1. Key Features
✔ Triple-Phase Precision Separation – Achieves <1% residual oil-in-water and <0.5% water-in-oil
✔ Self-Adaptive Control – Automatically adjusts to fluctuating flow rates (10–100% capacity)
✔ Compact Modular Design – 50% smaller footprint vs. conventional separators
✔ Predictive Maintenance – Machine learning detects fouling/emulsion risks 48+ hours in advance
✔ Cloud Connectivity – Remote monitoring via SCADA/IIoT platforms
2. Core Components
(1) Intelligent Separation Module
-
Inlet Cyclonic Distributor – Ensures even flow distribution and preliminary gas-liquid separation
-
Coalescing Plates – High-efficiency polymer composite plates for fine separation
-
Electrostatic Coalescer – Breaks stubborn emulsions (optional for heavy crude)
-
Smart Weir System – Automatically adjusts oil/water interface level
(2) Monitoring & Control System
-
Multiphase Flow Meter – Real-time measurement of oil/gas/water ratios (±2% accuracy)
-
Density/Pressure/Temperature Sensors – Integrated PT100 and radar gauges
-
Edge Computing PLC – Runs adaptive PID algorithms for process optimization
(3) Auxiliary Systems
-
Automatic Dumping Valves – Periodically discharge separated phases
-
Chemical Injection Skid – Demulsifiers and antifoam agents (optional)
-
Explosion-Proof Enclosure – ATEX/IECEx certified for hazardous areas
3. Technical Specifications
| Parameter |
Specification |
| Design Pressure |
1.0–6.9 MPa |
| Operating Temperature |
-20°C to 150°C |
| Throughput Capacity |
50–5,000 m³/day |
| Gas Handling Capacity |
Up to 500,000 m³/day |
| Separation Efficiency |
Oil: >99.5%, Water: >99%, Gas: >99.9% |
| Materials |
Carbon steel/316L stainless steel/duplex |
4. Working Principle
-
Inlet Conditioning: Wellstream enters through cyclonic distributor for initial gas breakout.
-
Primary Separation: Gravity and coalescing plates separate bulk oil/water phases.
-
Fine Separation: Electrostatic fields (if equipped) break micro-droplet emulsions.
-
Phase Export:
-
Smart Adjustment: Continuous sensor feedback optimizes weir heights and dump cycles.
5. Performance Advantages
-
30% faster separation vs. conventional vessels
-
20% reduction in chemical consumption
-
Zero human intervention in routine operations
-
40% lower CAPEX due to compact design
6. Applications
• Onshore/offshore production facilities
• High-GOR (Gas-Oil Ratio) fields
• Heavy oil fields with stable emulsions
• Marginal fields requiring modular solutions
7. Case Study: Bohai Bay Offshore Platform
-
Challenge: Unstable emulsion in 25°API crude with 80% water cut
-
Solution: Installed ITPS-3000 system with electrostatic coalescer
-
Results:
↗ Oil-in-water reduced from 3,000 ppm to <200 ppm
↘ Chemical demulsifier usage cut by 35%
→ Achieved API 12J compliance for over 2 years
8. Certifications & Standards
• API 12J (Specification for Oil-Gas Separators)
• ASME Section VIII Div. 1 Pressure Vessel Code
• PED 2014/68/EU (EU Pressure Equipment Directive)
• NACE MR0175 for sour service environments
9. Why Choose This System?
-
Plug-and-play operation – Reduces commissioning time by 60%
-
Adaptive to changing wellstream conditions – Handles slugs and foams
-
Lifetime technical support – Global service network with spare parts guarantee
