Vessel Internals & Functions

Training package PTP 2.1

Separators

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 Table of contents
Page No
1. Introduction. 02
2. Types of separators. 04
2.1. Spherical separators. 04
2.2. Vertical separators. 05
2.3. Horizontal separators. 06

3. Comparison of separators. 07
3.1. Vertical separators. 07
3.2. Horizontal separators. 07

4. Separator internals. 08
4.1. Primary separation section. 08
4.2. Secondary separation section. 10
4.3. Mist extraction section. 10
4.4. Liquid degassing section. 12

5. Mechanism of small particle separation. 13

5.1. Gravity separation. 13
5.2. Centrifugal separation. 14
5.3. Impingement separation. 14
5.4. Coalescence separation. 16

6. Bulk and Test separators. 17

6.1. Bulk(production) separator. 17
6.2. Test separator. 18
6.3. Cyclone separator. 19
6.4. Importance of separator pressure. 20

7. Separator control&safeguarding. 21
7.1. Separator control. 21
7.2. Monitoring. 22
7.3. Protection. 22
7.4. Safety Relief valves. 23
7.5. Rupture Discs. 24

8. Shutdown Systems. 24
9. Isolation of separators. 25
10. Start up of a production separator. 27
10.1. Purge system. 27
10.2. Checks and Tests. 27
10.3 Startup after ESD/PSD 29

SEPARATORS

1. Introduction
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 The produced fluid from oil formation consists of a mixture of oil, gas, free water and water in oil
emulsion. For several reasons each of three components i.e. oil, water and gas must be freed
from contamination by other two.

Oil processing involves separating the oil from other fluids (gas and water) for the following
reasons:

1. Crude oil must be free of gas so that storage tanks will not be a hazard due to escaping
gas.

2. Liquid must be removed from a gas stream to prevent it from accumulating in low
Inlet (oil,gas&water)
sections of a pipeline and restricting the flow of gas. If the gas is to be compressed liquids
must be removed to avoid damaging the compressor.

3. The water content in the oil must be low in order to maximize its commercial value. The
separated water tends to have oil associated with it and the oil must be removed before the
water is injected into the reservoir.

The vessel used to separate the liquids from the gases is called a separator. Separators are
usually made as cylindrical vessels and placed either vertically or horizontally. Vertical vessels
are more suitable in gas service and horizontal vessels are usually employed in oil (liquid) service
and where long residence times are required.

Gas outlet to comp / flare

Inlet (oil,gas&water) schoepentoeter

Mist extractor

Vortex breaker

Oil/water mixture to surge

tanks/production stations

Figure – 1 Typical separator

The function of a separator is to produce clean separation of free gas from oil at any pressure and
temperature and to prevent or eliminate liquid entrainment in the gas stream leaving the separator.

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The principle of separation is essentially by means of gravity based on the difference in density
between the fluids involved. Fluids which are not soluble in each other and have different
densities are usually separated by gravity force. The drop of liquid settling out of a flowing
stream depends among different things:

(1) Relative densities of the liquid and the gas.

(2) Size of the drop.

(3) Velocity of the gas in the stream.

The gravity separation perform well when particle sizes are relatively large and where flow
velocities are low. Therefore various methods are used to make the flow and make liquid drops
large. Turbulence and high velocities must be prevented in order to avoid re-mixing (re-
entrainment). If the fluid enter the vessel at high velocity ,it may create more turbulence and
result in liquid getting entrained in the gas stream.

When oil enters a separator it flows from the restricted volume of the flow line where a high
velocity is maintained, into the larger volume of the separator. In the separator the speed of the
oil and gas is greatly reduced. Due to the separator volume, expansion takes place and
consequently the gas comes out of solution.

The normal performance requirement of a separator is to produce gas free of liquid and liquid
free of gas provided that:

(1) The oil is not foaming.

(2) Flow to the separator is steady and is not surging.

(3) The gas temperature is above the cloud point of the oil.

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2. TYPES OF SEPARATORS

Separators are classified by the shape and orientation of the vessel and by the number of fluids to
be segregated. In terms of shape and orientation, there are three types of separators, in common
use are mainly two, Vertical and Horizontal.

The number of fluids to be segregated is usually, Two or Three.

If there are two fluids, such as gas and liquid, the separator is referred to as a two phase type if
three fluids are segregated such as gas, oil and water, the vessel is a three phase type. The
number of phases refers to the number of streams that leave the vessel .

SPHERICAL SEPARATOR

VERTICAL SEPARATOR

HORIZONTAL SEPARATOR

2.1 SPHERICAL SEPARATOR ( P.D.O. Facilities not in use )

The spherical separator provides good gas separation and liquid handling when space is
limited. However, when a well stream can contain excess mud or sand, be subject to surging
or foamy components, the spherical separator is not economical.
In this design the four separator sections are contained within a sphere. The top part of the
sphere contains the three sections for gas and liquid separation. The bottom part is the liquid
accumulation section.

Well stream
inlet

gas

Mist extraction
section

liquid

Gas out
Liquid
out

Figure. Spherical separator

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 The well stream enters the vessel at the top. Inside the sphere the stream is deflected to the
surfaces of the sphere along the walls over a dome covering the mist extractor. As the stream
enters the lower portion of the sphere, the gas and liquid vapors begin to rise and pass through the
mist extractor. Liquid droplets collect and fall downward. Gas leaves the vessel through a
vertical pipe above the mist extractor. Different from other separator designs, the gas outlet is at
the bottom.

Liquids accumulate in the bottom of the sphere. Gravity settling causes solids and water to go to
the bottom of the vessel. Liquid leaves the vessel near the bottom of the sphere under control of a
liquid-level controller.

2. 2 VERTICAL SEPARATOR

These types of separators, vertical only, perform a high efficiency demisting. They combine
the advantages of the best inlet device, the dish deflector, with the mistmat and a demister pad
into one vessel.
Gas outlet to comp / flare

Inlet (oil,gas&water)

Mist extractor

Dish deflector

Oil/water mixture to surge

tanks/production stations

Figure – 3 Vertical Separator

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 In this type the incoming gas initially meets a ' dish deflector.` This device reduces the velocity
of the inlet stream and changes the direction.

Gas moves up through the mist extraction section where any liquid drops entrained are dropped
down. If required an additional demister pad can be provided just before the gas exit to remove
very small liquid particles which are not removed in the mist extraction section.

2. 3 HORIZONTAL SEPARATOR

The oil and gas mixture enters through the inlet nozzle and hits an angle baffle (schopentoter)
where the direction of flow is changed. Here the heavier liquids fall to the bottom of the tank
while the gas and spray liquid rises.

This wet gas passes through the mist extractor (where the remaining small liquid particles are
removed) and then along the upper part of the separator to reach the gas outlet.

Gas outlet to comp / flare

Inlet (oil,gas&water)

schoepentoeter
Mist extractor

Vortex breaker

Oil/water mixture to surge

tanks/production stations

Figure- 4 Hoizontal Separator

The liquid from which the gas has been removed moves along the bottom of the separator to the
oil outlet through a vortex breaker, then the plates act as baffles, which prevent wave formation in

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the liquid. Level is maintained normally at about 1/3 of the height of the separator. A large
liquid surface is thus maintained which facilitate gravity separation.

3. COMPARISION OF SEPARATORS

Comparison between vertical and horizontal separators

3.1 Vertical Separator : Recommended for gas service.

Advantages :

1. Good bottom drain and easier to clean out

2. Reasonable liquid surge capacity.
3. Liquid level control not so critical- efficiency does not vary with liquid level.
4. Require limited floor space.

Disadvantages :

1. Top mounted instruments and controls require long access ladders and
platforms.
2. Proper degassing of liquids only at low viscosity.
3. Limited gas capacity.
4. More expensive than horizontal.

3.2 Horizontal Separator : Recommended where long residence times are required e.g.
degassing viscous liquids and liquid / liquid separators

Advantages :

1. Easy to fix and remove instruments.

2. Better degassing of liquid.
3. Better suitable for foaming curds because of the large interface in relation to the
liquid volume
4 Cheaper than vertical separators.

Disadvantages :

1. Difficult to clean of mud, sand and paraffin.

2. Liquid level control more critical.
3. Require more floor space.

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4. SEPARATOR INTERNALS

Separator internals can be studied by following sections

4.1. Primary Separation Section

4.2. Secondary Separation Section

4.3. Mist Extraction Section

4.4. Liquid Degassing Section

4.1. PRIMARY SEPARATION SECTION

In the primary separation section the liquid is removed from the inlet stream. It is required to
reduce the velocity of the entering stream, and to separate slugs and large droplets of liquid from
the gas stream to minimize gas turbulence and re-entrainment of liquid particles. This is usually
achieved by changing the direction of the fluid which causes reduction in turbulence and
enlargement of particle size and to do so, some devices (internals) are constructed inside the
vessels.

Many types of inlet devices are used.

1. Schoepentoeter' for high GLR.

2. Half-open pipe for low gas liquid ratio (GLR)

3. Inclined plates

4. Wave breakers

5. Swirltube,etc.

Figure-6- Schoepentoeter

Inlet flow

schoepentoeter

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 l et l et
in in

Figure –4-1 Inclined plates Figure – 4-2 Wave breaker

Inclined plates and Wave breakers are good for breaking the emulsion also. When the inlet stream
pass through theses devices the velocity is reduced . Due to the reduction of velocity gas comes
out of solution. Gas being lighter than air it will rise, whereas the heavier oil falls to the bottom,
However, due to the difference in volumes, the oil is dispersed throughout the gas in small
droplets.

To prevent ( For vertical separators ) these droplets from being carried upwards with the rising
high velocity gas, the inlet pipe of a separator is placed so as to enter the separator tangentially.
This is done in cyclone separators. A swirl tube is used to generate centrifugal force in the
incoming fluid particles. The oil and gas mixture is swirled round and due to the resultant
centrifugal force the droplets of liquid falls to the bottom and gas particles will be thrown to the
top of the vessel.

Figure-6-Swirltube

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4.2. SECONDARY SEPARATION SECTION

Secondary Separation Section is used for removing maximum of smaller liquid droplets from
the gas. The major separation principle in this section is gravity settling from the gas stream after
the velocity has been drastically reduced.

The efficiency of this section primarily depends upon

A. Gas and liquid properties.

B. Liquid drop size.
C. Degree of gas turbulence.

The turbulence factor is often minimized by inlet arrangement and properly designed and
positioned straightening vanes.

Figure – 5 Straightening Waves

Another consideration of primary importance is the normal direction of gas stream travel. If the
principal direction of travel from inlet to outlet is vertical, then the upward gas velocity must be
limited to that value which permits the settlement of liquid particles counter currently in the
opposite direction.

4.3. MIST EXTRACTION SECTION

The upper exit section of the separator consists of what is known as a "Mist Extractor".

In this section it was found from field experience that it is not practical to rely on gravity settling
for removal very small particles (droplets) remaining in the gas stream after primary and
secondary separation. Therefore additional method (devices) were required to remove the small
particles from the gas and these devices make use of the following mechanisms.

A. Impingement
B. Centrifugal force
C. Coalescence

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 In each case the gas passes through a series of baffles involving several changes of direction.
Tiny droplets are collected on a surface where they are drained away from the gas stream and
form larger droplets that can fall back into the liquid accumulation section.

A. Impingement
There are two general types of impingement mist extractors mist mats and Vane packs
Mist mats are knitted wire mesh pads. The primary mechanism is impingement but also
centrifugal and gravity forces are utilized.

Vane packs are composed of metal plates which are formed into a labyrinth in which the
direction of the gas stream changes many times, generating large centrifugal forces. The
collected liquid must be protected from being re-entrained in the turbulence gas flow that passes
through the Pack.

A vane pack is often used instead of a mistmat, when plugging components may be present like
wax, asphalt or drilling mud.

gas

Vane packs

oil
Mist mat

B. Centrifugal force

In this mechanism a swirl tube is used in combination with either a mistmat or a vane pack. It
increases the gravitational forces on the liquid droplets. Many of these tubes are fitted in a tray,
which is called a swirl tray. The inlet stream is allowed to enter the vessel at a tangential
direction. When the particles swirl around the swirl tube the centrifugal force generated will
increase the gravitational force in the particles.

C. Coalescence

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 If the liquid particles entrained in the gas is too small they may not be able to separate from the
gas on gravity difference. We can separate them only after allowing them to join togther and
become a big particle. Coalescence is the property of very samll liquid drops joins togther and
become a big particle and drops down on density difference. of small particles into those large
enough to settle by gravity is provided by two mechanism

1. Agitation
2. Surface

coalescence needs agitation and surface to hit. Some of the particles will be absorbed by the wet
surface. These particles on the wet surface joins together and become big and then get separated
on difference in gravity.

4.4. LIQUID DEGASSING SECTION

The oil now flows into the liquid section of the separator passing through a series of baffles,
causing the oil to flow down and allowing more gas to escape.

A certain volume of oil is retained for a time in the separator by means of a controlled rate of
outlet flow. This gives a chance for the gas that may still be trapped in the oil to escape upwards
into the gas section. The larger the volume of oil kept in the separator, i.e. the higher the liquid
level, the longer the oil remains in the liquid section ( residence time more ). Residence time
depends up on the volume of the oil retained in the separator and the rate of production.

If, however, the level of the oil is increased too much, the oil surface may rise too close to the
turbulent zone, causing agitation, with the chance of oil being picked up by the gas stream and
carried over into gas outlet lines and to the compressor section,( known as liquid carry over) or
into the flare lines. There is a chance to form vortex at the liquid outlet nozzle and gas may go
with the liquid to the next processing section. To avoid this vortex breakers are provided.

Separator without vortex breaker Separator with vortex breaker

Gas Gas

Vortex breaker
vortex liquid liquid

Liquid outlet
Liquid outlet

5. MECHANISM OF SMALL PARTICLE SEPARATION

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 Gravity Separation

Centrifugal Force Separation

Impingement separation

Coalescence separation

5.1 GRAVITY SEPARATION

Gravity settling is by far the most widely used mechanism of separation. This results primarily
from the simplicity of the equipment necessary and the readily available force of gravity.

Gravity separation depends upon the following conditions.

1. The relative density of the liquid particle compared to that of the gas under vessel
operating conditions. If a mixture of oil and water is allowed to settle then the water
particles which are heavier will settle down and oil particles will move up and we get
these two components separated. If the differnce in densities between oil and water is
more then the rate of settling will be faster.

2. The relative size of the particle.

3. The vertical velocity of the gaseous stream, in spite of which the particle tends to separate
downward. If the velocity of the gas moving up is high then it will reduce the settling rate
of liquid particles from the gas.

4. The turbulence which exists in the vapour space of the separation vessel.

The function of a gravity settler is basically to reduce the velocity of the incoming well stream
from one which is turbulent and permits entrainment of particles to a velocity which is less
turbulent, allowing the suspended particles to collect. Any knock-out pot, accumulator, or
expanded section in a flow line will act as a gravity settler. The flow line itself will allow gravity
settling if the flow rate is sufficiently low.

Since the basic requirement for gravity settling is to minimize turbulence, it is important to
decrease the gas velocity immediately upon entering the separator and in some manner cause the
flow of gas to be uniform throughout the separation section. When this is accomplished the laws
of settling uses to determine a maximum gas velocity for the separation of liquid particles of
certain diameters.

If the gas flow in the separation section is vertical and upward the particles to be separated must
settle against the flow of gas. The calculated settling velocity for a certain particle diameter
indicates a maximum gas velocity for the separation of that diameter particle.

5.2 CENTRIFUGAL FORCE SEPARATION SECTION

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 In centrifugal force separation the direction of the inlet stream is changed many times. When a
gas stream changes direction, the liquid drops, having a density, offer more resistance to the
change in direction and tend to continue in a straight line.

This results in a collision of the larger liquid particles with the confining wall and a separation
from the less dense gas. Since most oilfield separation problems involve the suspension of
relatively heavy liquid particles in a less dense gas, the particles can be separated by centrifugal
force.

Figure - 7

The use of centrifugal force by itself for

particle removal is usually limited to the
initial separation of large volumes and large
drops of liquid. This principle, however, may
also be used for mist extraction.

The lower practical limit of particle size

which can be removed in centrifugal force
(cyclone type) mist extractors is thought to be
about 5 to 10 microns in diameter. Separation
of very smaller particles by this methods
results in pressure reduction.

5.3 IMPINGEMENT SEPARATION

Impingement is probably the most widely used principle for tiny particles collection in
liquid and gas separation. This type separation depends upon entrained particles striking
an obstruction rather than the containing walls. The obstructions act as collecting
surfaces.

There are two general types of impingement mist extractors which are presently in wide
usage, the difference in the two types being the intensity of the centrifugal force utilized.

1. Vane type

2. Knitted wire mesh type

VANE TYPE

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As gas approaches an obstruction it tends to flow around it. As in the case of centrifugal force
separations, the heavier drops tend to continue in a straight line and strike the collecting surface.

When the diameter of the obstructions are large compared to the size of the liquid particles to be
removed and the change in directions of the gas in drastic, a large amount of centrifugal force is
generated. This type impingement separator, usually referred to as a vane type.

Refering to the figure, its shows the approaches the operation of centrifugal force separators and
are characterized by moderately high pressure drops. Liquid that is collected within the vanes
must be returned to the liquid accumulating section. Most variations in vane type mist extractors
result largely from different methods used to protect and drain the collected liquid.

KNITTED WIRE MESH EXTRACTORS

A second type of impingement separation device is a knitted wire mesh pad. The primary
mechanism of separation in the knitted wire mesh is impingement. It also utilizes centrifugal and
gravitational force in the collection of small liquid Particles.

As the gas and entrained particles approach the wire obstructions as indicated in figure the gas
turns to miss the wire while the particle tends to continue in a straight line. A portion of the
particles in line with the obstructions impinge upon them and are collected.

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After particles strike the collecting surface in a knitted wire mesh, they form into a thin liquid
film, wetting the wire surface. If the gas flow is upward, the liquid film slowly moves to the
lowest point on the wire. Here the film grows until a droplet forms large enough to break away
from the collecting surface and drop back against the flow of gas.

This droplet size is many times larger in diameter than the average particle collected. For
instance, a mist extractor may be removing many 10 micron diameter particles but the diameter
of the drops draining from the mist extractor will be in the order of 1000 to 5000 microns in
diameter.

If the gas passes horizontally through a knitted wire mesh pad the large droplets formed will flow
through the pad in the direction of the gas velocity, but they will quickly fall by gravity from the
flowing stream because of their greatly increased size.

The presence of a liquid film on the wire and the large droplets formed cause some scrubbing
action which further aids the removal of tiny particles.

Knitted wire mesh mist extractors usually used in oil and gas separators are designed to produce
high separation efficiencies for particles 10 microns and larger in size.

5.4 Coalescence

Coalescence of small particles into those large enough to settle by gravity is provided by two
mechanism

1. Agitation
2. Surface

The surface of the element is usually wet and small particles striking same are absorbed.

A common example of coalescing occurs when water drops form on the wind-shield of a car as it
is driven in fog. As the tiny water drops which make up the fog strike the windshield, they
combine with other drops and eventually form a drop large enough to run down the glass.

Several of the internal devices of a separator such as deflector plates, straightening vanes, baffles,
etc. and even the vessel walls are forms of coalescers. In each device, liquid drops adhere to the
surface of the device and combine with other drops until a large drop forms which will fall out.
The effectiveness of separation will also depend upon the total amount of coalescing surface area
that is present.

In the mist extraction section specially designed coalescing devices may be installed.

6. Bulk and Test separators

6.1 Bulk ( Production) Separator

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 Inlet from Gas out
the wells
Gas

Liquid

Liquid out

Figure - Bulk separator

 Purpose of a bulk separator (production separator) is to receive well fluid from the
manifold and reduce the pressure initially and separate it into two phase, liquid and gas. The
incoming stream which is mainly a mixture of oil, water and gas is allowed to enter at the inlet of
the separator through a schoepentoeter( or some other device).

 When the inlet steam passes through the schoepentoeter the velocity and direction
changes. Due to reduction in pressure( flashing) more gas leaves the liquid. Large liquid particles
falls down and the gas leaves with little carry over of small liquid particles.

 When the gas stream pass through the mist extraction section this very small liquid
particles impinge on mist extractor, many particles join together and become big particle and
falls down.
Gas before leaving the vessel pass through a demister pad fixed at the outlet nozzle. Demister pad
removes any entrained liquid which is not removed at the mist extraction section. Liquid is
allowed to stay sometime inside the vessel before it leaves inorder to release any dissolved gas
particles. Liquid leaves the separator through the vortex breaker .

6.2 Test Separator

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Testing of a well is very important. Well testing is to measure the amount of oil, gas and water
produced from a well with in a specified time. Well test results gives lot of information about that
well and also about the reservoir.

 Working of a test separator is almost similar to that of a bulk separator. Test separator is
three phase separator. It separates the incoming well stream into oil, water and gas. The inlet
stream first separates into gas and liquid. Gas pass through the mist extraction section and any
entrained liquid particles will be removed there. Gas leaves the vessel through the exit nozzle
under pressure control. Liquid which is a mixture of oil and gas falls to the bottom of the vessel.

 Here due to the difference in gravity oil particles moves upward and forms a different
layer at the top. A baffle( weir plate) separates oil and water compartments. Oil which is light
overflows the baffle plate and will be collected in the oil compartment. Water which is heavy
stays at the bottom and will be collected in the water-boot, which gives enough time to separate
oil completely. Oil and water leaves the separator on level control.

FM

The purpose of the test separator is to separate the incoming stream of well fluids in to oil, water
and gas and measure the amount of oil, water & gas produced with in a specified period of time.
To get the correct result from a well test we need to control pressure and levels and measure
accurarely the amount of oil, water& gas produced.

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 Pressure is controlled by the PCV on gas outlet line. Pressure control is very important. If the
pressure fluctuates then the test result will not be correct. The gas produced from the well is
measured by a flow meter, usually one with a Daniel orifice meter. This allows the replacement
of the orifice plate while the separator and gas line under pressure. Using the correct size orifice
palte is a must to get accurate readings.

Water level is controlled by LCV-2. The amount of water produced is measured by a flowmeter.
Oil level is controlled by LCV-1. The amount of oil produced is also measured by another flow
meter. The level controller for oil ( LCV-1) is usually works on gap control. This is used to give
sufficient residence time for the oil to realease any trapped gas. Gas, oil and water produced is
measured and totalised for the test period.

6.3 Cyclone separator

Mist extractor

compressor

Gas inlet

Liquid out

Cyclone separators are used to remove liquid particles from a gas stream, normally before the
gas send to a compressor. They are the same or similar to the scrubber provided at the inlet of a
compressor.

The inlet gas stream is allowed to enter the separator at a tangential direction. In some cases a
swirl tube will be provided to increase the centrifugal action. When the gas stream enter the
vessel at a tangential direction it swirls( cyclonic effect) around and heavier liquid drops falls
down and gas particles moves up. This is due to the difference in centrifugal force generated due
to the cyclonic effect.

Centrifugal force will be more on large and heavy particles. So liquid particles with a higher
centrifugal force get separated from gas very easily. Gas particles which are lighter moves up
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with the additional centrifugal force received due to the cyclonic effect. The shape of the cyclone
separator gives enough time for the gas to drop down the entrained liquid particles while it moves
up.

6.4 What is the importance of the pressure in the separator ?

Separator pressure is to be maintained at the normal operating range because of

many reasons.

The flow of fluid from one end to another end of a pipeline is proportional to the
difference in the pressure. If we want to move a fluid from `A` to `B` then we
should have a higher pressure at A than at B. Flow of fluids from `A` to `B` can
be increased either by increasing the pressure at `A` or reducing the pressure at `B`.

wellhead separator

A B

Let us think that the location `A` is wellhead and location `B` is the separator. So if
we increase or decrease the pressure in a separator, it will effect the production
rate. If we reduce the pressure in the separator vessel, we can increase the
production or flow through the flow line, but we will not be able to send the gas
and liquid from the separator to the next processing section.

If we are increasing the separator pressure then the load on the pumps
( ESP, Beam Pump or PCP ) has to be increased to maintain the same flow. So we
have to keep an optimum pressure in the separator. This pressure should be
sufficient to push the liquid to the next processing section and supply gas to
compressors at the required suction pressure and same time maintaining the load on
pumps. Separator pressure effects the rate of separation also. If the pressure is
reduced then more gas will be separated. The rate of separation of oil and water
also effected by the changes in the separator pressure. So it is important to maintain
the separator pressure at the normal operating range.

7. Separator Control and safeguarding systems (Bulk&Test separator)

7.1 Separator controls

Pressure within the separator is controlled at the required level in order to

maintain optimum separation conditions and to provide the necessary pressure to
send gas to the compressors and discharge the liquid to the down stream process.
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 A constant pressure is maintained by means of a pressure controller (PRC) which
controls the opening of a PCV (usually pneumatically operated) in the gas outlet
line.

The inlet pressure to the separator is manually controlled by the wellhead choke
and inlet manifold choke. In some case gas from the separator will be directly
routed to the gas compressors. Separator pressure will be maintained by the suction
pressure controller of the compressor. The vessel pressure then floats with the gas
compressor suction pressure controller and any extra pressure relieving to flare via
pressure controller.

The separator is protected against very high pressure by means of pressure

switches. Both high and low pressure switches will when activated, operate alarms
and or shut the separator off from the flow station header. High pressure is
relieved through a pressure relief system actuated by the high pressure switch.

FLARE
STATION ESD

SAFEGUARDING PCV
SYSTEM RUPTURE
DISK PC
RV PHH

ESD COMPRESSOR
DP

PEA

GAS
ESD LHH

LRC

LIQUID
INLET LLL

LCV ESD

Figure- Separator Safeguarding system

Level in the vessel is controlled by the LCV ( level control valve ) on liquid
outlet line. In the three phase separators there will be two LCV`s to control the
level of oil and water separately. By maintaining a level in the separator we are
sure that enough time is given for the gas and oil to separate. The level control
valve in the water outlet line, maintains a water level in the separator. This
ensures that the water is retained in the vessel for sufficient time to allow oil to
separate from the water
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 7.2. Monitors

To monitor the process inside the vessel, the following gauges will be installed.
Pressure gauge to indicate the operating pressure of the separator. Temperature
gauge to indicate the gas phase operating temperature, Level gauges to show the
operating liquid level in the separator.

Separator pressure, level , temperature and the flow of oil, gas and water can be
monitored from the control room through SCADA system or through DCS.
Totalised flow of gas and oil also indicated in the control room.

7.3. Protection

The vessel is protected by ESD valves on the feed inlet line and on the liquid outlet
line. The main protection elements are:

· Hiigh High Level ( LHH )switch is provide to detect a high oil level in the
separator and it activates a process shutdown of the separator. This is to stop any
liquid going out with the gas to the compressor or to the flare and to avoid
overpressurising of the vessel

· Low Low Level ( LLL ) switch to detect a low oil level in the separator and
activate a process shutdown of the separator. This is to avoid gas going out through
the liquid outlet line.

· Level switch detect a low water level in the separator and it activates a process
shutdown of the separator. This ensures that gas does not exit via the oil outlet.

· Pressure switch (PHH)detects a high pressure in the separator and it activates a

process shutdown of the separator. This ensures that vessel is not getting
overpressurised.

7.4 Safety Relief Valves And Rupture Discs

In all production facilities, three levels of safety are provided. and these are

1. alarm system
2. shutdown system
3. safety relief system.

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The majority of pressure relieving devices used in production operations are safety
relief valves. These are automatic valves used to prevent excessive over pressure in
vessels and piping systems.

The alarm and shut down systems are provided to allow an operator to detect and take
corrective action in the event of an upset. The safety relief system must be provided to
protect the vessel in the event the corrective reaction or shutdown is not made rapidly
enough or in the event the alarm and shutdown systems fail.

example.

Consider a high pressure production separator with a design working pressure of 1400
psi and which is operating at 1 000 psi.

Suppose something goes wrong and causes blocking of the outlet of the vessel, so that
the pressure begins to build up inside the vessel.

First, provision is made to warn the operator that something abnormal is starting to
occur. As the pressure builds up above the normal operating range of 1000 psi, say, to
1100 psi, and the operator may get a high pressure alarm
( warning ) This calls the operator's attention that pressure is increasing, so that he can
take corrective measures. Sometimes the alarm may not work or the operator was not
in the control room, then the pressure will start increase again.

At 1200 psi, a second signal High High pressure switch comes in to action and a
shitdown signal is sent to the separator and to close the inlet ESD valve. This should
stop the pressure increase and protect the vessel from high pressure. But sometimes
ESD valves don't operate quickly enough to prevent over pressuring the vessel or don't
operate at all.

Then pressure continues to increase in the vessel, the third level comes into action. At
a predetermined set pressure at or below the 1400 psi , the safety relief valve will open
to relieve the pressure and protect the vessel. When the other protective devices
fail to prevent over pressure or fail to operate, so the safety relief valve protects the
vessel from rupturing by relieving the excess pressure.

7.5 Rupture Disc

Rupture discs are another pressure relieving device. Under certain conditions, rupture
discs can be a very important element in a pressure relieving system.
Rupture discs are designed to rupture or burst automatically at a predetermined
pressure. This is usually higher than the safety relief valve set pressure. The rupture
disc, as a secondary measure, can be relied on to provide emergency over pressure
protection.

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A rupture disc opens by rupturing the thin metal disc held between the two flanges. It
cannot be reset once operated, it must be replaced. They may be installed in parallel or
in series with safety valves, or both. Rupture discs are often installed in series or
immediately below a safety relief valve when it is necessary to protect the relief valve
from continuous exposure to corrosive material. They should be installed in parallel or
on a separate outlet, only if the loss of the system contents can be tolerated.

8. Shutdown systems

Types of Shutdown

PSD Planned
Emergency
Process Maintenance
shutdown
Shutdown shutdown

I.A.Header Flare.K.O A.P.K.O

Manual Fire Power
pressure drum level drum level
initiation detection low failure high high

PSD PROCESS SHUT DOWN

The following occurrences would justify a process shutdown either separate equipment items or a
complete system.

1 Change in production requirement involving the removal of an item of equipment or

system from the process.

2 Control problems on an individual item of equipment.

An automatic process shutdown of an equipment item or system will occur when process upsets
or control problems result in an item of equipment operating outside its design operating ranges.

A full matrix of PSD action (manually and automatically initiated) can be refered to P & I
Diagrams from the specific operating mannual.

A PSD of the separator initiated on high pressure or high level causes the inlet ESD valve and
liquid outlet ESD valve to close. A PSD on low oil and water levels(Test)cause only the liquid
outlet valve to close.

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Bulk separator PSD can effect the other running facility, a test separator PSD does not affect any
other part of the station. All these valves will remain in their PSD position until the operating
deviation that caused the PSD is corrected and the re-set is operated.

Separator may be shutdown by operator intervention by means of the control room mounted PSD
switch.

ESD comes into effect when any of the incidents shown in the above picture takes place. ESD
can be activated manually also. ESD shuts down the complete unit.

Shutting down a vessel or whole plant for a planned maintenance comes under a manual
shutdown.

9. Isolation of separators

Following procedure is only an outline. Plant operating manual is to be referred for actual
isolation.

Before isolating a separator all coonected sections( production stations, CCR) are to be informed
and any rwritten procedure aavilable is to be followed.

1. Divert all the wells to other separator.

2. Change the gas lift selection(if the well is gas lifted).

3. If condensate from compressor knock-out vessels is lined up to the separator then it is to be

redirected to another separator.

4. Initiate separator shutdown.

5. Close separator inlet valves, bypass valve and inlet ESD.

6. Close liquid outlet valves.

7. Close other inlet lines, if any ( condensate from compressor, etc).

8. Close gas outlet valves.

9. Install tags ` ISOLATED NOT TO OPERATE , and chains on all block valves on inlet and
outlet lines to the separator

10. Close relief and safety valves.

11. Drain the liquid.

12. Depressurise the vessel to flare.

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13. Purge the separator with Nitrogen. Purging is to be carried out in such a way that nitrogen
reaches the all corneres inside the separator. The points toinject Nitroge to and purge outlet
from the separator is to be selcted accordingly.

14. Install or reverse the blinds for positive isolation. If installation of spades is difficult in some
lines, positive isolation is to be done by dropping spools or block valves.

To vent

NC To compressor
C

C Separator LIC
LG

NC NC

Liquid outlet NC NC
C : CLOSE C
NC : NORMALLY CLOSE
NC
Closed drain header

Separator isolation

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10. Start-up of Production Separator

After major maintenance shutdown - purging required.

Afrer PSD or ESD - Purging not required

Following is the general out line for start-up procedure for a production
separator. For a specified separator a separate procedure are available in the
operating manual of a gathering facility.

10.1 Purge System

1. When starting-up after maintenance (i.e. hydrocarbons have been removed

from the system), the contained air must be PURGED out, by using nitrogen.
When selecting nitrogen injection point and purged nitrogen outlet points,
consideration is to be given to achieve the maximum possible circulation of
nitrogen through the vessel to push out all the oxygen inside.

NOTE The system must be totally isolated from all interconnecting system during
purging.

2. If the inlet manifold is full of air then the manifold should be included as part
of the system to be PURGED. The gas lines between the separator and the LP
flare must also be free of air.

3. CHECK the gas outlet from the vessel to know the content of oxygen.
Purging can be stopped when Oxygen content shows below 2 percent.

4. CHECK content of gas to LP flare by explosive meter.

10.2 Checks and Tests

1. SAFETY CHECK - CHECK that area is clean.

2. CHECK that ALL utilities ( instrument air, fire water system, etc)
are ON.

3. CHECK that ALL spectacle blinds are OPEN.

4. CHECK that ALL level, pressure and flow transmitter and gauges impulse
lines are OPEN.

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5 CHECK manually operated valve positions.
.

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 Valve Position

All oil manifold valves Closed

Inlet isolation valve to separator Closed
Bypass of Inlet isolation valve Closed
Separator drains / vents Closed
Upstream to separator LCV Closed
Downstream to LCV Closed
LCV bypass Closed

Oil outlet drain of LICA Closed

Gas outlet valve Open
Isolation valves on gas lines to LP flare Open
Isolation valves on RV line Open

5. CHECK that the downstream surge tanks and shipping pumps have been
purged.

6. CARRY OUT any other checks and tests explained in the operating manual
concerned to your area.

7. Check that purge gas flow to the surge tanks has been established.

8. CHECK that the required relief valve is locked OPEN to the vessel and flare.

9. CHECK that the level and pressure control valves are in automatic mode. If
doubtful about a valve's operation (e.g. due to valve seizure) CHECK its
operation by stroking it on manual mode.

Equalise Pressure and Open Inlet ESD valve

OPEN ESD valves only when the pressures on either side of the valve are
approximately equal. This is in order to protect the soft valve seat and hence
maintain valve shut-off integrity.

First OPEN the vent valve immediately downstream of the inlet isolation valve
bypass. This will release any contained pressure upstream of the ESD valve.
On equalising pressure across the ESD valve, the differential pressure switch
will permit the inlet ESD valve to open. CLOSE the vent valve.

OPEN the inlet ESD valve by operating first control room panel reset button
and than the local separator re-set button.

Next OPEN the inlet isolation valve bypass. The separator will slowly
pressurise to the set point of. Once the inlet line and separator pressures are
approximately equal then open the inlet isolation valve
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 If the inlet manifold has just been purged (and the flowlines are all shut off
prior to the manifold) then all the inlet valves may be OPENED immediately
without following the above sequence.

10.3 Start-up after ESD/PSD

If starting-up after plant ESD or vessel PSD and not after vessel has been
shutdown for maintenance (i.e. vessel still contains hydrocarbons under
pressure) then:

1. CHECK liquid level is below high level trip. If not, drain vessel to the closed
drains header via drain lines until liquid level is below high level alarm.

2. CHECK that vessel pressure is at or below set point.

If the pressure is higher than the normal operating pressure, depressurise the
vessel before opening the inlet line. Rest of the operations can be carried out as
per the above procedure.

NOTE: Before resetting the liquid outlet ESD, the position of the LCV and
isolation valve on liquid outlet line is to be checked. It is advisable to keep
LCV on manual in closed position. Isolation valve must be on closed position
before resetting the ESD. This is to avoid overpressurising of the surge tanks
( next processing system)

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