Oil gas separators

Types of oil gas separators

An oil gas separator is a crucial component in separating the mixed flow of crude oil, natural gas, and produced water into three distinct streams. There are several types of separators based on their different operating principles, configurations, and designs.

• Horizontal separators: Gas-oil and gas-liquid mixtures enter the separator through an inlet pipe, which usually has a diverter at the top. The diverter makes the mixture flow diagonally down the separator's height, increasing the time spent in the separator and allowing better separation of the three components. The water with a high percentage of settlement will be at the bottom of the separator, while crude oil will float on top of the water layer, and natural gas will be above the oil layer.
• Vertical separators: vertical separators allow gas to escape easily through the top of the separator. Like horizontal separators, gas-liquid mixtures enter the separator and separate into three components. Gas vertical separators are usually more extensive than horizontal separators.
• Manifold separators: An oil manifold allows more than two wells to be connected to a single pipeline. The oil manifold separator separates crude oil, natural gas, and produced water through one pipeline by using valves, fittings, gaskets, and gauges. The advantage of manifold separators is that they save pipeline costs, but the time spent in manifold separators is less than in horizontal or vertical separators.
• Two-stage separators: Oil and gas separators usually separate the components in two or three phases. Two-stage separators separate the gas and oil/ water mixture. The gas exits the separator, and then an emulsion of oil and water is treated with demulsifiers and processed in the subsequent three-phase separator.

Three-phase separators: three-phase oil gas separators are the most common types of separators. They usually have vertical or horizontal configurations and are suitable for wells that produce oil, gas, and water simultaneously.

Specification & Maintenance

The performance of oil gas separators relies heavily on their specifications. The separator's efficiency will significantly improve if the separator is appropriately sized for the application. Separator efficiency is frequently correlated to the aspect ratio, which is the length to diameter ratio. Typical aspect ratios range from 2 to 6, with longer separators offering better separation.

Coalescer elements are also a crucial oil gas separator specification. These elements gather small water droplets and transform them into larger ones that can settle out of the gas stream. Some separators have resin-coated fiberglass coalescers, while others use stainless steel mesh. The choice of material and type will affect the element's lifespan and separation efficiency.

Maintaining gas oil separators is crucial for their proper functioning. Regular maintenance prevents the need for early replacements and reduces the risk of equipment failures. Cloudy water or excessive amounts of oil in tap water indicate that a separator requires cleaning. The first step is to locate the drain point and open it to let out the oil.

While performing oil gas separator maintenance, shut down all nearby equipment and adhere to the site health and safety regulations. Identify the separator's components and take out the weir and drain plugs as instructed in the manual. Take out any debris and examine the weir closely for corrosion or damage to see whether it needs cleaning or replacement. Please take out the weir and drain plugs and clean them with a wire brush to remove dirt and debris.

Since gravitational separation in an oil water separator relies heavily on time, maintaining the optimal retention period is vital. In addition to ensuring sufficient time for the water and oil layers to separate from each other, regularly inspecting the weir will help avoid any water coming into the outlet pipe.

Return the debris to the gas oil separator after cleaning it. Close the drain point and restart all equipment. Note that different separators require unique maintenance methods. Therefore, it is essential to get familiar with the operator's manual because it includes specific instructions that should always be followed.

Scenarios

Crude oil/gas separators are widely used in the petroleum industry and related fields to separate crude oil, natural gas, and other impurities. Their main applications include:

• Petroleum Extraction: Oil separators are used in oil well extraction. After crude oil and natural gas are pumped from the underground formation, they need to be separated to ensure that only crude oil is sent for subsequent processing, while natural gas can be collected for use or sale.
• Oil Refining: In oil refining plants, crude oil contains numerous impurities, including water, sediment, and other hydrocarbons. Separators are used in the initial processing stages to separate these impurities, allowing the refined crude oil to undergo further refining processes.
• Naturual Gas Processing: In natural gas processing, gas separators play a crucial role. The natural gas extracted from the underground often contains hydrocarbon condensate and water vapor. By using oil separators, these impurities can be eliminated, ensuring that the processed natural gas meets the required quality standards for sale and use.
• Petroleum Storage and Transportation: Oil separators are also used in storage tanks or transportation pipelines. They can separate water, sediment, or other impurities from crude oil, preventing equipment corrosion and ensuring oil quality during storage and transport.
• Offshore Oil Platforms: Offshore oil platforms are an important source of oil production. Due to environmental protection and resource utilization considerations, oil gas separators are essential for separating oil and gas on these platforms to avoid marine pollution and maximize resource recovery.

How to Choose Oil Gas Separators

• Flow Rate and Capacity:

  It's crucial to ensure that the chosen oil gas separator has a flow rate and capacity that matches the specific requirements. The size and rate of the separator must be compatible with the expected volume of mixed fluid.

• Separation Efficiency:

  The separator's ability to distinctively separate oil, gas, and water phases, referring to its efficiency, should be considered. Users need to choose a separator that can provide the desired separation quality.

• Operating Conditions:

  For example, temperature and pressure ranges. Buyers need to ensure that the selected separator can work under their particular operating conditions.

• Materials and Corrosion Resistance:

  Considering the separator's materials and their corrosion resistance is crucial. This guarantees that the separator can endure the corrosive environments commonly present in oil and gas production.

• Maintenance Requirements:

  When selecting an oil and gas separator, it's essential to consider the maintenance needs of the separator, like cleaning and servicing requirements. Selecting a separator with reasonable maintenance demands can help reduce operational costs and downtime.

• Compliance with Regulations and Standards:

  The chosen separator must conform to the relevant regulations and industry standards to ensure its safety and environmental compliance.

• Cost and Lifetime:

  Cost and lifetime performance of the oil gas separator should be taken into account. Users need to balance initial investment costs and long-term operating expenses, including maintenance and energy consumption.

Oil Gas Separators Q&A

Q1: How does an oil gas separator work?

A1: Oil gas separators use physical principles such as density, buoyancy, and vortex motion to separate oil and gas. Firstly, the mixed fluid enters the separator and flows along the inlet pipe, where its velocity decreases. Then the mixed fluid is distributed horizontally in the separator. Due to the difference in density, oil starts to float on the water surface, while gas bubble rise to the top. Finally, the oil, water and gas are collected respectively by the oil weir, water outlet and gas vent.

Q2: What are the advantages of oil gas separators?

A2: Oil gas separators can effectively separate gas from oil, reducing pipeline blockage and equipment damage, and protecting the safety of production. Besides, they are easy to operate and maintain, allowing automatic production. Adaptable to various working conditions and separable mediums, oil gas separators are also suitable for different enterprises and industries.

Q3: What types of oil gas separators are there?

A3: There are three main types of oil gas separators: the cyclone separator, the gravity separator and the electric separator. The cyclone separator uses the centrifugal force to separate gas and oil. The gravity separator makes use of the buoyancy and sedimentation speed to separate the mixed liquid layer by layer. The electric separator uses electrical fields to attract oil molecules and separate them from the gas molecules.

Q4: What should buyers pay attention to when using oil gas separators?

A4: Select appropriate oil gas separators according to the amount, composition and working conditions of the mixed gas and liquid. Maintain oil gas separators regularly to ensure their normal operation. Pay attention to the disposal of separated materials. Oil separators are usually equipped with some additives that can help the separation of gas and oil.