Project Case Study
3-phase Separator
Oil and Gas- Middle East
Test Separator Skid
Skid-mounted test separators perform a vital function in the analysis of both onshore and offshore wells.
Certified & High Capacity
CE/UKCA & ATEX certified; processes for safe and efficient Oil and Gas testing and management.
Delivered in 28 Weeks
Strict timeline met by collaborating with suppliers to tailor equipment and integrate with existing infrastructure.
Overview
This case study involves a three-phase test separator skid designed for an oil and gas exploration operation in the Middle East. Such test separators are crucial in well testing – they separate oil, gas, and water from produced fluids so that each can be measured and analyzed. The client needed a portable, robust solution that could operate on both onshore and offshore well sites. The main objectives were to obtain accurate well fluid measurements, ensure safe handling of potentially high-pressure flows, and meet international certification standards for use in hazardous locations.
Solution
Kapwell designed and delivered a skid-mounted 3-phase separator that serves as a self-contained test unit. The separator is equipped with an inlet section to distribute the well flow, an internal oil/gas partition with specialized weirs and controls for oil-water separation, and mist elimination for the gas phase. The skid format allows the unit to be easily transported and quickly installed at different well sites. Inside the vessel, baffles and retention time facilitate oil-water separation, while a mist extractor (e.g., a vane pack or mesh pad) ensures the gas leaving the separator is free of liquids. The system was delivered complete with pressure and temperature sensors, flow meters on each outlet, and safety devices so that well performance data can be collected accurately and safely. Kapwell’s design accounted for the range of flow conditions typical in well testing, ensuring reliability both onshore and on a rocking offshore platform.
Key
Features
Skid-Mounted Test Separator
The entire three-phase separator is built on a single skid with all piping, valves, and instruments included. This portable design makes it ideal for deployment in well testing campaigns, as it can be lifted and moved as a unit. The skid also includes drip pans and lifting points, facilitating easy transport and setup.
Certified for Hazardous Service
The separator is CE/UKCA & ATEX certified for operation in explosive oilfield environments. It was also built in compliance with ISO/API standards for well test separators, meaning it can safely handle high pressures and sour fluids often encountered in Middle East well tests. These certifications and standards ensure safe and legal operation in any region.
High Separation Efficiency
Though primarily a test unit, it boasts advanced internals to optimize separation. Multi-phase flow is effectively split into oil, water, and gas with minimal cross-contamination. For instance, the gas outlet has a mist eliminator to capture any residual liquids, ensuring the gas phase is clean for measurement. The unit can handle fluctuating flow rates (common during well cleanup) without sacrificing separation quality, delivering reliable data.
Instrumentation & Measurement
Equipped with calibrated flow meters for oil, gas, and water, and automated level controllers, the separator provides accurate real-time measurements of each phase. This data allows the client to assess well performance (e.g., oil output, gas-oil ratio, water cut) with confidence. The instrumentation is integrated into the skid’s control panel and can transmit data to the client’s data acquisition system.
Challenges & Innovation
One challenge in this project was ensuring the separator could function effectively in both onshore desert conditions and offshore marine environments. Kapwell addressed this by using robust materials (e.g., corrosion-resistant alloys for saline offshore conditions) and a flexible design that remains stable on moving platforms. The innovation in this case lies in the combination of mobility and performance: typically, high-efficiency separators are stationary, but Kapwell’s design maintained high separation efficiency while making the unit trailer/rig-movable. Another challenge was meeting the tight delivery timeline to align with the client’s drilling schedule. By standardizing certain components and leveraging Kapwell’s in-house fabrication capacity, the separator skid was delivered in 28 weeks without compromising customization. Kapwell also innovated by designing the skid to be self-sufficient: it included all required safety features (flare line, relief valves, etc.), meaning the client could deploy it rapidly with minimal auxiliary hookups.
Client Benefit
Accurate Well Testing
The client can now perform precise well tests, obtaining reliable measurements of oil, gas, and water production. This data is critical for reservoir evaluation and planning production strategies. The high-quality separation ensures that measurements (like gas volume or oil volume) are not skewed by carryover or mixing, thus improving the decision-making process for the field development.
Operational Flexibility
The skid-mounted nature of the separator gives the client flexibility to move the unit between different sites and wells. They can quickly redeploy the test separator as needed, which is cost-effective since one unit can serve multiple wells. This mobility reduces the need for multiple separators and saves on equipment costs.
Enhanced Safety & Compliance
With full ATEX and CE compliance, the client is assured that the separator meets global safety standards. This is especially important in well testing, where high-pressure hydrocarbons are handled. The safety systems and certifications mean reduced risk of accidents and adherence to regulatory requirements (no issues in getting work permits or approvals).
On-Time Project Execution
The separator was delivered in 28 weeks as planned, allowing the client to use it in their scheduled well testing campaign without delay. This timely delivery helped avoid costly rig downtime waiting for equipment. Furthermore, the reliability of the unit means less unexpected downtime during tests, so the client can maximize valuable rig time.
Timeline
Delivered in 28 weeks. The project followed a fast-track schedule to coincide with the client’s drilling program. Through efficient project management and early procurement of long-lead items, Kapwell delivered the 3-phase separator skid on time, ready for immediate deployment in the field.