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Figure 1: Oil and Gas 1 Stage Separation Process Flow Diagram (Simplified)
Figure 1: Oil and Gas 1 Stage Separation Process Flow Diagram (Simplified)
Introduction
The well-streams (or well fluids) produced from well platforms may consist of crude oil,
gas, condensates, water and various contaminants. The purpose of the separator is to
split the flow into desirable fractions. An oil/gas separator is a pressure vessel that is
installed either in an onshore processing station or on an offshore platform. Based on
the vessel configurations, the oil/gas separators can be divided into horizontal, vertical,
or spherical separators. In teams of fluids to be separated, the oil/gas separators can be
grouped into gas/liquid two-phase separator or oil/gas/water three-phase separator. In
this paper, the three phase separator is used as the basis for the discussion and
presentation of the Piping and Instrumentation Diagram (P&ID) of an oil and gas
separation process.
The figure below shows a simplified flow diagram of the oil and gas 1 st stage separation
process.
Figure 1: Oil and Gas 1st Stage Separation Process flow Diagram (Simplified)
Inlet temperature is often in the range of 100-150 degrees C. On the example platform,
the well stream is colder due to Subsea wells and risers.
The pressure is often reduced in several stages but commonly, three stages are used,
and these allow controlled separation of volatile components. The purpose is to achieve
maximum liquid recovery and stabilized oil and gas, and separate water. A large
pressure reduction in a single separator will cause flash vaporization leading to
instabilities and safety hazards.
The retention period is typically 5 minutes, allowing the gas to bubble out, water to settle
at the bottom and oil to be taken out in the middle. In the first stage separator, the water
content is typically reduced to less than 5%.
Figure 2 show the Piping and Instrumentation Diagram (P&ID) of the 1 st stage (3-Phase)
separator.
Figure 2: P&ID of an Oil and Gas 1st Stage (3-Phase) Separator
Piping
Piping is a system of pipes used to convey fluids (liquids and gases) from one location
to another. The engineering discipline of piping design studies the efficient transport of
fluid.
The gas that has been separated from the well fluid mixture is directed through a pipe
which is equipped with several valves including a pressure valve which by means is an
actuator valve. The actuator valve works hand in hand with a pressure transmitter (PT)
and control (PC) in order to monitor and regulate the pressure of the gas flowing
through the piping system.
Below are figures showing external (Figure 8) and internal view (illustrated and with the
major components) of the separator vessel (Figure 9).
At the crude entrance there is a baffle slug catcher that will reduce the effect of slugs
(Large gas bubbles or liquid plugs). However some turbulence is desirable as this will
release gas bubbles faster than a laminar flow. At the end there are barriers up to a
certain level to keep back the separated oil and water. The liquid outlets from the
separator will be equipped with vortex breakers to reduce disturbance on the liquid table
inside. This is basically a flange trap to break any vortex formation and ensure that only
separated liquid is tapped off and not mixed with oil or water drawn in though these
vortices. Similarly the gas outlets are equipped with demisters, essentially filters that will
remove liquid droplets in the gas.
Gate valves are primarily designed to start or stop a flow (in this case the flow of well
fluids) when a straight line flow of fluid and minimum flow restriction are needed. In
service, these valves are pretty much kept either fully open, or fully closed. When turned
open, the disc of the gate is completely removed allowing contents to pass. Although
this gives the valve good shut-off properties and is bidirectional, they cannot be quickly
opened or closed and are sensitive to vibration when open.
Relief Valve
Flange
Actuators are a means by which a valve can be automated so that no human interaction
with the valve package is necessary to cycle the valve. Actuators can be remotely
operated and can act as shutdown mechanisms in case of an emergency situation,
wherein human interaction can be dangerous.
The diaphragm-style actuator includes a rubber diaphragm and stem in a circular steel
housing. This style of actuators is ideal for valves requiring shorter travel, such as
diaphragm valves and globe valves.
Reducer / Expander
Generally, the control valve size is smaller than the corresponding line size. This
change in diameter should be clearly indicated in the P&ID with reducer and expander.
The former is the component in a pipeline that reduces the pipe size from a larger to a
smaller bore (inner diameter). While the latter on the other hand, expands the pipe size
from a smaller to a larger bore.
An increase in fluid pressure to the actuator is required to cause this valve to open.
Pressure Transmitter
.
Pressure controller receives data reading from pressure transmitter, compared that
reading to a programmed setpoint, and signals a control element (in this case, an
actuator valve) to either close or open depending on the corrective action needs to be
taken.
Level Transmitter
Level transmitter provides an electrical output proportional to the well fluid level in the
separator vessel. It may provide an output upon reaching a specified value (point level)
or repeatedly after each measurement (continuous level).
Level Controller (mounted in the control room)
It regulates the level of the well fluids by processing the reading it receives from the
level transmitter and then, compares the reading from a specified setpoint before it
gives signal to the actuator valves which will either open or close depending on the
corrective action that needs to be taken.