Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Introduction to Three-Phase Separation

• Understand the role of three-phase separators in oil & gas processing.
• Identify the physical properties of oil, gas, and water that impact separation.
• Differentiate between two-phase and three-phase separators.

2. Principles of Three-Phase Separation

• Explain separation mechanisms: gravity settling, coalescence, and momentum separation.
• Analyze how droplet size, density difference, and fluid viscosity affect separation efficiency.
• Understand gas-liquid and liquid-liquid interface dynamics.

3. Types of Three-Phase Separators and Their Applications

• Identify horizontal, vertical, and spherical separators and their advantages.
• Understand free-water knockouts (FWKO) and their role in separation.
• Learn about high-pressure and low-pressure separators for different field conditions.

4. Key Components of a Three-Phase Separator

• Explain the function of:
• Inlet diverters (cyclonic, vane-type, baffle plates).
• Mist extractors (mesh pads, vane packs, demisters).
• Weir plates and interface level controllers.
• Pressure and level control systems.

5. Separation Efficiency and Optimization Techniques

• Optimize residence time and separator dimensions for improved efficiency.
• Implement chemical treatment (demulsifiers, defoamers) for water-in-oil and oil-in-water separation.
• Control foaming, emulsions, and sand production issues.

6. Instrumentation and Control Systems in Separators

• Understand level controllers, pressure regulators, and flow measurement devices.
• Implement automated control strategies for enhanced separation performance.
• Integrate SCADA and DCS systems for real-time monitoring.

7. Troubleshooting Common Separation Problems

• Identify causes and solutions for:
• Foaming and emulsions affecting separation performance.
• Poor oil-water separation leading to off-spec crude.
• Gas carryover and liquid carry-under issues.
• Sand and solids accumulation in separators.

8. Safety, Environmental Considerations, and Regulatory Compliance

• Implement pressure relief systems, flame arrestors, and gas venting protocols.
• Ensure compliance with API, ASME, OSHA, and environmental regulations (MARPOL, EPA).
• Develop hazard mitigation strategies for separator overpressure, leaks, and fire risks.

9. Case Studies and Practical Applications

• Analyze real-world three-phase separation challenges and operational improvements.
• Participate in hands-on separator operation and troubleshooting exercises.
• Develop a customized separation optimization plan for a given field condition.

Target Audience

• Production and process engineers
• Oil & gas facility and operations personnel
• Mechanical and chemical engineers in upstream processing
• Field technicians and maintenance personnel
• HSE and compliance officers