THREE-PHASE
SEPARATOR
From wellhead to gathering station. Engineered for the operating conditions your team actually deals with -- not the ideal ones.
Where This Separator Works
Engineered for the operating conditions your team actually deals with -- not the ideal ones.
High Water-Cut Production Wells
As reservoir water cut climbs past 60-80%, conventional separators struggle to maintain stable oil/water interface and on-spec oil export quality. Our three-phase separator uses a 316L corrugated plate coalescer to aggressively break emulsions and accelerate water dropout -- keeping dehydration performance stable even when water cut exceeds 90%.
High GOR Wellhead Stations
High gas-oil ratio inlets create severe slug flow and turbulence that degrades separation efficiency. Our cyclone inlet device pre-removes more than 90% of associated gas before fluid contacts the liquid phase -- dramatically reducing vessel sizing requirements and downstream flare or compression loads.
Multi-Well Gathering & Transfer
Commingled production from multiple wells brings mixed fluid compositions, variable flow rates, and intermittent sand production. Automated sand removal, float-ball level control with DCS signal output, and flexible nozzle layouts make this separator a reliable hub for gathering station operations.
Skid-Mounted Rapid Deployment
For EPC projects and oilfield expansions where time-to-production matters, we supply fully factory pre-fabricated separator skids -- all valves, piping, instruments, and fittings integrated and tested before shipment. Site installation measured in days, not weeks.
Field Reference
Three-Phase Separator Skid Package -- Xianhe Oilfield, He50 Well Area
Modular oil/gas/water separation with integrated metering and export. Fully factory pre-fabricated for rapid field installation.
Separation Principle & Internal Design
Inlet fluid enters through a cyclone inlet device positioned at the vessel head. The centrifugal action immediately separates more than 90% of associated gas from the liquid stream, eliminating the slug-driven turbulence that is the primary cause of carry-over in conventional separators. The partially degassed liquid drops into the vessel body, where the gravity separation zone allows oil and water to stratify by density differential.
In the liquid phase, a 316L stainless steel corrugated plate coalescer accelerates oil droplet coalescence. Dispersed oil droplets -- too small to rise under gravity alone -- are captured on the corrugated surfaces and merge into larger droplets that rise rapidly into the oil layer. This coalescer performance is critical for high water-cut and surfactant-laden crude streams.
At the gas outlet, a wire mesh demister rated at 5 μm captures entrained liquid mist before gas exits the vessel. This protects downstream compressors, dehydration units, and metering systems from liquid contamination.
The oil/water interface is maintained at setpoint by a float-ball level controller. Both the oil level and water level outputs are available as 4-20 mA signals for DCS or SCADA integration, enabling unmanned operation at remote sites.
Automated sand removal prevents sediment buildup on the vessel floor -- a common cause of corrosion pitting and reduced effective volume in heavy crude and sandy well applications. Manual drain connections are included as a backup.
Cross-section schematic: cyclone inlet → gravity zone → coalescer → demister → three-phase outlet nozzles with labeled flow paths.
Engineering Specifications
| Parameter | Standard Range | Notes |
|---|---|---|
| Orientation | Horizontal / Vertical | Selected by flow rate and footprint constraints |
| Design Pressure | 0.6 - 10.0 MPa (g) | Higher pressure on request |
| Design Temperature | -20°C to +200°C | Extended range with material upgrade |
| Vessel Shell Material | Q345R / Q345R+316L clad / 316L SS | Per fluid corrosivity and H₂S/CO₂ content |
| Internal Coalescer | 316L corrugated plate pack | Handles high water-cut and emulsified crude |
| Demister | Wire mesh, 5 μm rating | Vane pack available for high-velocity gas |
| Corrosion Allowance | 3 mm standard | Up to 6 mm for sour service |
| Design Life | ≥ 10 years | Per GB 150 design basis |
| Level Control | Float-ball (oil layer + water layer) | 4-20 mA output, DCS compatible |
| Sand Removal | Automated pneumatic / hydraulic | Manual drain backup included |
| Design Code | GB 150 (primary) / ASME VIII Div.1 | Dual certification available for export |
| Nozzle Layout | Fully custom | Per client P&ID and skid piping design |
| Vessel Testing | Hydrostatic at 1.25× design pressure | Pneumatic test available where applicable |
| NDT | RT / UT / MT / PT | Per design code weld class requirements |
| Documentation | As-built drawings, weld maps, MTRs, test records | 3.1 material certificates available |
| Third-Party Inspection | SGS / BV / DNV / TÜV | On request |
Standard Factory Configuration
Every three-phase separator leaves our facility with the following as standard:
- Cyclone inlet distributor (proprietary geometry, patented)
- 316L corrugated plate coalescer assembly
- 5 μm wire mesh demister with support grid
- Float-ball oil/water interface level controller (× 2 sets)
- Automated sand removal system with control valve
- Pressure relief valve (spring-loaded, per code)
- Pressure gauge and transmitter connection flanges
- Thermometer connection
- Inspection manhole (≥ DN450)
- Lifting lugs and saddle supports
- Surface treatment: internal sandblast Sa2.5 + coating or lining per service; external primer + finish coat
- Factory hydrostatic pressure test
- Nameplates per GB 150 and pressure vessel regulation requirements
OEM / ODM Customization Options
The following are available as customer-specified options -- all engineered and fabricated in-house:
Vane pack demister (high-efficiency)
High-velocity gas streams where wire mesh is rate-limited
Electric heating jacket
Pour-point crude, Arctic or cold-climate installations
Foam suppression baffles
Surfactant / chemical EOR production streams
H₂S / sour service material upgrade
CO₂ > 3% or H₂S > 300 ppm partial pressure
ATEX / IECEx certified instrumentation
Zone 1 / Zone 2 hazardous area classification
Full skid integration
Valves, piping, instruments, control panel, cable tray -- factory pre-wired and tested
Dual GB 150 + ASME VIII Div.1 certification
Export projects requiring ASME U-stamp
Manufactured Under Full Certification.
Tested Before Every Shipment.
QA Process -- What Happens Before Your Equipment Ships
Material Traceability
All pressure-bearing plates, pipes, and fittings are procured with mill certificates. Heat and lot numbers are recorded. 3.1 certificates available.
Welding Qualification
All welders hold valid qualifications per GB/T 19869 (or ASME IX). WPS and PQR are maintained and available for client review.
Non-Destructive Testing (NDT)
Weld inspection conducted in our CNAS-accredited lab: RT, UT, MT, and PT applied per design code. Records retained in quality dossier.
Hydrostatic Pressure Test
Every vessel is hydrostatically tested at a minimum 1.25× design pressure. Witnessed testing available. Pneumatic testing where applicable.
Dimensional & Doc Verification
Final inspection against approved drawings. Quality dossier compiled: weld maps, NDT reports, hydro records, MTRs, and sign-offs.
Export Preparation
Nozzles blinded, internals preserved, export-grade crating applied. Full export documentation provided for international logistics.
Delivered. Commissioned. Operating.
Xianhe Oilfield -- He50 Well Area
CNOOC Wushi Oilfield Group
AwardedIndustry-Leading Warranty
Standard: 2 years from commissioning or 26 months from shipment. (Industry average: 1 year). Reflects true confidence in manufacturing quality.
Long-term partners: up to 2.5 years, including prioritized spare parts availability.
After-Sales Support
- • Remote technical consultation during commissioning
- • Spare parts identified and documented at delivery
- • Site visit support available for complex scenarios
Ready to Specify?
Let's Start with Your Process Parameters.
Our engineers review every inquiry directly -- no automated routing. Send us your inlet conditions, and we'll respond with a preliminary equipment sizing and project reference within 24 hours.
Free Engineering Resource
Submit your process parameters and receive:
- ✓ Preliminary separator sizing estimate (diameter, L/D ratio)
- ✓ Relevant project case reference
- ✓ Applicable certification & doc checklist for your region
*No commitment required. Our process engineers respond within 24 business hours.
LINSON OIL -- 21+ Years | 5,000+ Projects
87 Patents | Sinopec & CNPC HSE Certified