Three Phase Separators

THREE PHASE SEPARATORS
Dr. Vikas Mahto

Professor
Department of Petroleum Engineering
Indian School of Mines, Dhanbad
Horizontal Separators
Three phase separators are designed as either horizontal or vertical pressure vessels Figure 1 is
a schematic of a three phase horizontal separator.
Figure 1: Simplified flow diagram of typical three phase horizontal separators
The fluid enters the separator and hits an inlet diverter. This sudden change in momentum
provides the initial gross separation of liquid and vapor. In most designs, the inlet diverter
contains a downcomer, which directs the liquid flow below the gas/oil interface, to the vicinity of
the oil/water interface. The liquid collecting section of the vessel provides sufficient time so that
the oil and emulsion form a layer or "oil pad" above the free water. Figure 1 illustrates a typical
horizontal separator with an interface controller and weir. The weir maintains the oil level and
the interface controller maintains the water level. The oil is ski
skimmed
mmed over the weir. The level
of the oil after the weir is controlled by a level controller, which operates the oil dump valve.
The produced water flows from a nozzle in the vessel located upstream of the oil weir. An
interface level controller senses the height of the oil/water interface. The controller sends a signal
to the water dump valve, thus allowing the correct amount of water to leave the vessel so that the
oil/water interface is maintained at the design height.
The gas flows horizontally and out through a mist extractor to a pressure control valve, which
maintains constant vessel pressure. The level of the gas/oil interface can vary from twenty-five
twenty
percent of the diameter to seventy
seventy-five
five percent of the diameter, depending on the relative
importance
nce of gas/liquid separation. Most frequently, the level of the gas/oil interface is set at
fifty percent of the diameter.
Figure 2 shows an alternate configuration known of three phase separators as a horizontal three
phase separator with a bucket-and
and-weir design.
Figure 2: Simplified schematic of a typical, horizontal three phase separator with a bucket-
bucket
and-weir design
This design eliminates the need for a liquid interface controller. Both the oil and water flow over
weirs. Level control is accomplished by simple displacer floats. The oil overflows the oil weir
into an oil bucket where its level is controlled by a level controller, which operates the oil dump
valve. The water flows under the oil bucket and then over a water weir. The level after this weir
is controlled by a level controller, which operates the water dump valve. The back of the oil
bucket should be high enough to assure that if the bucket becomes flooded, oil will not flow over
the back of the bucket and out with the water.
The height of the oil weir controls the liquid level in the vessel. The difference in height of the
oil and water weirs and specific gravity differences control the thickness of the oil pad. It is
critical to the operation of the vessel that the water weir height be sufficiently below the oil weir
height so that the oil pad thickness provides sufficient oil retention time. If the water weir is too
low or the difference in specific gravity is not as great as anticipated, then the oil pad could grow
in thickness to a point where oil will be swept under the oil box and out the water outlet.
Normally, either the oil or the water weir is made adjustable so that changes in oil/water specific
gravities or
Vertical Separators
Figure 3 shows a typical configuration for a vertical three phase separator.
Figure 3: Simplified schematic of a typical vertical three phase separator
Flow enters the vessel through the side. As in the horizontal separator, the inlet diverter separates
the bulk of thee gas. A downcomer is required to transmit the liquid through the oil/gas interface
so as not to disturb the oil skimming action taking place. A chimney is needed to equalize gas
pressure between the lower section and the gas section.
The spreader, or downcomer,

comer, outlet is located at the oil/water interface. From this point, as the
oil rises, any free water trapped within the oil phase separates out. The water droplets flow
countercurrent to the oil. Similarly, the water flows downward and oil droplets trapped
trapp in the
water phase rise countercurrent to the water flow.
Figure 4 shows the three different methods of control that are often used on vertical separators.
Figure 4: Schematics of the three methods of level control often used on vertical three phase
pha
separators
The first is strictly level control. A regular displacer float is used to control the gas-oil
gas interface
and regulate a control valve dumping oil from the oil section. An interface float is used to control
the oil-water
water interface and regulate a water outlet control valve. Because no internal baffling or
weirs are used, this system is the easiest to fabricate and handles sand and solids production best.
The second method shown uses a weir to control the gas

gas-oil
oil interface level at a constant position.
pos
This results in a better separation of water from the oil as all the oil must rise to the height of the
oil weir before exiting the vessel. Its disadvantages are that the oil box takes up vessel volume
and costs money to fabricate. In addition, sedi
sediment
ment and solids could collect in the oil box and be
difficult to drain, and, lastly, a separate low
low-level
level shutdown may be required to guard against the
oil dump valve failing to open.
The third method uses two weirs, which eliminates the need for an interface float. Interface level
is controlled by the height of the external water weir relative to the oil weir. This is similar to the
bucket and weir design of horizontal separators. The advantage of this system is that it eliminates
the interface level control. The disadvantage is that it requires additional external piping and
space. In cold climates, the water leg can be installed internal to the vessel so that the vessel
insulation will prevent it from freezing.

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THREE PHASE SEPARATORS

Dr. Vikas Mahto

Figure 1: Simplified flow diagram of typical three phase horizontal separators

Figure 3 shows a typical configuration for a vertical three phase separator.

Figure 3: Simplified schematic of a typical vertical three phase separator

The spreader, or downcomer,

The second method shown uses a weir to control the gas

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