•On the separator there are two Safety Relief
Valves, normally a pilot operated relief valve set
to open when pressure exceeds working pressure
Both SRV are set to 100% of
vessel WP

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operated) operated
Safety SEPARAT
Devices OR
pilot
•Piloted operated Safety
Valves

Supplier: Keystone outle

t
Inlet: 3” 600 # RF
Outlet: 4” 600 # RF
Operation: Designed for
modulating action. It opens at set
pressure, as process pressure inlet
increases, the valve will open more
and be full lift at 105% of set.
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Safety SEPARAT
Devices
•Piloted operated Safety Valves
OR
Operation: At set pressure, the pilot relieves,
depressurizing the volume above the piston and the
piston lifts permitting discharge from the main valve.

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 SEPARAT
Safety Devices OR
•Located on the effluent inlet separator, a 3” or 4”
check-valve prevents the release to atmosphere
of all the energy vessel gas pressure and liquid, in
a case of a line inlet rupture.

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 SEPARAT
Safety Devices OR
•On old separators a Rupture disc is installed
instead of one of the SRV. The problem is that it
will be not close (after burst) when pressure in
the vessel goes back
Rupture discstoare
normal.
set to 110% of
vessel WP

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 SEPARAT
Safety Devices OR
•The sight-glass is a visual level indicator. In the
event the glass breaks, it is equipped with safety
valves that prevent fluids inside the separator
from escaping.

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 SEPARAT
Metering •Oil metering: OR
Devices - 3” Rotron
vortex meter, High flow -
2” Floco positive
displacement meter, low
flowrate
•Gas metering:
- Daniel orifice
-
Barton chart recorder
•Water metering:
- 2” Floco
positive displacement
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 SEPARAT
Liquid Metering Devices OR
•Oil /water metering: “Floco”
Positive displacement meter to measure low
and medium flow rates.
It measure the liquid passing through it by
separating the liquid into segments and counting
the segments.
The seals on the bridge prevent the liquid
from returning to the inlet side.
The rotor movement is transferred to a
register (readout device) with magnetic coupling.
2” Floco (F2500-2) = range is 100 to 2200 bbl/d
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(3400 bbl/d intermittent)
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 SEPARAT
quid Metering Devices
OR
il /water metering: “Floco”
Positive displacement meter

1 2
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 SEPARAT
quid Metering Devices
OR
il /water metering: “Floco”
Positive displacement meter

- It is important to check the Floco gearing is set for the

correct units.
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 SEPARAT
Liquid Metering Devices OR
•Oil metering: “Rotron”
The ball vortex meter consist of a body with
an offset chamber and a rotor.
The rotational velocity of the liquid vortex is
proportional to the rate of flow.
The rotor movement is transferred to a
register (readout device) with magnetic coupling.
Ball bearing Sleeve bearing
2-in. 850 to 6800 bbl/d 1700 to 8500 bbl/d
Rotron
3-in.
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2000 to 17000 bbl/d 3400 to 22000 bbl/
Rotron d
 SEPARAT
Liquid Metering Devices
OR
•Oil metering: “Rotron” ball vortex meter

- The meter body is divided by a septum. The calibration

plug causes a proportional increase or decrease in rotor
speed. - Meter
registration
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Liquid Metering Devices SEPARAT
•Data Quality : 2” Floco versus 3” Rotron
OR

PERFE
CT

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Gallons
Gas Metering Device SEPARAT
OR
•The Daniel
Orifice Meter:
Differential
pressure
combined with
Static pressure
and gas
temperature
allow a gas rate
to be calculated.
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Gas Metering Device SEPARAT
OR
•The Daniel
Orifice Meter:
-During the test, the
gas flowrate may
change, therefore,
different sizes of
orifice plates are
used.
-It’s important to
have an apparatus
that allows the
orifice plate to be
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changed without
Gas Metering Device SEPARAT
OR
•The Daniel Orifice
Meter:
-Size of the orifice is
stamped on the outer edge
of the downstream side of
the plate.
- Size of the pipe ID or
Line Bore, is found on the
Never change separator
name plate of the Daniel
pressure or change choke
itself.
with the orifice plate
installed.
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Gas Metering Device SEPARAT
OR
•Straightening
Vanes:
-To obtain accurate
differential pressure
data, gas flow must
be laminar at the
meter.
-Straightening
Vanes are
positioned before
the meter to reduce
disturbances
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created by the
Gas Metering Device SEPARAT
OR
Caution: liners are
crossed, HP side of the
Barton is connected
on the upstream side L
P
of the Daniel orifice H
P
and the LP on the
downstream side.
•To obtain accurate H
P

data, gas is filtered

through scrubbers to LP

remove all impurities.

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Gas Metering Device SEPARAT
OR
•Barton chart
recorder: -
records gas
differential pressure.
-
records static pressure
(taken downstream
orifice). - may also
record gas line
Barton manifold
temperature.
valves are here on
“by-pass” position.
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Gas Metering Device SEPARAT
•Barton chart OR
recorder:
bellow
s

HP LP

-DP spring 100“H2

ranges (inches O
of(400
water) 200”H2
in.H20 =
14.73
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O
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300”H2
0
Gas Metering Device SEPARAT
Barton chart recorder: OR
Low viscosity
oil
Stem disc Torque tube
shaft
H.P. (rotation = 8
bellows deg)

L.P.
bellows

Compensat
ing
chamber DP calibrated
spring

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“O”ring Pulsation
dampener
Gas Metering Device SEPARAT
Barton chart recorder: OR

Connected
with 3 links to
the PEN

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Shrinkage Tester SEPARAT
•It measures the oil OR
Pressure
volume change between
separator conditions and
atmospheric conditions
(Pressure & Temp.)
•Direct reading in %. Level

-if shrinkage
measurement= 5%, the
shrinkage factor (1-shr) Temperatu
re
in this case is 0.950
•Requires Temperature
reading in the same time
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that the final reading,
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hrinkage Tester operation SEPARAT
OR
1 2 3

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 SEPARAT
DATA QUALITY OR
When taking separator readings always ensure:
•Meter readings are taken at the correct time for
accurate rate calculations.
•Take readings at regular time: 5, 10, 15
minutes, etc.
•BSW & SG’s should be recorded at the time the
sample was taken and not the reading.
•Completeness of data, e.g.: oil SG, Shrinkage
(with tank or shrink.tester), are quoted with
temperature.
•Only enter actual measurements, e.g.:do not
enter the previous BSW reading because you
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forgot to take it this time.

 SEPARAT
DATA QUALITY OR
X
•Separator bypass before
SI well: build up data
necessary for
interpretation is damaged.

V
•Separator bypass after
SI well: a clean BHP
curve is obtained for
accurate interpretation.
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How the system Works Together SEPARAT
OR
•Closing one burnerhead
-causes:
an increase of oil line
backpressure - further
opening of the oil ACV

•Decrease of
-sep.press:
decrease oil line back
pressure (decrease of
GOR2) -
open oil ACV (less
pressure drop across
ACV) -
increase the gas line
backpressure (higher gas
velocity)
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-open gas ACV
(less pressure drop across
ACV)
 SEPARAT
EQUIPME OR
NT
•Standard 3 phases horizontal, SWT
separators:
description 1440 psi 720 psi WP 600 psi
WP WP
Vessel size 42” x 10’ 42” x 15’ 36” x 10’
Nominal capacity
Gas @ low liquid 60 41 MMSCFD 28 MMSCFD
level Gas @ high MMSCFD 18 MMSCFD 10.8
liquid level 25 10 500 BPD MMSCFD
Liquid @ low liquid MMSCFD 23 800 2 600 BPD
level
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Liquid @ high 6 650 BPD BPD 10 500
liquid level 14 000 BPD
 SEPARAT
EQUIPME OR
NT
•Standard 3 phases horizontal, SWT
separators:

Connections
are:
Effluent inlet= 3”
602 F
Oil, Gas & Water
outlets = 3” 602
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M
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Vent outlet = 4”
 SEPARAT
EQUIPME
NT
•NON-Standard 3 phases horizontal
OR
Separator (type N) -High flowrate (90
MMSCFD) -
Cyclone inlet cluster (foam-free separation)

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EQUIPME SEPARAT
•Separator (SEPS-A):
NT OR
-Smart weir system
(clean-up thru separator)
- Coriolis metering

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 SEPARAT
EQUIPME OR
NT
•Vertical
Separator (2200
psi WP)
- High flowrate
(100 MMSCFD)
-
Cyclone inlet
cluster (foam-free
separation)

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 SEPARAT
OR
References:

. On Line Training
. FOH for SWT (Run & Report)
. InTouch: Technical Data Sheet
& Maintenance manual
. + Animations: “Gpc”,“Llc”,“Gopm”,“Gas
fr”,”Shrink”, ”Separator
preparation”,”Separator operation”
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References (cont) : AnimationsSEPARAT
OR

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 SEPARAT
SEPARATOR OR

The End

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