The three-phase separator is a critical piece of equipment for handling mixtures of oil, water, and gas, widely used in industries such as petroleum and chemical processing. To ensure the safe and stable operation of the equipment, meticulous preparation must be conducted before commissioning, and the startup process must follow standardized procedures. This article provides a detailed overview of the pre-operation preparation, startup procedures, and operational recording requirements for three-phase separators, ensuring their normal operation and optimal performance.
Pre-Operation Preparation
Before a three-phase separator is put into operation, thorough inspection and preparation are essential. These preparations include equipment checks, system testing, and cleaning to ensure the equipment can operate safely and smoothly.
1. Equipment Inspection
Valves and Instruments Inspection: First, inspect all valves, instruments, pipelines, and their accessories to ensure they are intact and free from leaks. Instruments must be accurate and capable of reliably measuring relevant parameters.
Pipelines and Accessories: Check the connections of pipelines and accessories to ensure they are secure, unobstructed, and that switches operate smoothly without blockages or jams.
System Pressure Testing: Conduct a pressure test on the system according to pressure vessel standards to ensure it can withstand the rated working pressure and avoid potential safety hazards.
Automation Control System Check: Inspect all automation control systems, including level control and pressure monitoring systems, to ensure they are functioning correctly, accurately, and reliably.
Equipment Cleaning: Clean the three-phase separator and its pipelines to remove any debris that could affect the separation process. The equipment must remain clean and unobstructed.
2. Safety Preparations
Safety is a prerequisite for equipment operation. Potential safety hazards must be assessed, and necessary safety measures implemented. For example, install anti-leakage devices and emergency shutdown systems to handle unexpected situations and ensure operator safety.
Startup Procedures
After completing the preliminary inspections and preparations, the startup of the three-phase separator should follow a specific sequence to ensure normal and stable operation.
1. Valve Operation and Inspection
Open the pressure gauge control valve to ensure normal pressure in the separator.
Open the vent valve at the top of the separator and the upper and lower control valves of the level gauge.
Inspect the inlet and outlet pipelines to ensure they are unobstructed and free from blockages.
Operate the sewage outlet electric valve: open the electric valve, then the gate valve before it, and slowly open the gate valve after it.
2. Hot Water Injection and Inspection
Open the inlet valve and begin injecting hot water into the separator. During this process, carefully inspect all connections for leaks or abnormalities.
Monitor the oil chamber level: as the level changes, gradually close the gate valve after the sewage electric valve until the oil chamber level reaches 0.5 meters (as indicated by the magnetic level gauge). Then, close the sewage electric valve and its front and rear gate valves.
Stop water injection by closing the inlet valve once the hot water injection is complete.
3. Gas Injection Operation
Slowly open the direct-through gate valve at the gas outlet to inject nitrogen into the separator. Close the vent valve and exhaust valve once the nitrogen concentration at the end of the gas line meets the standard.
Stabilize the gas pressure: after the pressure in the separator stabilizes, close the direct-through valve of the gas line electric regulating valve to ensure stable gas pressure.
4. Equipment Inspection and Adjustment
Re-inspect all connections to ensure there are no leaks or abnormalities.
Adjust oil-water separation: open the front and rear control valves of the oil and water chamber float valves, and adjust the electric regulating valve at the gas outlet to ensure smooth oil-water separation.
5. Injection of Oil-Gas Mixture
Begin feeding the oil-gas mixture into the separator by slowly opening the inlet valve.
Adjust the pressure: when the internal pressure exceeds the gas line pressure, adjust the opening of the direct-through valve to regulate the gas pressure. Simultaneously, set the electric regulating valve to control the pressure at 0.15 MPa.
6. Level Adjustment and Control
Observe the oil and water chamber levels and the separation efficiency after fully opening the inlet valve. Adjust the height of the water guide pipe as needed to meet technical requirements.
7. Switching to Automatic Control Mode
Once the separator is confirmed to be operating normally, open the front and rear valves of the oil and water electric valves, close the float level control valves, and switch to automatic control mode to ensure efficient and stable operation.
Operational Recording Requirements
To ensure long-term stable operation and provide data for future analysis, operators must meticulously record the equipment's operating status and relevant parameters.
1. Initial Oil Injection Records
During the initial oil injection, operators should closely monitor the site and record the separator's pressure, inlet/outlet oil temperature, and other parameters every 15 minutes.
2. Records After Stabilization
Once the separator's liquid level stabilizes, record the pressure, inlet/outlet oil temperature, oil chamber level, water chamber level, inlet crude oil water content, outlet crude oil water content, and sewage oil content every 2 hours.
Additionally, record the flow rates of oil, water, and gas, as well as chemical dosing amounts, to ensure the separator maintains optimal performance.
Accurate and timely records enable operators to monitor the equipment's performance in real-time, identify and resolve issues promptly, and ensure efficient operation of the three-phase separator.
Conclusion
As a critical separation device widely used in the oil and gas industry, the three-phase separator's pre-operation preparation, startup procedures, and operational recording are of utmost importance. Through rigorous preparation and scientific startup processes, the separator can achieve high efficiency and safety during operation. Detailed operational records not only help identify potential issues but also provide valuable data for future maintenance and fault analysis.
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