Three phase separators separate gas, oil, and water. They consist of three zones: an inlet zone, a liquid-liquid settling zone, and a gas-liquid separation zone. Key factors that affect separator efficiency include the inlet flow pattern and devices, feed pipe geometry, entrainment, and internals. Separators can be horizontal or vertical, with horizontal separators often used for foamy streams and liquid-liquid separation, while vertical separators handle large liquid slugs. Proper sizing considers flow rates, residence times, velocities, and droplet sizes to achieve efficient phase separation with minimum carryover.
Presentations about Oil & Gas separators, fundamentals and how they work in the industry developed by Hector Nguema having Petroskills course as a reference
Separators are used to separate oil, water and gases from crude extracted from well. This presentation describes different types of separators and their parts and functioning.
Presentations about Oil & Gas separators, fundamentals and how they work in the industry developed by Hector Nguema having Petroskills course as a reference
Separators are used to separate oil, water and gases from crude extracted from well. This presentation describes different types of separators and their parts and functioning.
An overview of distillation column design concepts and major design considerations. Explains distillation column design concepts, what you would provide to a professional distillation column designer, and what you can expect back from a distillation system design firm. To speak with an engineer about your distillation column project, call EPIC at 314-207-4250.
Basics of two phase flow (gas-liquid) line sizingVikram Sharma
This article was produced with the objective to provide a condensed fundamental insight in gas-liquid line sizing using Lockhart-Martinelli correlation. The content of this article is purely academic by nature.
This presentation was created to provide a quick refresher to single-phase fluid flow line sizing. The content of this presentation was obtained from various literature (handbooks and website).
Please provide your comments
Troubleshooting in Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FLOW DIAGRAM FOR TROUBLESHOOTING
5 GENERAL APPRAISAL OF PROBLEM
5.1 Is the Problem Real?
5.2 What Is the Magnitude of the Problem?
5.3 Is it the Column or the Associated Equipment which is Causing the Problem?
6 PROBLEMS IN THE COLUMN
6.1 Capacity Problems
6.2 Efficiency Problems
7 PROBLEMS OUTSIDE THE COLUMN
7.1 Effect of Other Units on Column Performance
7.2 Column Control System
7.3 Improper Operating Conditions
7.4 Auxiliary Equipment
8 USEFUL BACKGROUND READING
9 BIBLIOGRAPHY
FIGURES
1 FLOW DIAGRAM FOR TROUBLESHOOTING
2 DETERMINATION OF COLUMN CAPACITY
Types of Distillation & column internalsBharat Kumar
More:- https://chemicalengineeringworld.com
Distillation is a method of separating the components of a solution which depends upon distribution of the substances between a gas and liquid phase, applied to cases where all components are present in both phases.
* What is distillation ?
* Types of Distillation
* Batch Distillation
* Azeotropic Distillation
* Flooding
* Priming
* Coning
* Weeping
* Dumping
* Packed Column
* Tray column
* Reflux Ratio
* Relative volatility
* Distillation column
Distillation is a method of separating mixtures based on differences in volatility (volatility is the tendency of a substance to vaporize. Volatility is directly related to a substance's vapor pressure.) of components in a boiling liquid mixture. Distillation is a unit operation, or a physical separation process, and not a chemical reaction
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
The Design and Layout of Vertical Thermosyphon ReboilersGerard B. Hawkins
The Design and Layout of Vertical Thermosyphon Reboilers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE DESIGN PROBLEM
5 COMPUTER PROGRAMS
6 GENERAL CONSIDERATIONS
6.1 Heating Medium Temperature
6.2 Fouling Resistance
7 DESIGN PARAMETERS
7.1 Overall Arrangement and Specifications
7.2 Geometry Elements
8 ANALYSIS OF COMMERCIALLY AVAILABLE
PROGRAM RESULTS
8.1 Main Results
8.2 Supplementary Results
8.3 Error Analysis
8.4 Adjustments to Design
9 OPERATING RANGE
10 CONTROL
10.1 Control of Condensing Heating Medium Pressure
10.2 Control of The Condensate Level
10.3 Control of Sensible Fluid Flow Rate
11 LAYOUT
11.1 Factors Influencing Design
11.2 A Standard Layout
12 BIBLIOGRAPHY
Pressure Safety Valve Sizing - API 520/521/526Vijay Sarathy
No chemical process facility is immune to the risk of overpressure to avoid dictating the necessity for overpressure protection. For every situation that demands safe containment of process gas, it becomes an obligation for engineers to equally provide pressure relieving and flaring provisions wherever necessary. The levels of protection are hierarchical, starting with designing an inherently safe process to avoid overpressure followed by providing alarms for operators to intervene and Emergency Shutdown provisions through ESD and SIL rated instrumentation. Beyond these design and instrument based protection measures, the philosophy of containment and abatement steps such as pressure relieving devices, flares, physical dikes and Emergency Response Services is employed
An overview of distillation column design concepts and major design considerations. Explains distillation column design concepts, what you would provide to a professional distillation column designer, and what you can expect back from a distillation system design firm. To speak with an engineer about your distillation column project, call EPIC at 314-207-4250.
Basics of two phase flow (gas-liquid) line sizingVikram Sharma
This article was produced with the objective to provide a condensed fundamental insight in gas-liquid line sizing using Lockhart-Martinelli correlation. The content of this article is purely academic by nature.
This presentation was created to provide a quick refresher to single-phase fluid flow line sizing. The content of this presentation was obtained from various literature (handbooks and website).
Please provide your comments
Troubleshooting in Distillation Columns
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 FLOW DIAGRAM FOR TROUBLESHOOTING
5 GENERAL APPRAISAL OF PROBLEM
5.1 Is the Problem Real?
5.2 What Is the Magnitude of the Problem?
5.3 Is it the Column or the Associated Equipment which is Causing the Problem?
6 PROBLEMS IN THE COLUMN
6.1 Capacity Problems
6.2 Efficiency Problems
7 PROBLEMS OUTSIDE THE COLUMN
7.1 Effect of Other Units on Column Performance
7.2 Column Control System
7.3 Improper Operating Conditions
7.4 Auxiliary Equipment
8 USEFUL BACKGROUND READING
9 BIBLIOGRAPHY
FIGURES
1 FLOW DIAGRAM FOR TROUBLESHOOTING
2 DETERMINATION OF COLUMN CAPACITY
Types of Distillation & column internalsBharat Kumar
More:- https://chemicalengineeringworld.com
Distillation is a method of separating the components of a solution which depends upon distribution of the substances between a gas and liquid phase, applied to cases where all components are present in both phases.
* What is distillation ?
* Types of Distillation
* Batch Distillation
* Azeotropic Distillation
* Flooding
* Priming
* Coning
* Weeping
* Dumping
* Packed Column
* Tray column
* Reflux Ratio
* Relative volatility
* Distillation column
Distillation is a method of separating mixtures based on differences in volatility (volatility is the tendency of a substance to vaporize. Volatility is directly related to a substance's vapor pressure.) of components in a boiling liquid mixture. Distillation is a unit operation, or a physical separation process, and not a chemical reaction
Safety is the most important factor in designing a process system. Some undesired conditions might happen leading to damage in a system. Control systems might be installed to prevent such conditions, but a second safety device is also needed. One kind of safety device which is commonly used in the processing industry is the relief valve. A relief valve is a type of valve to control or limit the pressure in a system by allowing the pressurised fluid to flow out from the system.
The Design and Layout of Vertical Thermosyphon ReboilersGerard B. Hawkins
The Design and Layout of Vertical Thermosyphon Reboilers
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 THE DESIGN PROBLEM
5 COMPUTER PROGRAMS
6 GENERAL CONSIDERATIONS
6.1 Heating Medium Temperature
6.2 Fouling Resistance
7 DESIGN PARAMETERS
7.1 Overall Arrangement and Specifications
7.2 Geometry Elements
8 ANALYSIS OF COMMERCIALLY AVAILABLE
PROGRAM RESULTS
8.1 Main Results
8.2 Supplementary Results
8.3 Error Analysis
8.4 Adjustments to Design
9 OPERATING RANGE
10 CONTROL
10.1 Control of Condensing Heating Medium Pressure
10.2 Control of The Condensate Level
10.3 Control of Sensible Fluid Flow Rate
11 LAYOUT
11.1 Factors Influencing Design
11.2 A Standard Layout
12 BIBLIOGRAPHY
Pressure Safety Valve Sizing - API 520/521/526Vijay Sarathy
No chemical process facility is immune to the risk of overpressure to avoid dictating the necessity for overpressure protection. For every situation that demands safe containment of process gas, it becomes an obligation for engineers to equally provide pressure relieving and flaring provisions wherever necessary. The levels of protection are hierarchical, starting with designing an inherently safe process to avoid overpressure followed by providing alarms for operators to intervene and Emergency Shutdown provisions through ESD and SIL rated instrumentation. Beyond these design and instrument based protection measures, the philosophy of containment and abatement steps such as pressure relieving devices, flares, physical dikes and Emergency Response Services is employed
The Innopipe removes fluids from natural gas lines.
We remove liquids like produced water, hydrocarbon condensates and chemicals from natural gas lines. Results include better pipeline integrity; minimized corrosion issues; reduced use of inhibitors; black powder reduction or elimination; extended pipeline life; slug reduction and control; reduced pigging; and improved plant and pipeline operations and predictability due to more consistent operations.
The Innopipe separator differs from conventional designs because it addresses the most common flow pattern in gas transmission and gathering lines: annular flow. We are less expensive to build and have much broader operating parameters than most gravity-inducing designs.Innopipe inline separator provide 99.9% separation efficiency. Innopipe is designed to be piggable, and can be built to any size and design code in the world including CSA, ASME, GOST, DNV, ANSI, DIN, CE, ISO, AS, CFR, PD and TUV. Innopipe also has an almost negligible pressure drop across it.
For more information visit www.innopipe.com
2. Three Phase Separators
Introduction
• Three phase separators are used to separate gas and two liquids of different
densities typically oil and water.
• They are a combination of Liquid - Liquid andVapor Liquid separators.
• They are typically employed in oil & gas fields in downstream of wells.
3. Three Phase Separators
Zones
Regardless of the internal configuration all liquid / liquid and gas / liquid / liquid
separators consist of three basic zones:
• Inlet section
• Liquid-liquid settling section
• Gas- Liquid Separation zone
4. Water
Oil
Inlet Nozzle(Three Phase Flow)
Water
Outlet
Nozzle
Oil Outlet
Nozzle
Gas Liquid
Separation
Zone
Liquid-Liquid
Separation
Zone
Oil
Water
Gas
Inlet
Zone
Three Phase Separator
General Figure
6. Factors
Flow Pattern at Separator Inlet
• The amount of liquid entrained into the gas
phase as droplets is generally small for
most flow conditions, but will typically
begin to increase fairly rapidly as the
transition to annular flow is approached.
• Taking into account both
entrainment/droplet sizes and steadiness of
flow, sizing the feed pipe for
stratified/wave flow is desirable, if possible.
While Annular Flow is highly undesired.
8. Typical guidelines are:
• Provide 10 diameters of straight pipe upstream of the inlet nozzle without
valves, expansions/contractions or elbows.
• Path changing fittings must be avoided in the immediate upstream of
separator as it can change the flow regime and can also cause circulation of
flow.
• If a valve in the feed line near the separator is required, it should only be a
full port gate or ball valve.
Factors
Feed Pipe Geometry
9. • Inlet devices are typically selected and sized
based on the inlet momentum (sometimes
referred to as dynamic pressure) of the
separator feed stream.
• The intent is to reduce the energy/velocity
of the feed fluids to provide conditions
favorable for phase separation
Factors
Inlet Devices
10. Most Commonly used devices include
• Diverter Plates
• Half Pipe
• Vane Distributor
• Inlet Cyclone
Inlet
Devices
11. It can be used for flows with little gas load and
little tendency for foaming. Disadvantages
include
• Poor Bulk Separation
• Liquid Droplets get shattered
• Creates fine droplets which is undesired
Review of Inlet Devices
Diverter Plate
12. Half open pipes are the modified versions of
90° elbow devices suitable for both vertical
and horizontal separators, with slightly
improved bulk liquid removal and reasonable
gas distribution.
• In horizontal vessels, the last section of the
half open pipe should be horizontal;
pointing opposite to the flow direction in
the vessel and with its opening directed
upward.
• In vertical vessels, the last section is closed
and its opening is directed downward
Inlet Devices
Half Pipe
13. The inlet vane distributors work by smoothly
dividing the incoming flow into various segments
using an array of curved vanes.
The benefits of this device compared with
simpler deflectors such as deflector plates
include
• Reduced agitation and hence
• Improved phase operational performance
• More stable level control
• Reduced foaming.
Inlet Devices
Vane Distributor
14. The inlet cyclonic device is used in horizontal
and some vertical separators where there is a
requirement for
• High momentum dissipation
• Foam reduction
• High capacity
“Further comparison of inlet devices will be
discussed later on”
Inlet Devices
Inlet Cyclone
17. • The applicable entrainment
mechanism for a given set of
conditions is strongly dependent on
the liquid phase Reynolds number.
• For many separation applications, the
main liquid entrainment mechanism is
the shearing off of roll-wave crests .
• The onset of entrainment by this
mechanism would be expected to
coincide approximately with the
wavy/annular transition.
Factors
Entrainment
18. • Presence of impurities (paraffin, sand, scale, etc.)
• Foaming tendencies of the crude oil
• Corrosive tendencies of the liquids or gas.
• Operating and design pressures and temperatures
• ResidenceTime
Factors
Misc.
19. Configurations
There are two main configurations of three phase separators
• Horizontal
a) HorizontalThree Phase Separator with Boot
b) HorizontalThree Phase Separator with Overflow weir
c) HorizontalThree Phase Separator with Bucket and Overflow weir
d) HorizontalThree Phase Separator with coalescer
• Vertical
20. • Horizontal separators are almost always used for high GOR wells, for
foaming well streams and for liquid-liquid separation.
Configurations
Horizontal Separators
21. • A vertical separator can handle relatively large liquid
slugs without carryover into the gas outlet.
• It thus provides better surge control and is often used
on low to intermediate gas-oil ratio (GOR) wells and
wherever else large liquid slugs and more sands are
expected
Configurations
Vertical Separators
22. Configurations
HorizontalThree Phase Separators with Boot
• A horizontal separator with a boot is
commonly used for gas-liquid-liquid
separation where a small amount of
water is present in hydrocarbon liquid
• Because the surge volume spans the
entire vessel length this configuration
handles slugs well as long as the
settling region is sufficient for the
heavy phase to settle into the boot as
the slug is separated.
• In the most common configuration
the interface is maintained
23. Configurations
HorizontalThree Phase Separators with Overflow
Weir
• A settler with a single overflow weir is
a common configuration for gas-
liquid-liquid separation, where the
liquid-liquid interface is well defined.
• Where slugs are possible the
submerged weir is preferred. In this
design the overall level will rise and
liquid residence time will increase
when a slug enters the separator
24. • A settler with a “bucket”, and an
overflow weir, is commonly
used for applications where a
small amount of hydrocarbon is
to be separated from water.
Configurations
HorizontalThree Phase Separators with Overflow
Weir and Bucket
25. Configurations
HorizontalThree Phase Separators with Coalescer
• Coalescer internals can be used
with all of the above horizontal
three phase separator
configurations.
• The design is best suited for
separation of difficult-to-
separate dispersions and for
high outlet product quality
specifications
26. FactorsThat Determine
Vessel Orientation
Feature Vertical Horizontal
Compact separator Yes Yes
Small footprint Yes -
Small liquid surge drum Yes -
Solid removal with liquid Yes -
Small capacity flare KO drum Yes -
Gas dominated services Yes -
Liquid dominated services - Yes
27. Feature Vertical Horizontal
Three phase separation - Yes
Liquid-liquid separation - Yes
High liquid degassing residence
time
- Yes
Pigging and slug flow separation - Yes
Foaming feed - Yes
High liquid surge capacity - Yes
Large capacity flare KO drum - Yes
Solid removal through jetting - Yes
High liquid and vapor flow rates Yes Yes
FactorsThat Determine
Vessel Orientation
28. • Have good bottom-drain and clean-out facilities.
• Can handle more sand, mud, paraffin, and wax without plugging.
• Fewer tendencies for entrainment.
• Has full diameter for gas flow at top and oil flow at bottom.
• Occupies smaller plot area..
Advantages of
Vertical Separators
29. • Advantages of these separators are:
• Require smaller diameter for similar gas capacity as compared to vertical
vessels.
• No counter-flow (gas flow does not oppose drainage of mist extractor).
• Large liquid surface area for foam dispersion generally reduces turbulence.
Advantages of
Horizontal Separators
30. • Providing sufficient time to allow the immiscible gas, oil, and water phases
to separate by gravity.
• Providing sufficient volume in the gas space to accommodate rises in the
liquid level that result from the surge in the liquid flow rate.
• Allowing for variation in the flow rates of gas, oil, and water into the
separator without adversely affecting separation efficiency.
• Increasing gas flow yields improved droplet capture, but also increases re-
entrainment which results in liquid carryover and limits separation capacity.
Tidbits for
Separator Sizing
31. Data and Information Required
to Specify and Size Separators
• Separator environment: wellhead, offshore, gas plant
• Service: K.O. drum, gas-liquid separator, surge, flash drum, reflux drum, crude oil
separator, solids removal
• Physical space limitations
• Typical sizing parameters for this service
• Separator effluent requirements / separation efficiency needed: Bulk liquid
removal and/or fine mist removal.
• Effect of separation efficiency on downstream equipment
• Conditions of service: clean, fouling, or potentially plugging service determines
types of entrainment separation devices that may be considered
32. Data and Information Required
to Specify and Size Separators
• Operating Conditions: gas and liquid flow rates, operating temperature and
pressure, gas and liquid physical properties
• Design factor for sizing:Typically design factor is based on either maximum
operating flow rate alone or operating flow rate plus a factor.This decision
should be based on specific service and project criteria
• Liquid residence time requirements for de-gassing or other needs for this
service based on experience or specific project criteria
• Liquid-liquid settling time requirements
33. Data and Information Required
to Specify and Size Separators
• Inlet slug size and frequency
• Surge time requirements
• Nature of fluids being contained: hazardous properties (toxic, flammable,
lethal, etc.) and corrosively
• Mechanical design conditions: design pressure and temperature, corrosion
allowance, material of construction, minimum design metal temperature,
and any project specific requirements
34. • Vapor Liquid Separation Zone
a) WithoutWire mesh
b) WithWire Mesh
• Liquid-Liquid Separation Zone
a) Conventional
b) With Boot
c) With OverflowWeir
Criterion for
HorizontalThree Phase Separator Sizing
35. • Check that the vapor velocity satisfies the following equation in order to
avoid entrainment. The area used for the vapor velocity shall be the vertical
cross-sectional area above high liquid level.
ut = terminal velocity of liquid droplet (m/s)
uh = horizontal vapor velocity (m/s)
L1 = distance between vapor inlet nozzle and vapor outlet nozzle (mm)
H1 = height of vapor section(the section above the high level
u
L
H
uh t
1
1
Vapor Liquid Separation Zone
Without Mesh
36. • The minimum vapor space above the high liquid level should be larger than
15% of the drum diameter or 300 mm, whichever is the greater to avoid
entrainment of liquid
Vapor Liquid Separation Zone
Without Mesh
37. • Maximum allowable velocity at wire mesh pad is calculated by following formula
• Vapor velocity passing through wire mesh pad shall be equal to or smaller than
maximum allowable velocity. Actual pad length is larger than required pad length
by 100 mm for support plate.
L2 = L1 + 100
• Height from high liquid level to underside of wire mesh (H1) shall be 0.50L1 or
minimum 150 mm to avoid re-entraining from liquid surface.
u K
DR
a
g
g
100
L Q
u
a
a
1
1000 3600
Vapor Liquid Separation Zone
With Mesh
38. • Check that the velocity through
mesh pad is kept high enough for
good separation.
=Vapor velocity at wire mesh
0 3 11. . u u ua wm a uwm 0 15. m/ s
2
1000
1
3600
LQ
u a
wm
wmu
Vapor Liquid Separation Zone
With Mesh
39. • Check the liquid velocity which is given by following equation in order to
avoid entrainment of heavier liquid. Terminal velocity of heavier droplets
shall be estimated by
u
L
H
uh t
1
1
Liquid-Liquid Separation Zone
Conventional
u
gD
t
P h
2
18
40. • Total liquid flow rate (sum of heavier and lighter)
shall be used for liquid velocity (uh ). Sectional
area (A1) for liquid velocity shall be based on
H1+H2.
• (4)The minimum vapor space above the high
liquid level should not be less than 15% of the
drum diameter or 300 mm, whichever is the
greater for avoiding entrainment of liquid.
• (5) Lighter Liquid Low Level (LLL) should be
separated at least 200 mm from Heavier Liquid
High Interface Level (HIL). Outlet nozzle of higher
liquid should be extended above HIL by min. 100
mm.
Liquid-Liquid Separation Zone
Conventional
41. • Holding time of heavier liquid in boot (from low interface level (LIL) to high
interface level (HIL)) shall be minimum five (5) minutes as a guideline.
Minimum height from LIL to HIL shall be 300 mm.
• Minimum boot diameter shall be 250 mm (10") for good operability of
heavier draw off. Commercial pipe up to 24" should be applied from
economical standpoint.
• Maximum boot diameter shall be 1/3 of the drum inside diameter. When
larger diameter is required, consult mechanical engineer
Liquid-Liquid Separation Zone
With Boot
42. • LS (length of separation zone) should be no
less than 0.85D (diameter). A approximate LS
from inlet nozzle to boot center can be given
as follows.
• L1 : nozzle nominal diameter (mm) + 200
• L2 : Boot diameter (d) + outlet nozzle nominal
diameter + 0.1*drum diameter + 350
• L3 : nozzle nominal diameter (mm) + 200
• Calculate and check LS
• LS = L - (L1 + L2 + L3), LS0.85D
• Criteria for Uh is checked
Liquid-Liquid Separation Zone
With Boot
43. • Check the lighter liquid velocity in this zone for heavier droplet separation.
Liquid-Liquid Separation Zone
With Overflow Weir
u
L
H
uh
s
t
1