KALABAGH GAS & CONDENSATE FIELD

Three-Phase Weir Plate Separator

Report
Submitted by: Hamza Talat (Internee at Kalabagh Field)
Submitted to: Saqib Jamil (Incharge Kalabagh Field)
Introduction:
A horizontal pressure vessel called a three-phase weir plate separator is used to separate a
mixture of gas, oil (a light liquid), and water (a heavy liquid) into different phases. With the
help of internal components like weir plates to regulate liquid levels, it works on the basis of
density difference and gravity separation. The liquid section is separated into compartments
by the weir plate, which guarantees that each phase leaves by its assigned outlet with the
least amount of contamination from the others.
In order to promote the separation of gas from liquids, the entering mixed stream enters
through the intake device and has its velocity decreased. While the liquids flow into the
liquid section, the gas rises and leaves through the gas outlet at the top of the separator. A
weir plate aids in maintaining the proper levels and interface position between these liquids,
with the lighter oil forming a layer above the heavier water. Achieving effective separation
requires careful consideration of the vessel's dimensions, weir heights, and retention
durations.
Oil and gas production facilities frequently use three-phase weir plate separators,
particularly when the generated fluids need to be prepared for export or additional
processing. Using the computation results from the design spreadsheet, this report
describes the separator's design foundation, geometry, weir arrangement, hydraulic
performance, and retention time analysis.

Principle of Operation:
A three-phase weir plate separator works on the principle of gravity separation, using the
natural density differences between gas, oil, and water. The inlet stream enters the vessel
at high velocity and is slowed down by an inlet distributor or baffle, allowing the gas to
disengage from the liquid. The gas rises to the top section of the vessel and flows to the gas
outlet.
The liquid portion, now containing oil and water, flows into the separation section. Because
oil is lighter, it rises to form a layer above the water. A weir plate separates these two liquid
phases by maintaining different liquid levels for each.
This arrangement ensures each phase leaves through its designated outlet with minimal
contamination. The process is aided by controlled retention times and calm liquid surfaces, allowing
even small droplets to settle out by gravity before the fluids exit the vessel.
 Types of Horizontal design Separator shown

Design Basis:
With a design efficiency factor of 0.85 and an acceptable material stress of 1100 psi, the
separator is intended to function at a pressure of 500 psi. The density of the fluids is 0.19
lb/ft³(barrel per day) for vapor, 62.4 lb/ft³ (barrel per day) for heavy liquids (water), and 49.92
lb/ft³ (barrel per day) for light liquids (oil). Viscosities are minor for the vapor phase, 0.24 cP
for oil, and 0.682 cP for water. When calculating gas capacity, the Souder’s-Brown K-value
is 0.2871.
With a volumetric rate of 48.18 ft³/s and a gas mass flow of 32,955 lb/hr, the flow rates are
noteworthy. Light liquid moves at 72,753 lb/hr (0.4048 ft³/s) while heavy liquid moves at
4,547 lb/hr (0.02024 ft³/s). The volumetric flow of the entire liquid is 0.4251 ft³/s. In order to
ensure that both gas–liquid and liquid–liquid separation can take place effectively, these
values serve as the basis for deciding on vessel sizing and compartment proportions.
This design foundation guarantees adherence to industry norms like GPSA regulations and
API 12J. Additionally, it takes operating flexibility into consideration, enabling the separator
to operate under a range of load situations without suffering a noticeable decrease in
efficiency.

Separator Geometry:
With an overall length of 26.50 feet and a computed vessel diameter of 7.749 feet, the L/D
ratio is 3.42. Proper phase separation is made possible by this ratio, which offers a fair
balance between residence duration and footprint. The selected length is enough because
some interior portions have a minimum length requirement of 2.87 feet.
The volume of the vapor section is 76.51 feet, and the volume of the heavy liquid part is
127.52 feet. With a 0.5-inch corrosion allowance, the shell and head have thicknesses of
3.648 and 4.374 inches, respectively. The shell's entire surface area is 644.79 feet, while the
heads' total is 50.56 feet. These measurements satisfy the mechanical strength standards
of ASME Section VIII under the specified working circumstances and pressure.
The shape guarantees sufficient room for internal components such as the exit nozzles, weir
plate, and intake distributor. Additionally, it provides access for maintenance and potential
future additions like coalescing plates or mist extractors.

Weir Plate Design:

The proper interface between the water and oil phases is maintained by the positioning of
the weir plate. The high heavy liquid level (HHLL) is matched by the water weir's height of
5.749 feet. 3.584 feet is the established height of the interface between heavy and light
liquids. The high light liquid level (HHL) is 2.874 feet, while the heavy liquid level (HLLL)
falls to 0.906 feet at low levels.
The distribution of cross-sectional areas is as follows: the heavy liquid section is 15.904 ft²
(33.74%), the light liquid section is 21.593 ft², and the vapor part is 9.639 ft² (20.45% of
total). These ratios reduce phase carryover and provide steady separation. The area of the
low light liquid is 3.079 ft², while the net light liquid area is 21.319 ft².
For steady operation, the weir plate design is essential. It guarantees that the water phase
stays deep enough for oil droplets to rise and separate before leaving and that the oil
phase overflows into its compartment without being significantly contaminated by water.

Weir Plate Type Separator

Hydraulic Performance:
The vapor section's gas velocity of 3.483 feet per second is significantly less than the 4.999
feet per second permitted limit as established by the Souder’s Brown equation. In the gas
outlet, this lessens the chance of liquid entrainment. With a total liquid velocity of 4.644 feet
per second, the flow may be kept fluid without experiencing too much turbulence.
The computed liquid transfer velocities between phases are 17.316 in/min from light to
heavy and 6.094 in/min from heavy to light. These numbers show that there is less remixing
at the interface because the liquid phases interchange at regulated rates. The design allows
for sufficient leeway to manage brief surges or variations in flow without compromising
separation effectiveness.
Overall, the hydraulic design supports continuous, stable operation, ensuring the separator
can handle the specified throughput without overloading either the gas or liquid sections.

Retention Times:
The heavy liquid entering the light liquid portion has a retention time of 119.52 seconds (2
minutes), whereas the light liquid entering the heavy liquid section has a retention time of
339.64 seconds (5.66 minutes). The duration of gas retention is 0.574 seconds. Overall
retention for heavy and light liquids is 300 seconds (5 minutes) and 180 seconds (3 minutes),
respectively.
These durations provide a safety margin to guarantee high-quality separation because they
surpass the minimums of three minutes for oil and five minutes for water that are advised
by API 12J. Additionally, longer retention periods facilitate the handling of emulsified fluids
and lessen the need for chemical demulsifiers.
One of the most crucial aspects of separator design is adequate retention time, which
enables gravity to efficiently separate the phases. Both the water and oil phases will have
adequate time to settle before being released thanks to this design.

Applications:

Three-phase weir plate separators are widely used in:

• Oil and Gas Production: Separating produced fluids into saleable oil, disposal water,
and fuel or export gas.
• Petrochemical Plants: Separating mixed hydrocarbon and aqueous phases with
entrained gases.
• Wastewater Treatment: Removing oils and gases from industrial wastewater streams
before discharge.
• Refineries: Pre-treatment before downstream processing units to reduce load on
equipment like desalters and heat exchangers.
Their design flexibility allows them to be adapted for both offshore and onshore
installations, with configurations suitable for high pressure, high temperature, and varying
water cuts.

Advantages:

• Simple Operation: Has few moving elements and mostly depends on gravity and vessel
geometry.
• Simultaneous separation: Saves money and space by handling gas, oil, and water all in
one unit.
• High Capacity: Able to effectively process huge amounts of multiphase fluid.
• Customizable Design: Weir heights, internals, and retention periods can all be adjusted
to suit certain process circumstances.
• Low Energy Requirement: Phase separation itself doesn't require an external power
source.

Disadvantages:

• Large Footprint: Horizontal separators require considerable space, especially for high
flow rates.
• Sensitivity to Fluid Properties: Changes in density, viscosity, or flow rates can reduce
efficiency.
• Poor Performance with Emulsions: Stable emulsions may require chemical treatment
or heating.
• Limited to Steady Flow: Slugging or sudden surges in inlet flow can upset separation
performance.
• Regular Maintenance Needed: Solids build up and corrosion must be monitored and
controlled.
User Input:

Output:
 User Output

Length of Separator Ltotal (ft) 188.000

Diameter of Separator Dtotal (ft) 6.778

Length to Diameter ratio L/D 27.735
Weir Height HW (ft) 4.778

Thickness of Shell ts (in.) 3.254

Thickness of Head tH (in.) 3.889
Approx. Vessel Weight W (ton) 270.396

High Liquid Level HHLL (ft) 4.7785

Normal Liquid Level HNLL (ft) 2.828

Conclusion:

A tried-and-true device for dividing multiphase fluids into separate streams of water, oil,
and gas is the three-phase weir plate separator. In order to minimize cross-contamination
between phases, its design makes use of gravity separation concepts, supported by
meticulously considered vessel size, retention periods, and weir heights. A correctly
positioned weir plate ensures steady operation across a range of process circumstances
by providing precise control over the oil–water interface.
According to the design calculations, this separator has enough margins for gas velocity,
retention durations, and liquid handling capacity to satisfy both mechanical and process
performance criteria. Safety, dependability, and convenience of use are guaranteed by the
geometry, flow distribution, and compartmental volumes all adhering to API and ASME
design criteria.

References:
• Chemical Engineering Progress Textbook 1994.