Operation and maintenance considerations for oil and gas separators

Dr. Vikas Mahto

Professor
Department of Petroleum Engineering
IIT(ISM), Dhanbad-826004

Over the life of a production system, the separator is expected to process a wide range of
produced fluids. With breakthrough from water flood and expanded gas lift circulation, the
produced fluid water cut and gas-oil ratio is ever changing. In many instances, the separator fluid
loading may exceed the original design capacity of the vessel. As a result, many operators find
their separator no longer able to meet the required oil and water effluent standards, or experience
high liquid carry-over in the gas. Some operational maintenance and considerations are discussed
below:

Periodic inspection

It is normal practice to inspect all pressure vessels and piping periodically for corrosion and
erosion. In the oil fields, this practice is not generally followed (they are inspected at a
predetermined frequency, normally decided by an RBI assessment) and equipment is replaced
only after actual failure. This policy may create hazardous conditions for operating personnel and
surrounding equipment. It is recommended that periodic inspection schedules for all pressure
equipment be established and followed to protect against undue failures.

Installation of safety devices

All safety relief devices should be installed as close to the vessel as possible and in such manner
that the reaction force from exhausting fluids will not break off, unscrew, or otherwise dislodge
the safety device. The discharge from safety devices should not endanger personnel or other
equipment.
Low temperature

Separators should be operated above hydrate-formation temperature. Otherwise hydrates may

form in the vessel and partially or completely plug it thereby reducing the capacity of the
separator. In some instances when the liquid or gas outlet is plugged or restricted, this causes the
safety valve to open or the safety head to rupture. Steam coils can be installed in the liquid
section of oil and gas separators to melt hydrates that may form there. This is especially
appropriate on low-temperature separators.

Corrosive fluids

A separator handling corrosive fluid should be checked periodically to determine whether

remedial work is required. Extreme cases of corrosion may require a reduction in the rated
working pressure of the vessel. Periodic hydrostatic testing is recommended, especially if the
fluids being handled are corrosive. Expendable anode can be used in separators to protect them
against electrolytic corrosion. Some operators determine separator shell and head thickness with
ultrasonic thickness indicators and calculate the maximum allowable working pressure from the
remaining metal thickness. This should be done yearly offshore and every two to four years
onshore