Vertical Three-Phase Separator Conversion Using T-Joint Segmentation
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Solution Overview
Problem
Current phase separation technologies for crude oil, particularly three-phase separators, are costly, complex, and inefficient, leading to unreliable measurements and high operational costs, especially in mature oil reservoirs where two-phase separators become obsolete.
Innovation Solution
A vertical three-phase separator device and method that converts existing two-phase vertical separators into three-phase separators using a 'T' joint to split the fluid flow, incorporating interfase and high level sensors, and positive displacement and magneto-inductive sensors for accurate phase separation and measurement, reducing equipment costs and operational complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If horizontal three-phase separators (FWKO) are used for separating gas, water and oil under pressure, then separation efficiency is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent divides the three-phase separation process into two sequential two-phase separation stages. The first stage separates gas from the liquid mixture using a vertical separator. The second stage separates oil from water using another vertical separator. This segmentation transforms a complex single three-phase separator into simpler, modular two-phase separation units that are easier to construct and maintain while achieving the same separation efficiency.
2Device complexity
If two-phase separators are used for gas-liquid separation, then device simplicity is maintained, but the ability to perform three-phase separation is lost
Solution Approach 1:
The patent combines two simple vertical two-phase separators into a integrated three-phase separation system. By connecting the liquid outlet of the first separator to the inlet of the second separator, and properly configuring the outlets, the system achieves three-phase separation capability while maintaining the simplicity and vertical configuration of the individual two-phase separator units.
3Measurement precision
If water cut measuring systems are used with high water cut (>95%), then oil/water separation measurement is attempted, but measurement reliability decreases due to equipment error margin
Solution Approach 1:
The patent extracts the water phase measurement function from the combined oil-water measurement system. By using a dedicated water level sensor in the second vertical separator that specifically monitors the water layer height, the system can accurately measure water production even when water cut exceeds 95%. This separate measurement approach removes the measurement from the unreliable range of mass flow equipment and places it in the reliable range of level sensing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables reliable, low-cost, and efficient three-phase separation with reduced control times, suitable for mature oil reservoirs, extending the lifespan of two-phase separators and improving measurement accuracy with minimal investment and low maintenance.
Implementation Method 1
a vertical separator which comprises: a first fluid inlet on its upper portion, and a second fluid inlet on its middle portion; a first fluid outlet line for the gas phase in the upper part of said separator, above said first fluid inlet; a second fluid outlet line for the oil phase in the middle portion of said separator, above said second fluid inlet, and a third fluid outlet line for the water phase in the bottom portion of said separator
Implementation Method 2
separating the phases of a three-phase fluid of the crude oil type
Implementation Method 3
a horizontal fluid feed line that splits into two lines prior to entering the vertical separator by means of a 'T' joint, thereby forming a first vertical ascending feed line and a second vertical descending feed line
Data Source
AI summary
A new device and method for separating all phases of a three-phase fluid of the crude oil type, by means of a two-phase fluid separating device provided with a âTâ joint for splitting the feed flow. The invention allows the conversion of two-phase separator into a three-phase fluid separating device, updating its functionality, increasing service life, using most of the original parts and components.