Horizontal Separators
OTSO designs and manufactures horizontal separators that efficiently remove impurities from natural gas streams. Our horizontal separator designs and PureSEP™ internals cover a wide range of conditions including foam reduction, liquid/liquid separation, high to medium gas/oil ratio streams, and large volumes of gas and/or liquids.
All OTSO Horizontal Separators are designed with PureSEP™ HORIZONTAL SEPARATOR INTERNALS to ensure safe, continuous and reliable operation. Our horizontal separators are engineered in a wide variety of configurations to meet your specific production requirements for volume, gravity, pressure, foaming, paraffin, hydrates, impurities, corrosion, and other production parameters. Learn more about our PureSEP™ separator internals below.
SplitFLO™ High Efficiency Separator
OTSO’s Horizontal Inline Separators are designed to handle some of the widest volume ranges of large gas/liquid and oil/water interfacial areas to speed the separation process.
OTSO’s Horizontal SplitFLOW Separator is the go to option for applications where flow velocity reduction is of primary concern. This vessel is uniquely suited for high gas flow rates due to its ability to process high flow rates without increasing vessel size. Making the SplitFLOW – High Efficiency Horizontal Separator the clear economical choice for such applications.
Examples
- Horizontal Test Separators
- Horizontal Production Separators
- Horizontal Wellhead Separators
- Horizontal Gas Scrubbers
- Horizontal Inlet Separators
Types
Inline™ Horizontal Separator
Horizontal Inline Separator
Horizontal Separators Designed for Reliable Performance and Versatility
The Horizontal Inline Separator delivers reliable production performance for a large assortment of pressures, flow rates and gas/oil ratios. This is achieved through OTSO’s PureSEP™ internals, which allow for a multitude of configurations. This proven unit also offers the distinct advantage of separation speed due to spacious oil/water and gas/liquid areas where separation can occur. The combination of flexibility and performance makes the Horizontal Inline Separators our most versatile Horizontal Separator.
How it works
Horizontal Inline Separators must control inlet momentum, vapor demisting, liquid retention and the outlet flow of liquids. These four specific functions are the lifeblood of this Horizontal Separator.
The most common arrangement for this Horizontal Separator has the Inlet located one end, and the gas & liquids outlets located on the opposing end of the separator.
Liquids and Gas enter the vessel through the Inlet where initial bulk separation occurs. As gasses rise, oil and water fall into the retention area, settle, separate and exit the oil and water outlets. Gas is further purged of oil & water with a mist extractor and vortex breakers are used to prevent re-entrainment.
Horizontal Inline Separators must control inlet momentum, vapor demisting, liquid retention and the outlet flow of liquids. These four specific functions are the lifeblood of this Horizontal Separator.
The most common arrangement for this Horizontal Separator has the Inlet located one end, and the gas & liquids outlets located on the opposing end of the separator.
Liquids and Gas enter the vessel through the Inlet where initial bulk separation occurs. As gasses rise, oil and water fall into the retention area, settle, separate and exit the oil and water outlets. Gas is further purged of oil & water with a mist extractor and vortex breakers are used to prevent re-entrainment.
Inlet Momentum Regulation
The most common choice for inlet momentum control is with a splash plate or dished head. Although these two devices do provide inlet energy disbursement, there are superior methods for inlet regulation such as OTSO’s Maelstrom Revolution™.
The Maelstrom Revolution™ is superior to traditional “splash plate and dished heads” type inlet momentum regulation, whereas centrifugal force is used to rapidly accelerate oil, water and gas separation. Another key benefit of the Maelstrom Revolution™ is its ability to virtually eliminate foam. Such efficiency at the initial separation phase has a profound impact on separator function, so much so that smaller vessels can be used when a Maelstrom Revolution™ is incorporated.
The importance of better separation and foam elimination is not merely a performance benefit. It also has a positive impact on our clients bottom line. Simply put, better separation yields higher oil and gas recovery.
Liquid Retention
After inlet momentum disbursement occurs, liquids fall to the liquid retention area for further separation through coalescing. Horizontal separators are especially proficient at this process due to the larger area they inherently provide. The use of OTSO’s PureSEP™ internals are routinely incorporated within the liquid retention section to reduce liquid / liquid coalescing time.
Demisting
The importance of demisting can’t be overstated. The coalescing and ultimate removal of liquid droplets from the gas stream is vital to meeting pipeline gas specifications further downstream. OTSO’s PureSEP™ line of separator internals provide our clients with numerous options for demisting, such as serpentine vanes, wire mesh and coalescing ball media. As is the case with all other sections of the vessel, the proper demister for the job, or a combination thereof are selected based on each vessel’s operating conditions.
Outlet Control
Outlet control is used to prevent the re-entrainment of separated gasses and liquids. A vessel’s internal configuration of either a bucket and weir, bucket and riser, spillover weir, fixed weir, or standpipe are the typical mechanisms used for outlet control. The use of vortex breakers at the gas and liquid outlet is also commonplace to prevent vortex occurrence.
OTSO’s engineering team is highly apt in the configuration of the outlet section and selection of the proper locations for vortex breakers. Our team can offer assistance for your specific application to ensure proper configuration is achieved.
Applications
Due to their versatility, OTSO’s Horizontal Inline Separators have been used successfully in the following applications.
- Horizontal Production Separators
- Horizontal Test Separators
- Horizontal Inlet Separators
- Horizontal Wellhead Separators
- Horizontal Slug Catchers
- Horizontal Flare Scrubbers
- Horizontal Free Water Knockouts
- Horizontal Gas Scrubbers
- Horizontal Floating Production Separators
SplitFLOW™ High Efficiency Horizontal Separator
SplitFLOW™ High Efficiency Horizontal Separator
Reduces Flow Velocity, Handles High Gas Flow Rates Without Increasing Vessel Size
OTSO’s SplitFLOW is the go-to option for applications where flow velocity reduction is of primary concern. The dual flow design splits inlet flow velocity in half, resulting in a dramatic reduction in flow velocity. The SplitFLOW separator is also the clear economical choice for these applications due to its unique ability to process high gas flow rates without increasing vessel size.
The SplitFLOW Separator covers the full gamut of flow rate and gas/oil ratio conditions, but it is better suited when used as a High GOR (High Gas Oil Ratio) separator due to its capacity for processing high volumes of gas.
HOW IT WORKS
Inlet nozzle location is the key ingredient to the Horizontal SplitFLOW Separator. Unlike typical arrangements that have the inlet and outlet on opposite ends of the separator, the inlet on the Horizontal SplitFLOW Separator is located in the center of the vessel.
OTSO PureSEP™ internals can be added to ensure safe, continuous and reliable operation, while meeting production requirements for volume, gravity, pressure, foaming, paraffin, hydrates, impurities, corrosion, and other production parameters.
INLET MOMENTUM REGULATION
Inlet momentum is regulated by two Maelstrom Revolution™ devices due to its superior performance in comparison to traditional splash plate and dished head type inlet momentum control devices. In consideration for the Horizontal SplitFLOW Separators split flow design, the inlet device is designed to evenly split and direct flow to each Maelstrom Revolution™.
DEMISTING
As is the case with inlet momentum control, demisting must accommodate dual flow as well. Top mounted gas outlets are located on each side of the vessel, while bottom mounted liquid outlets are mounted on both sides of the vessel for each half of the flow. External gas and liquid outlet piping is used to link the separated gas and liquids into their respective flowlines.
OTSO’s PureSEP™ line of separator internals provide numerous options for demisting, such as serpentine vanes, wire mesh and coalescing ball media. Our team can offer assistance for your specific application to ensure proper demisting configuration.
APPLICATIONS
Although capable of handling all conditions of a typical Horizontal Separator, the SplitFLOW Separator is the go to option for large, high pressure applications where flow velocity reduction is of concern. This vessel is uniquely suited for high gas flow rates due to its ability to process high flow rates without increasing vessel size. As a result, the Horizontal SplitFLOW Separator is the clear economical choice for such applications.
BENEFITS
- Dramatic Reduction in Gas Velocity
- Splits Flow of Multiple Streams
- Handles High Gas Flow w/ Reduced Vessel Size
- High Gas Volume Capacity
- Excels in High Pressure Applications
- Support Full Lineup of PureSEP™ Internals
- Achieves Optimum Oil/Water Separation
SpiralFLOW-H™ Horizontal Separator
SpiralFLOW-H™ Horizontal Separators
Efficient, Compact Footprint w/ High Volume Gas Scrubbing
The SpiralFLOW-H™ Horizontal Separators unique design utilizes centrifugal force to efficiently achieve high volume gas scrubbing while maintaining a small, compact footprint. This unit is ideal for pipeline gas/liquid processing due to the inlet and outlet ports being located on both sides of the vessel, making them “in-line” with the pipeline.
HOW IT WORKS
The vessel’s fixed vane arrangement uses the power of centrifugal force to create a spinning rotation at the inlet phase. This powerful, centrifugally generated spin forces liquids and solids to separate by casting them to the walls of the vortex tube. Gas flow plays a further role in the separation process by pushing solids and liquids down the vortex tube where the solids, liquids and a small percentage of gas exits the vortex tube. The exiting gas is recycled and placed back into the flow while solids and liquids drain to the sump.
APPLICATIONS
The SpiralFLOW-H™ excels at removing liquids for the gas stream. The ideal location for this unit is a gas dominate pipeline or processing facility application with a gas stream containing up to 3bbl of liquids per MMscfg.
BENEFITS
- Utilizes Centrifugal force for Optimum gas/liquid separation
- Small footprint w/ large gas volume capacity
- Ideally Suited for pipeline installations
- High Gas Scrubbing Efficiency without Internals
- Low Maintenance
- Removes 99.9% Particles Down to 10 Microns
SIZES AVAILABLE
- 1MM Unit
- Designed for liquid to gas ratios of 1BBL per MMscf of gas.
- 3MM Unit
- Designed for liquid to gas ratios of 3BBL per MMscf of gas.
Maelstrom Revolution
Maelstrom Revolution
Superior Gas/Liquid Separation & Foam Elimination
OTSO’s Maelstrom Revolution™ provides superior inlet momentum regulation through the dissipation of fluid energy. Traditional inlet control devices such as a splash plate or dished head simply can’t compete with the performance of this innovative unit. The Maelstrom Revolution™ utilizes centrifugal force to rapidly accelerate oil, water and gas from the inlet stream. An additional benefit of this unit is its ability to eliminate foam.
Such efficiency at the initial separation phase has a profound impact on overall separator function. In fact, reduction in vessel size is the norm when the Maelstrom Revolution™ is incorporated.
The importance of better separation and foam elimination is not merely a performance benefit. It also carries with it a positive impact on our clients bottom line. Simply put, better separation yields higher oil and gas recovery.
HOW IT WORKS
The Maelstrom Revolution™ is a tangential inlet separation device flanged connected to the inlet nozzle. Its tangentially mounted inlet and single spiral-tubular arrangement creates extreme centrifugal force that generates a spinning motion at the inlet phase. As centrifugal spinning ensues, liquids and solids are forced to the walls of the Maelstrom Revolution™. Throughout this spinning process, gas rises and exits, while liquids casted to the Maelstrom Revolution™ walls further separate and fall into the vessels liquid retention area.
Reduces Vessel Size & Weight
To mitigate foam disengagement concerns, it’s common practice for engineering design vessels with excess capacity. The Maelstrom Revolution™ is the solution to such issues due to its ability to not only eliminate foam and rapidly separate gas and liquids at higher flow rates than traditional inlet devices. As a result, considerable reductions in vessel footprint and weight are experienced in separators containing a Maelstrom Revolution™.
APPLICATIONS
The Maelstrom Revolution™ is suited for any application involving the separation of gas, liquids and solids. The Maelstrom Revolution™ is especially apt at mitigating foam, making it the ideal choice for applications requiring foam elimination.
The Maelstrom Revolution™ has been used successfully in the following applications.
- Production Separators
- Test Separators
- Scrubbers
- Slug Catchers
- Free Water Knockouts (FWKO)
BENEFITS
- Excess Capacity for Foam Management is not required, Eliminates Foam and Improves Flow
- Retrofitting Available – If Manway is Present, Dramatic Debottlenecking Results are Achieved
- Suitable for Vertical and Horizontal Applications
- Removal of Carryover Liquids in Outlet Gas Stream
- Reduces Sediment and Emulsion
- Reduces / Eliminates De-foaming Chemical Cost
- Minimized footprint, reduced weight and ease of installation
PureSEP Horizontal Filter Internals
PureSep™ HORIZONTAL SEPARATOR INTERNALS
High Performance Oil/Water Separation
We’re redefining what’s possible with oil/water separation with the release of our PureSep™ Coalescing Ball Media (PS-CB). The PureSep™ Coalescing Ball medias unique design maximizes surface area allowing gravity to separate oil and water with extreme efficiency. Superior performance is achieved in both heated and ambient separation systems such as Free Water Knockouts (FWKO), and capable of handling high mix oil/water dispersions and covers all API oil gravities.
Smaller Vessels w/ Increased Volume
PureSep™ PS-CB’s improves separation efficiency by causing oil droplets to rapidly coalesce into larger size droplets which rise much faster than the smaller droplets seen in standard coalescing media.
As such, separators outfitted with PureSep™ Coalescing Ball media experience increases flow rates allowing for smaller, more efficient vessels that save you money.
Why PureSep™
- Cleanout – Random packing can easily be removed and cleaned. Without fixed or moving parts PS-CB media simplifies routine maintenance and cleaning.
- Water Quality – Can remove 98.5% of oil particles with proper chemical treatment.
- Reduces BS&W Content – High quality discharge equals separation efficiency and reduced fuel requirements.
- Chemical Costs Savings –High performance can reduce chemical dosages costs as much as 50%.
- Consistent Performance – Even under variable conditions, PureSep™ Coalescing Ball media tolerates mixed operating conditions such as flow rates, solids contamination and oil/water blends.
- Reduces Space – The PS-CB system is efficient, allowing a smaller vessel to withstand higher flow-rate capacities with increased separation proficiency.
- Plugging Resistant – PS-CB systems unique ball spacing design minimizes common plugging problems experienced by other coalescing methods.
- Perfect for Retrofitting – PureSep™ Coalescing Ball media easy to install, making it the perfect coalescing replacement option for separation vessels.
PureSep™ Corrugated Plate (PS-CP)
OTSO’s PureSep™ PS-CP Coalescing Media is a long standing, high performance separation system. Its fitted, open matrix and compact design contains a high surface area that increases coalescing while minimizing plugging.
Features Include:
- High surface area per Ft3
- Plugging Resistant Design
- Material Based on Temp. – Stainless Steel, Carbon Steel, PVC & Polypropylene
- Space efficient design
PureSep™ Vane (PS-V)
In most cases, serpentine vane mist extractors are efficient in gas/liquid separation and are effective in both vertical separators and horizontal separators.
Vane spacing and shape allow coalescing to occur and separate into small liquid particles without plugging. The serpentine vane pack is located vertically in the separator allowing for velocity to increase by approximately 40% as the gasses pass between the serpentine vane plates, causing liquid particles to collide against the plate walls to scrub liquids from the gas stream.
PureSep™ Wire Mesh (PS-WM)
Wire mesh is another method of removing particles from the gas stream and is typically used at the gas outlet for final clean-up. Wire mesh has tightly grouped wires that rely on droplet coalescing from gas flow as its separation mechanism.
Due to plugging concerns from common gas impurities such as paraffins, asphaltenes and salts, wire mesh is only recommended for applications where a clean inlet gas stream is present.
