Yuhong Group: Complete Pressure Vessel Solutions – From Separators to Heat Exchangers
Yuhong Group Co., Ltd. designs and manufactures a comprehensive range of thermal and pressure equipment for global industries. Our core offerings include shell and tube heat exchangers, pressure vessels, air coolers, and process separators – including two-phase and three-phase separators for oil, gas, and water separation. We also supply critical components: finned tube bundles, U-tube bundles, heat exchanger tubesheets, and all related parts – ensuring full support for new projects and maintenance.
Shown in the attached photographs and schematic is a horizontal three-phase separator – a pressure vessel designed to separate incoming well streams into gas, oil, and water phases. The schematic illustrates the internal components including the inlet diverter, baffles, demister, weir, and level control nozzles that enable efficient phase separation.
Product Focus: Three-Phase Separator – Engineered for Efficient Phase Separation
A three-phase separator is a pressure vessel that separates a mixed inlet stream into three distinct phases: gas, oil (liquid hydrocarbon), and water (produced water). The separation is achieved through a combination of gravity settling, impingement, and coalescing, with internal components designed to maximize separation efficiency.
Based on the images and schematic, this separator exhibits:
Configuration: Horizontal vessel – providing maximum liquid surface area for gravity separation
Material: Carbon steel (ASME SA516 Gr.70) – with optional corrosion-resistant lining or clad plate
Construction: ASME Section VIII, Division 1 compliant with U-Stamp certification
Internal components: Inlet diverter, baffles, demister, weir, and level control nozzles
Application: Oil/gas/water separation in upstream and midstream processing
Key Components & Their Functions in a Three-Phase Separator
| Component | Function | Role in Equipment Performance |
|---|---|---|
| Inlet Diverter / Impingement Plate | Redirects incoming flow; reduces velocity | Prevents liquid carryover; protects downstream internals from erosion |
| Baffle Plates | Direct flow; promote gravity settling | Enhance liquid/liquid separation; prevent short-circuiting |
| Demister / Mist Eliminator | Removes entrained liquid droplets from gas | Ensures clean gas outlet; prevents liquid carryover |
| Weir Plate | Controls liquid level; maintains oil/water interface | Enables oil/water separation by gravity; maintains stable interface |
| Level Control Nozzles | Provide connections for level instruments | Enable level control and interface control |
| Pressure Control Valve | Maintains vessel pressure | Ensures stable operation; prevents overpressure |
| Shell | Pressure-containing boundary | Contains process fluids; designed for pressure/temperature |
| Dished Heads | End closures | Provide pressure containment; designed per ASME |
| Nozzles (Gas Out, Oil Out, Water Out) | Process fluid outlets | Enable phase-specific discharge |
| Manway | Access for inspection and cleaning | Enables internal maintenance and inspection |
| Heat Exchanger Tube Bundle (optional) | Heating/cooling within the vessel | Can be installed for temperature control |
| Finned Tube Bundle (external) | External heating/cooling | Can be added for temperature control of outlet streams |
| U-Tube Bundle (internal) | Internal heat exchange | For temperature control within the vessel |
Technical Highlights of Our Three-Phase Separator
ASME U-Stamp certified: Full compliance with ASME Section VIII, Division 1 – ensuring global acceptance for safety and regulatory requirements.
Optimized internal design: Inlet diverter, baffles, demister, and weir are designed using computational fluid dynamics (CFD) or empirical correlations to maximize separation efficiency and minimize liquid carryover.
Custom engineering: Designed to your specific flow rates, fluid properties, pressure, and temperature conditions.
Material flexibility: Carbon steel (SA516 Gr.70), stainless steel (304/316L), clad plate, or nickel alloys – selected based on service fluid corrosivity.
NDE & PWHT: Full NDE (RT, UT, MT, PT) and PWHT as required by ASME code – ensuring weld integrity.
Hydrostatic testing: Every separator is pressure-tested before shipment – documented with test reports.
Knowledge Module: Separator Types – Two-Phase vs. Three-Phase
| Type | Phases Separated | Key Features | Typical Application |
|---|---|---|---|
| Two-Phase Separator | Gas + Liquid | Simple design; demister for gas | Gas processing; compressor suction scrubbers |
| Three-Phase Separator | Gas + Oil + Water | Inlet diverter, baffles, demister, weir | Oil & gas production; refinery feed preparation |
| Horizontal Separator | Gas + Liquid(s) | Larger surface area; better gravity settling | High liquid flow; three-phase separation |
| Vertical Separator | Gas + Liquid(s) | Smaller footprint; better solids handling | Slurry service; limited floor space |
| Test Separator | Gas + Liquid(s) | Portable; compact design | Well testing; temporary installations |
Knowledge Module: Three-Phase Separation – How It Works
Based on the schematic provided, the separation process follows these steps:
Inlet Flow: The incoming mixed stream (gas, oil, water) enters through the inlet nozzle.
Inlet Diverter: The flow is redirected by the inlet diverter/impingement plate, causing a sudden velocity drop. This initiates the separation of gas from liquids.
Gravity Separation: The liquids fall into the liquid section of the vessel. Oil (lighter) rises to the top, water (heavier) settles to the bottom.
Baffles: Baffle plates promote liquid/liquid separation by reducing turbulence and preventing short-circuiting.
Weir Plate: The weir maintains the oil/water interface level. Oil flows over the weir, while water remains on the inlet side.
Demister: Gas passes through the demister (mist eliminator) where any remaining liquid droplets are captured and returned to the liquid section.
Outlet Streams: Gas exits through the top nozzle, oil exits through the oil outlet, and water exits through the water outlet – each with level control valves to maintain proper levels.
Knowledge Module: Internal Components & Their Importance
| Component | Why It Matters | Common Issues |
|---|---|---|
| Inlet Diverter | Prevents erosion; reduces turbulence | If damaged, liquid carryover increases |
| Demister (Mist Eliminator) | Ensures gas quality | Fouling reduces efficiency; requires periodic cleaning |
| Weir Plate | Controls oil/water interface | Improper level leads to oil in water or water in oil |
| Baffles | Improves separation efficiency | Corrosion or damage reduces effectiveness |
| Level Control Nozzles | Enables level control | Clogged nozzles cause poor level control |
Advantages of Ordering Separators from Yuhong Group
ASME U-Stamp certification: Full code compliance – accepted worldwide for regulatory and insurance purposes.
Complete design & fabrication: From process design to final delivery – all in-house, including internal components.
Material verification: PMI (Positive Material Identification) on all pressure-retaining components.
NDE & documentation: Complete NDE reports, hydrostatic test reports, and ASME data reports included.
Component integration: Vessels supplied with all internals – inlet diverter, baffles, demister, weir – and external accessories.
Component-Only Supply – We Also Provide for Maintenance & Spares
If your existing separator needs replacement parts, we supply individual components without ordering a complete new vessel:
Inlet diverters / impingement plates – to your dimensions
Baffle plates – carbon steel or stainless steel
Demister / mist eliminator pads – stainless steel or alloy
Weir plates – carbon steel or stainless steel
Nozzles and flanges – SA105, SA182 – any facing type
Manway covers and gaskets – complete access closure assemblies
Dished heads – formed to your dimensions and thickness
Heat exchanger tubes – for internal coils or external heat exchange
Finned tube bundles – for external heating/cooling applications
Typical Applications for Three-Phase Separators
| Industry | Application | Why Horizontal Separator |
|---|---|---|
| Oil & gas production | Wellhead separation, test separation | Handles high liquid volumes; good gravity settling |
| Refining | Feed preparation, emulsion breaking | Separates oil/water before refining |
| Chemical processing | Liquid/liquid separation | Separates immiscible liquids |
| Power generation | Knock-out drums, steam separators | Removes moisture from steam or gas |
| Cryogenic / LNG | Phase separation in liquefaction | Separates gas/liquid at low temperatures |
Knowledge Module: Separator Sizing & Design Considerations
| Parameter | Consideration | Impact on Design |
|---|---|---|
| Gas flow rate | Must be below critical velocity for liquid carryover | Determines vessel diameter and demister sizing |
| Liquid flow rate | Must allow adequate residence time for gravity separation | Determines vessel length and liquid capacity |
| Oil/water density difference | Larger difference = easier separation | Affects weir height and interface control |
| Emulsion tendency | Difficult to separate; may require heat or chemicals | May require internal coils or chemical injection |
| Pressure and temperature | Affects gas density and liquid properties | Determines wall thickness and material selection |
| Slug flow | Inlet flow surges | May require larger vessel or slug catcher upstream |
Quality Assurance & Documentation
Every three-phase separator we fabricate includes:
ASME U-Stamp certification – with Manufacturer’s Data Report
Material Test Certificates (MTC) per EN 10204 3.1
NDE reports – RT, UT, MT, PT as required
PWHT records – time-temperature charts
Hydrostatic test report – documented and witnessed
Internal component inspection report
PMI (Positive Material Identification) – 100% verification
Third-party inspection (SGS, BV, TÜV) – at buyer's request
Get a Quotation for Your Three-Phase Separator
To quote a three-phase separator like the one in your photographs, send the following to jimmy@steelseamlesspipe.com:
Flow rates (gas, oil, water)
Fluid properties (density, viscosity, corrosivity)
Inlet conditions (pressure, temperature)
Required separation efficiency (liquid carryover, oil in water)
Required material (carbon steel, stainless steel, clad)
Any drawing or sketch available
We will respond with a technical proposal, general arrangement drawing, and competitive price – typically within 72 hours.
