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Troubleshooting the separators

Alexander Romanov Follow
Process Engineer at Aibel 188 31 0

An underperforming separator is a common problem in the upstream processing plants.

Several different types of separators can be met in the oil and gas fields. Typically, they are
gas/liquid type or liquid/liquid type separators. When a separator starts to underperform, it
requires troubleshooting. First, the effect of poor performance is observed. Then the cause
for it should be identified. Possible solutions have to be evaluated based on the collected
data.  
Effects:
Separator performance negatively affects the downstream process equipment when the
effluent streams are out of spec, such as:
Too much liquid in the separated gas.
Gas blow-by to the liquid outlet.
Too much oil in water/ too high content of BS&W in oil.
  The need to troubleshooting comes up when either the one or more of the mentioned
conditions occur due to degraded performance over time, or when the operating conditions
are no longer within the original design envelope. Changes in the operating conditions may be
due to introduction of subsea tieback. Alteration of production stream composition due to
waterflooding front break-through to the production wells is among other conditions.
Causes:
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Separators may underperform at given operating conditions due to various reasons.
common are:
Wrong type of equipment was chosen in a first place.
Right type of equipment was chosen, but sized incorrectly.
Operating conditions changed outside of the working envelope of the equipment.
  Separator troubleshooting always begins with assessment of the process as a whole,
collecting the data, such as vessel design specifications, operational data, maintenance
program, and the vessel performance. The quality of the data are critical for the
understanding the causes of the issues, and developing the possible steps addressing these
issues. To provide a good baseline, collection of consistent data over a period of time is
essential.
Evaluation of the separator performance regarding various effects may include following:
Sampling the fluids from inlet and outlet streams. Measurements of sediment content,
presence of emulsion, and droplet size distribution are helpful in identification of the
performance issues.
Mapping of the fluids interface, presence of a “rag” layer and its thickness, if there are
suitable means of doing it, e.g. sample nozzles.
Sampling of the solid phase and identification of its composition to determine its origin.
  Good understanding of the separating process with appropriate utilization of various
diagnostic techniques will provide clear picture of the separator operation and will reveal the
cause of the poor performance.
Possible solutions:
Individual assessment is required to proposes a specific solution based on the findings.
Some solutions, though, are often preferable due to their relative ease of implementation:
Retrofit of the separator internals.
Modification of inlet pipe geometry and the type of fittings/valves used upstream the
separator.
Evaluate recycle streams. “Bad oil” streams may deteriorate separator performance
significantly.
Mesh demisting designs and plate packs are susceptible to fouling. Evaluate if this is the
case.
Review the operating liquid levels. Review the measurement instruments, their calibration. 
Usually there are multiple ways to improve the separator performance in each specific case.
Evaluation of economic and technical parameters should be taken into consideration in order
to choose the most viable option. 

Published By

Alex Alexander Romanov Follow

Process Engineer at Aibel
ander
Roman
ov
31 comments
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M. M. Ameerul Zaeem Md Zuhri

2y
Fresh Graduate from Universiti Teknologi Malaysia
Ameerul
Zaeem
Hi. Do you know who can can do the performance verification on liquid carry over?
Md
Zuhri Like Reply

Vladimirs Filimonovs
3y
VladimirsChief Engineer of Jack Up Barges at Zakher Marine International Inc. ARAMCO & ADNOC
approved.
Filimonovs
Hello dear Alexander. Could you please, give me an advice. AC compressor Oil
separator got a noise ( some knocking or bubbling). OIL separator Type 5540/13
"Castel". Looks like noise in the lower part of it. What is this? Note; when try to
recognize level by stick to ear -there is no observed any "knocking'' Thank you in
advance.
Like Reply 5 Replies

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Vladi Vladimirs Filimonovs 3y

Chief Engineer of Jack Up Barges at Zakher Marine International Inc. ARAMCO &
mirs ADNOC approved.
Filimon
OK Spasibo, Serega!
ovs
Like Reply

Serg Sergejs Kucajevs 3y

Refrigeration Service Engineer at GEA Refrigeration
ejs
Kucaje
Vladimirs Filimonovs там в нижней части стоит поплавковый клапан.
vs
Когда уровень масла поднимется до определённой отметки,
поплавок открывается и масло выдавливается в картер
компрессора.
Like Reply 1 Like

Edison Contreras Panibra

4y
Edison MSc Petroleum Engineering specializing in Design and management development and operation
of gas and gas condensate fields
Contreras
Panibra Abelardo Contreras ...This is interesting for your students...
Like Reply 1 Like

Onyeka Onwuemene R.Engr (COREN). M.Eng. PMP®

4y
Onyeka
Onyeka
Oil, Gas & Energy - Petroleum & Project Engineering | Consultant | Ex. Addax
Onwuemene
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R.Engr Troubleshooting of separator performance cannot be overlooked as it is easily one
(COREN).of the most critical equipment in a production facility. In the case where its gas
M.Eng. outlet feeds another critical equipment such as a compressor used for gas lift
PMP® and/or gas injection, its importance cannot be over-emphasized. I think separator
design should be dynamically adaptable to subsurface reservoir changes as the
field ages. For example, the incidence of high liquid carryover in a separator usually
occurs after a period following increased ageing in wells. Some of the
characteristics of an ageing field is high water cut, increased solution gas and
greater sand production. A quick look at adapting separator to this new regime is
the inclusion of an adjustable weir during design, properly designed inlet baffles and
inclusion of de-sanding and increased maintenance of gas outlet mesh into facility
maintenance schedules. As a proactive measure, separators should be designed
with future production profiles in mind as this will help operators deliberately adjust
to changes.
Like Reply 3 Likes 2 Replies

Onye Onyeka Onwuemene R.Engr (COREN). M.Eng. PMP® 4y

Oil, Gas & Energy - Petroleum & Project Engineering | Consultant | Ex. Addax
ka
Onwue
Alexander Romanov I agree with you Alex. Often times what we save now
mene
on CAPEX is usually suffered on OPEX at the mid to later stages of well
R.Engr
production, facilities maintenance and brownfield retrofits. Bottomline is to
(CORE
create a balance and ensure that design at least meets future baseline
N).
requirements.
M.Eng.
PMP® Like Reply 2 Likes

Alex Alexander Romanov 4y

Process Engineer at Aibel
ander
Roman
Great input, Onyeka. In the end everything goes down to how much design
ov
capacity the operator is willing to invest during the project phase. Too big
separator would accommodate future changes in the production fluids, but
capex would be a limiting factor. (And space/weight, if we are talking
offshore).
Like Reply

Dheya Al-Gallaf
4y
Dheya Sr. Process Engineer at Mustang-HDP
Al-
Gallaf This is 3 phase separator (V,L1,L2) the velocity of which L droplet to be considered
to calculate the critical velocity...& this velocity is for vertical /up flow , but
diameter/area for horizontal, how?
 Like Reply 1 Reply
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Alex Alexander Romanov 4y

Process Engineer at Aibel
ander
Roman
good overview of sizing of various types can be found here:
ov
http://petrowiki.org/Separator_sizing or if you have access to spe articles
could recoomend very basic but still very much used:
https://doi.org/10.4043/5592-MS
Like Reply

Shebl Wafa
4y
Shebl markting study and customer service manager at EGYPTIAN PETROCHEMICAL COMPANY
Wafa
Thanks for good knowledge
Like Reply

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