Topic outline

  • Separator Design Considerations and Operations-PET-SF74

    This course provides an overview of all significant aspects and considerations of separator design considerations and operations for those who are directly involved in supervising gas processing operations such as managers and process engineers who are mainly in charge of planning and development of new gas processing facilities or modifying existing facilities
    • Training Methodology & Objectives

      Training Methodology

      This Trainee-centered course includes the following training methodologies:-

      • Talking presentation Slides (PPT with audio)
      • Simulation & Animation
      • Exercises
      • Videos
      • Case Studies
      • Gamification (learning through games)
      • Quizzes, Pre-test & Post-test

      Course Objectives

      After completing the course, the employee will:-

      Apply and gain an in-depth knowledge on separator design considerations and operations Identify the principal components of the separator and positioning the oil and gas separator
      Recognize internal devices and separations aids for separator and the functional descriptions of separators for O&G Describe the three-stage compressor train and glycol dehydration system
      Explain the advantages and disadvantages of horizontal and vertical separators Determine the vessel impact on separator performance and process foamy crudes through separators
      Recognize two-phase separator designed for foam breaking Discuss the effect of vessel size on slosh frequency including the advantages and disadvantages of horizontal and vertical baffles for slosh mitigation
      Explain phase separation theory and apply retention-time method and droplet-settling method Employ solids-removal or sand protection, maintenance and troubleshooting
      Describe the operation fundamentals of separators in the oil and gas industry including the general components and features of a separator Apply the principle of separator operation and recognize the classification of oilfield separators
      Differentiate monotube versus dual tube oilfield separators and review functional, operating pressure and application classification of oilfield separators Separate the oil from the gas, remove the gas from the oil, separate the oil from water, maintain the optimum separator pressure and liquid seal in the separator
      Recognize the methods to remove oil and gas using separators and methods to remove gas from oil in separators Measure flow in oil and gas separators and calibrate flow instruments in separators
      Carryout operations and maintenance of separators and periodic inspection for corrosion and erosion
      • Course Description

        This E-learning course is designed to provide participants with a detailed and up-to-date overview of separator design consideration and operations. It covers the principal components of the separator and the positioning of oil and gas separator; the internal devices and separations aids for separator and functional descriptions of separators for O&G; the three-stage compressor train and glycol dehydration system; the advantages and disadvantages of horizontal and vertical separators; the vessel impact on separator performance and the processing of foamy crudes through separators; the two-phase separator designed for foam breaking; the effect of vessel size on slosh frequency; and the advantages and disadvantages of horizontal and vertical baffles for slosh mitigation
        Further, the course will also discuss the phase separation theory, retention-time method and droplet-settling method; the solids-removal or sand protection, maintenance and troubleshooting; the operation fundamentals of separators in the oil and gas industry; the general components and features of a separator; the principle of separator operation and the classification of oilfield separators; the monotube and dual tube oilfield separators; the functional, operating pressure and application classification of oilfield separators; the separation of oil from the gas, removal of gas from the oil, separation of the oil from water and maintenance of the optimum separator pressure; and the liquid seal in the separator
        During this course, participants will learn the methods to remove oil and gas using separators; the methods to remove gas from oil in separators; the measurement of flow in oil and gas separators and calibration of flow instruments in separator; the operations and maintenance of separators; and the periodic inspection for corrosion and erosion
        • Module 1 - Description of Oil and Gas Separators

          Contents:
            • Other Names for Separators
            • Principal Components of the Separator
            • Positioning of the Oil and Gas Separator
            • Separator  Requirements
            • Requirements of Separators
            • Bulk Water Removal
            • Functional Descriptions of Separators for O&G
            • Separator Components
            • Functions of a Separator
            • Requirements of Separators
            • Separator Depressurization
            • GOM Process Train
            • Bulk Water Removal
            • Metering
            • Three-stage Compressor Train
            • Glycol DehydrationSystem
            • Vertical vs. Horizontal Separators
            • Design Considerations
            • Separator Inlet Zone
            • Flow Distribution Zone
            • Gravity/Coalescing Zone
            • Outlet Zone
            • Separator Inlet Zone
            • Flow Distribution Zone
            • Gravity/Coalescing Zone
            • Outlet Zone
            • Separator Performance
            • Interior Vessel Impact on Separator Performance
            • Foaming in Oil and Gas Separators – Bad News
            • Processing Foamy Crudes Through Separators
            • Paraffin in Oil and Gas Separators – Bad News
            • Solids and Salt Handling
            • Corrosion in Oil and Gas Separators
            • Sloshing
            • Level Controls for Oil and Gas Separators
            • Video: 2 Phase Separator Vessel
            • Spacing of the Levels in Oil and Gas Separators
            • Nomenclature 
            • Module Quiz
          • Module 2 - Phase Separation Theory

            Contents:
              • 1. Retention-Time Method
              • 2. Droplet-Settling Method
              • 3. Overall Design Considerations
              • 4. Required Data
              • 5. Potential Problems
              • 6. Maintenance and Troubleshooting
              • 7. Troubleshooting
              • 8. Nomenclature
              • Video: Three Phase Separator
              • Module Quiz
            • Module 3 - Operation Fundamentals of Separators in the Oil and Gas Industry

              Contents:
                • Description
                • Various Names for Separators or Similar Vessels
                • Use at Oilfield Well Sites
                • General Components and Features of a Separator
                • Principle of Separator Operation
                • Classification of Oilfield Separators
                • Vertical Separator
                • Horizontal Separator
                • Spherical Separator
                • Classification of Oilfield Separators
                • Monotube vs. Dual Tube Oilfield Separators
                • Functional Classification of Oilfield Separators
                • Operating Pressure Classification of Separators
                • Application Classification of Oilfield Separators
                • Test Separators
                • Low Temperature Separator
                • Metering Separator
                • Separating the Oil from the Gas
                • Removing the Gas From the Oil
                • Removing the Gas From the Oil – Coalescer 
                • Separating the Oil from the Water
                • Maintaining the Liquid Seal in the Separator
                • Methods to Remove Oil and Gas Using Separators
                • Density Differences – Gravity Separation
                • Flow Direction Change
                • Use of Centrifugal Force
                • Methods to Remove Gas from Oil in Separators
                • Agitation Process to Separate Nonsolution Gas
                • Heat Effect in the Separator Process
                • Centrifugal Force for Separators
                • Measurement of Flow in Oil and Gas Separators
                • Calibration of Flow Instruments in Separators
                • Operations and Maintenance (O&M) of Separators
                • Periodic Inspection for Corrosion and Erosion
                • Installing Safety Devices
                • Low Temperature Precautions
                • Corrosive Fluid Precautions
                • Video: Intro to 2-Phase & 3-Phase Separators
                • Corrosive Fluid Precautions
                • Separators for the Oil and Gas Industry
                • Oil and Gas Separators
                • Separators for the Oil and Gas Industry
                • Module Quiz
              • Module 4 - Controls and Features for Oil and Gas Separators

                Contents:
                  • Valves
                  • Emergency Shutdown (ESD) Valves
                  • Accessories for Oil and Gas Separators
                  • High and Low Level Controls for Separators
                  • High and Low Pressure Controls for Separators
                  • Safety Relief Valve on Oil and Gas Separators
                  • Safety Heads and Rupture Disks on Separators
                  • Instrumentation and Control System
                  • Vessel Instrumentation
                  • Pressure Control
                  • Level Control
                  • Oil Level Control
                  • Level Control
                  • Level Measurement
                  • Level Transmitter
                  • Level Indication
                  • Level Switches
                  • Level Control
                  • Level Control Settings 
                  • Flow Control
                  • Process Monitoring
                  • Control Valve Standard
                  • Liquid Levels Definition
                  • Safety Devices in Separator 
                  • Comparison of Vertical and Horizontal Support Structures
                  • Video: Oil and Gas Horizontal Separator
                  • Geometry 
                  • PRV – Built-up Backpressure
                  • Process Design Considerations 
                  • Process Design Conditions
                  • Sizes and Capacities:
                  • Level Control Settings 
                  • P&ID
                  • Module Quiz
                • Module 5 - Phase Separation

                  Contents:
                    • Separator 
                    • Characteristics of Flow Stream
                    • Well Production
                    • Well Fluids 
                    • Natural Gas Solubility 
                    • Separation Terminology 
                    • Factors Affecting Separation 
                    • Gas-Liquid Separation Principles
                    • Separation Mechanisms 
                    • Separator Classification
                    • Classification of Separators
                    • Vertical Separator
                    • Horizontal Separator
                    • Advantage and Disadvantage of Horizontal Separator
                    • Spherical Separator
                    • Separator Types Comparing
                    • Separator Types and Selection Guide
                    • Classification of Separators
                    • Test Separator
                    • Well Manifold
                    • Production Separator
                    • Low Temperature Separator
                    • Free Water Knock Out Drum
                    • Foam Separator
                    • Filter Separator
                    • Cyclone Sand Separator 
                    • Classification of Separators
                    • Two Phase Horizontal Separator 
                    • Two Phase Vertical Separator 
                    • Three Phase Separator 
                    • Classification of Separators
                    • Separator
                    • Multi Stage Separator 
                    • Single Stage Separator
                    • Knockout Drum 
                    • Flash Drum
                    • Slug Catcher (Finger Type)
                    • Slug Catcher (Vessel Type)
                    • Scrubber
                    • Video: Gas Scrubber Design  
                    • Filter
                    • Skimmer
                    • Module Quiz
                  • Module 6 - Process Vessels Design Considerations

                    Contents:
                      • Process Vessels -Types and Functions
                      • Process Vessels- Vapor Liquid Separation
                      • Types of Gas/Liquid Separators
                      • Video: Gas/Liquid Separation
                      • Process Vessels- Solid Liquid Separation
                      • Process Vessels - Design Considerations
                      • Design Orientation
                      • Process Vessels Sizing Criteria
                      • Design Pressure
                      • Process Vessels Calculations
                      • General Tips In Process Vessels Design
                      • Typical Operating Problems
                      • Design Temperature and Pressure
                    • Module 7 - Quantifying Separation Performance in Gas/Liquid Separator

                      Contents:
                        • Introduction 
                        • Separator Parts 
                        • Separator
                        • Flow Pattern and Entrainment
                        • Flowpipe Geometry
                        • Entrainment 
                        • Droplet Sizes and Distribution 
                        • Inlet Device
                        • Inlet Device Separation Efficiency 
                        • Gas Gravity Separation Section 
                        • Droplet Settling Calculations 
                        • Separator 
                        • Mist Extractor 
                        • Mesh Pads 
                        • Use of Different Mist Extractor Types in Series
                        • Video: Mist Eliminator
                        • Liquid Gravity Separation Section
                        • Quantification of Gas Entrainment Into Liquid by a Plunging Jet 
                        • Handling Intermittent Flow 
                        • Conclusion 
                      • Module 8 - Separator Configurations and Sizing

                        Contents:
                          • Configurations
                          • Horizontal Separators
                          • Vertical Separators
                          • Horizontal Three Phase Separators with Boot 
                          • Horizontal Three Phase Separators with Overflow Weir 
                          • Horizontal Three Phase Separators with Overflow Weir and Bucket
                          • Horizontal Three Phase Separators with Coalescer
                          • Factors That Determine Vessel Orientation
                          • Advantages of Vertical Separators
                          • Separator Sizing 
                          • Data and Information Required to Specify and Size Separators
                          • Criterion for Horizontal Three Phase Separator Sizing
                          • Vapor Liquid Separation Zone Without Mesh
                          • Liquid-Liquid Separation Zone Conventional 
                          • Liquid-Liquid Separation Zone With Boot
                          • Liquid-Liquid Separation Zone With Overflow Weir
                          • Gas/Liquid Separation Theory 
                          • Oil/Water Separation Theory 
                          • Separator Sizing: Two-Phase Separator 
                          • General Sizing Procedure 
                          • Vertical Separator 
                          • Vertical Separator Sizing Procedure 
                          • Vertical 
                          • Example of Separator Selection 
                          • Horizontal Separator 
                          • Horizontal Separator Sizing Procedure 
                          • Horizontal 
                          • Example of Separator Selection 
                          • Video: Separator Sizing
                          • Module Quiz
                        • Module 9 - Separator Internals

                          Contents:
                            • Sections of Separators
                            • Separator Sections
                            • Primary Separation Section 
                            • Secondary Separation Section  
                            • Retention Time
                            • Mist Extraction Section 
                            • Liquid Accumulation Section 
                            • Mechanical Device
                            • Components of Separator 
                            • Module Quiz
                          • Module 10 - Troubleshooting Oil and Gas separators

                            Contents:
                              • Separation of Phases 
                              • Vapor-Liquid Separation 
                              • Gas Liquid Separators 
                              • Gravity Settling 
                              • Souders-Brown Approximation 
                              • Liquid/Liquid Separations 
                              • Fluid-Fluid Separators
                              • Three Phase Separators 
                              • Video: Three-Phase Separator 
                              • Horizontal Three-Phase Separator
                              • Separator Purpose’s 
                              • Separator’s Must Perform the Following 
                              • Horizontal Separator 
                              • A Well Stream Separator Must 
                              • Three Phase Separators 
                              • Factors Affecting 
                              • Factors 
                              • Inlet 
                              • Review of Inlet Devices
                              • Inlet Devices 
                              • Comparison of Inlet Devices
                              • Factors Other Internals 
                              • Factors 
                              • Foam in Oil Gas Separators
                              • Foaming Tendency
                              • How to Overcome this Foamy Crude Phenomenon?
                              • Defoaming Plates in 3-Phase Separator 
                              • Operation Problems
                              • Retention Time
                              • Recommended Retention Time 
                              • Potential Problems 
                              • Maintenance and Troubleshooting 
                              • Troubleshooting 
                              • Module Quiz
                            • Post-Test

                              Kindly complete the post-test to assess your knowledge about the topic after the course.