Tornado Technologies Inc

Separator Packages

What is a separator?

A separator is used to separate hydrocarbon streams produced at the wellhead. Gas, condensate and water are separated into their individual phases to allow metering of the gas and surface handling or transportation. The separation occurs through gravity and the mixture’s retention time in the vessel.

Condensate is lighter than water and gas is lighter than condensate, therefore, the water outlet nozzle is located at the bottom of the vessel and the condensate outlet is located in the middle of the vessel above the water and condensate interface. The gas outlet is located at the top of the vessel, separated from the rest of the vessel by a de-mister pad, which improves the separation from gas and liquids.

Typical separators will handle either gas and water (2 phase) or condensate-gas-water (3 phase) with additional packages providing adjacent storage in an attached tank. Liquids are either recombined after metering with the gas and sent down a pipeline or sent to a storage tank to be trucked away.

Different design and size criteria are based on the projected flow volumes, composition of the fluid mixture, operating pressure, temperature, and the amount time the mixture will be in the vessel (retention time) between liquid dumping.

Separators are most commonly used at wellhead production batteries and gas plants.

What are the main separator components?

  • Pressure Vessel

  • Inlet Diverter Plate

    allows the mixture of gas, condensate and water to enter the pressure vessel without foaming.

  • Mist Extractor or Eliminator

    to coalesce small particles of liquid that will not settle out from the gas by gravity

  • Adequate Controls:

    • Level Controller and Dump Valve

      allowing liquids to be pushed out of the separator vessel when full

    • Back Pressure Valve

      regulates the gas pressure of the separator package with the pipeline pressure downstream

    • Safety Relief Valve

      a code requirement in case the inlet pressure exceeds the design pressure of the separator package

  • Measurement

    Petrofield separators will most commonly measure the natural gas flow rate from a well using meter run (sized orifice plate). The information is either recorded on site by a chart recorder or sent electronically to a central location via remote monitoring system.

How can Petrofield assist me?

Petrofield will provide sizing advice to ensure any separator meets the client’s expected process conditions. We design and build a range of packages for both stock inventory and custom designed units suited for:

  • Sweet or sour applications
  • Vertical or horizontal separation
  • Two or three-phase design
  • Optional integral produced water storage tanks

Separators are available in a range of sizes and pressure ratings:

  • Size: 6-inch to 10-feet (OD)
  • Length: 30-inch to 30-feet
  • Pressure: 150 – 900 ANSI Class

Many options can be provided upon request. For example, our typical vertical separator skid includes a chemical pump and an extension for mounting an optional 500 gallon methanol tank. Methanol can be injected into the gas stream to reduce the risk of freezing.

Economical small diameter separator units are also available as a cost-effective solution for marginal, low producing well sites. For larger projects, be sure to ask Petrofield about our experience with custom designs for test headers and satellite packages. Our engineering experience is what sets us apart from the rest.

Does  Petrofield build Separator/Tank Combo Packages?

Yes. Petrofield manufactures steel, dual-wall, vacuum-monitored tanks in 106 and 212 BBL sizes that comply with EUB guide 55 requirements (Alberta). These tanks are normally integrated into our separator units (heated and insulated) in order to provide safe un-pressurized storage for produced water or condensate at the wellsite.

Petrofield's unique design has a complete permanent vacuum envelope around the walls and floors such that any failure in either containment system (inside or outside) will immediately be visible to the operator on the vacuum gauge. Most competitor’s typical non-vacuum type dual-wall containment systems (i.e. with sight plugs or drain valves) cannot make this same statement with regards to the outer containment integrity – the operator will only know that the outer containment has failed when it is already too late to prevent ground contamination.