Separators: Precision Engineering for Oil and Gas

In the oil and gas industry, separators are one of the most essential pieces of surface production equipment. These vessels are designed to divide oil, gas, and water into separate streams so that each can be processed and transported efficiently. At Smith Industries, we engineer and fabricate two-phase and three-phase separators that meet the highest standards of safety, quality, and performance. Whether you need an ASME code or non-code vessel, vertical or horizontal configuration, or customized dimensions, our separators are built to handle the demands of modern production.

What Is a Separator?

A separator is a pressure vessel used in surface production facilities to split the well stream into its component parts. Depending on the field conditions, the stream may contain a mix of crude oil, natural gas, water, and sometimes solids. The role of a separator is to use differences in density, gravity, and pressure to separate these phases.

• Two-phase separators divide the flow into gas and liquid.

• Three-phase separators further divide the liquid into oil and water streams.

This separation process is critical for safe, compliant, and efficient operations. Without properly designed separators, production facilities risk costly downtime, environmental hazards, and reduced performance.

Smith Industries’ Separator Capabilities

Smith Industries has extensive experience designing and fabricating separators that match the requirements of our clients’ projects. We offer:

• ASME code or non-code vessels: Clients may select a code-compliant option for regulated projects or a non-code version when applicable.

• Vertical and horizontal configurations: Orientation depends on space, flow characteristics, and operational needs.

• Custom dimensions: We currently fabricate separators ranging in size from 30” x 10’ to 10’ x 30’, ensuring flexibility across different project scales.

By combining engineering expertise with high-quality fabrication practices, Smith Industries delivers vessels that meet stringent industry standards while providing long-term reliability in the field.

The Difference Between Two-Phase and Three-Phase Separators

Understanding the distinctions between separator types helps operators select the right vessel for their project:

Two-Phase Separators

These units are designed to split gas from liquid. They are often used when there is little water content in the production stream or where downstream equipment will handle further separation.

Three-Phase Separators

Three-phase separators add a critical step by separating oil, water, and gas. They are essential in fields where water production is significant and must be carefully managed. Three-phase separators reduce the risk of emulsions, improve downstream efficiency, and help ensure compliance with environmental discharge standards.

Vertical vs. Horizontal Configurations

Separator orientation matters, and both vertical and horizontal vessels have advantages depending on field conditions.

• Vertical separators are well-suited for wells producing a small amount of liquid but a high gas-to-oil ratio. Their smaller footprint makes them ideal for offshore or space-constrained facilities.

• Horizontal separators are preferred when liquid volumes are high. Their longer design allows for better liquid retention time, which improves separation efficiency.

Smith Industries provides both options, giving clients flexibility to match equipment design with production realities.

Why Separator Design Matters

The design of a separator directly impacts safety, regulatory compliance, and operational performance. According to the U.S. Occupational Safety and Health Administration (OSHA), pressure vessels must be designed, constructed, and maintained to avoid risks of rupture or failure, as accidents involving separators can result in severe injury or environmental damage.

In addition, the American Petroleum Institute (API) highlights that separators must meet strict industry standards to handle corrosive fluids, high pressures, and varying temperatures. API’s recommended practices guide separator design in areas such as pressure relief, materials selection, and operational safety.

By fabricating separators to meet ASME code when required, Smith Industries aligns with these standards and provides clients with equipment that stands up to regulatory inspections and long-term use.

Key Applications in the Oil and Gas Sector

Separators are used in nearly every stage of surface production. Common applications include:

• Initial well testing: Determining the oil, water, and gas content of a new well.

• Production facilities: Continuous separation during standard operations.

• Enhanced oil recovery projects: Handling larger water volumes produced through injection processes.

• Gas processing plants: Ensuring a clean gas stream for transport and refining.

In each of these applications, separator reliability is critical. A poorly designed or undersized vessel can slow production, increase maintenance costs, and create compliance risks.

Engineering for Harsh Environments

Modern oil and gas projects are often located in extreme environments, from offshore platforms to arid deserts. Separators must be engineered to withstand:

• High pressures and temperatures

• Corrosive fluids like hydrogen sulfide (H2S) and carbon dioxide (CO2)

• Harsh weather conditions, including humidity and salt spray

Smith Industries uses advanced materials and coatings to improve corrosion resistance and extend service life, giving operators confidence that their equipment will perform in challenging conditions.

Customization Options

Every production site has unique requirements. Smith Industries works closely with clients to provide customization options such as:

• Internal baffles and mist extractors for improved separation efficiency

• Instrumentation and controls for monitoring performance

• Skid-mounted packages for ease of installation and transport

• Specialized coatings or linings for corrosive service

By tailoring separators to the specific needs of each operation, we help clients achieve efficiency, safety, and cost savings.

Safety and Compliance Considerations

Separators are pressure vessels, and safety is always the top priority. Routine inspections and maintenance are required to remain compliant with OSHA standards. Operators must also adhere to state and federal regulations on emissions and produced water disposal.

The use of code-compliant separators not only helps meet these requirements but also reduces the likelihood of unplanned outages. Smith Industries’ commitment to quality fabrication ensures that our separators operate safely under demanding conditions.

Why Choose Smith Industries

Clients select Smith Industries for their separator needs because we combine experience, innovation, and reliability. Our advantages include:

• Decades of engineering and fabrication expertise

• Flexible options for ASME code or non-code vessels

• Ability to fabricate separators in a wide range of sizes

• Focus on quality, safety, and compliance

We are not only a fabricator but also a trusted partner who helps clients find the best solution for their production challenges.

Conclusion

Separators are the backbone of surface production operations, providing safe and efficient division of oil, gas, and water streams. With Smith Industries’ expertise in engineering and fabrication, clients can count on reliable, code-compliant, and custom-designed vessels to support their projects. Whether you need a two-phase or three-phase separator, vertical or horizontal configuration, or custom dimensions, Smith Industries delivers equipment built to perform in the toughest conditions.