The unit was designed as a skid-mounted three-phase separator, allowing for easier transportation and faster on-site installation.

From a process perspective, the separator handles:

Gas capacity: 2.1 MMSCFD

Oil capacity: 18,000 BPD

Water capacity: 12,000 BPD

Such flow conditions require not only sufficient vessel volume, but also stable phase separation under fluctuating inlet conditions, which is often the more challenging part in real operation.

Design Approach

Rather than focusing only on vessel sizing, more attention in this project was given to internal configuration and control strategy.

For three-phase separation, maintaining a stable oil-water interface is critical. In this unit, dedicated level control systems were implemented for both oil and water phases, allowing independent discharge and reducing the risk of carryover.

The internal arrangement was designed to balance separation efficiency and pressure drop. Components such as inlet devices and mist extraction systems were selected based on expected flow behavior, rather than using a fixed template.

Another important aspect was the operating flexibility. While the design conditions allow for higher temperature and pressure ranges, the separator is expected to run at relatively moderate operating conditions. This requires the system to remain stable across a wide range, not just at a single design point.

Fabrication and Standards

The separator was fabricated in accordance with ASME Section VIII Div.1 requirements and certified with U Stamp.

For this type of project, compliance is only one part of the requirement. Equally important is the consistency in fabrication quality, especially for internal components that directly affect separation performance but are not always visible after assembly.

The unit was delivered complete with instrumentation, control valves, and necessary piping within the skid scope, reducing the amount of field work required on site.