Separatorsizing

Considerationsinseparatorsizesisimportantduringdesign.Theliquidcapacityofmostseparatorsissizedtoprovideenoughretentiontimetoallowgasbubblestoformand
separateout.

Contents
1Separatordesignbasics
2Settlingtheory
2.1Horizontalseparators
2.2Verticalvessels
2.3Drop/bubblesizes
3Retentiontime
3.1Horizontalvessels
3.2Verticalvessels
4Demistersizing
5Seamtoseamlength
5.1HorizontalVessels
5.2Verticalvessels
6Nozzlesizing
7Examplesofseparatorsizing
7.1Example1:verticaltwophaseseparatorwithameshpaddemistergivenvalues
7.2Example2:Horizontaltwophaseseparator
7.3Example3:Verticalthreephaseseparator
8Dragcoefficients
9Nomenclature
10Subscripts
11References
12NoteworthypapersinOnePetro
13Externallinks
14Seealso
15Category

Separatordesignbasics
Separatorsaretypicallysizedbythedropletsettlingtheoryorretentiontimefortheliquidphase.Forillustrationpurpose,ageneralprocedurebasedonretentiontimeappraoch
isasfollows
1.Estimateoverallvolumebasedontheretentiontimeandexpectedseparationperformanceforeachphase,andthemajorfactorsneededtobeconsideredinclude:
Expectedperforamance
Overallthroughput
Compositionofincomingfluids
Intensityofemulsion
Retentiontimeofeachindividalphase
Typesofvesselandinternals
levelsandalarms
2.Determinationofgascrosssectionalareabasedonsettlingtheoryorempiricalcorrelations,andtheotherfactorsinclude
Expectedliquidcarryoverrate
Avialablemisteliminator
Meanvelocityofgasflow
3.DetermineoilcrosssectionalareabasedonsettlingtheoryorempiricalcorrelationsbyfollowingsimilarprocedureinSteps1and2.
4.DeterminewatercrosssectionalareabasedonsettlingtheoryorempiricalcorrelationsbyfollowingsimilarprocedureinSteps1and2.
5.Determinevesseldiameterbasedoncrosssectionalareaforeachphase
6.Determinevessellengthtomeettherequiredretentiontimeforallphases
7.Selectinletdeviceanditerate.
8.Evaluationofseparationperformanceforaspecificapplocation..

Settlingtheory
Ingravitysettling,thedisperseddrops/bubbleswillsettleatavelocitydeterminedbyequatingthegravityforceonthedrop/bubblewiththedragforcecausedbyitsmotion
relativetothecontinuousphase.
Inhorizontalvessels,asimpleballisticmodelcanbeusedtodeterminearelationshipbetweenvessellengthanddiameter.Inverticalvessels,settlingtheoryresultsinarelation
forthevesseldiameter.

Horizontalseparators
Dropletsettlingtheory,usingaballisticmodel,resultsintherelationshipshowninEq.1.Forliquiddropsingasphase
(/File%3AVol3_page_039_eq_001.PNG)................(1)
where

d=vesselinternaldiameter,in.
dm=dropdiameter,m
hg=gasphasespaceheight,in.
Fg=fractionalgascrosssectionalarea
Leff=effectivelengthofthevesselwhereseparationoccurs,ft
T=operatingtemperature,R
Qg=gasflowrate,MMscf/D
P=operatingpressure,psia
Z=gascompressibility
l=liquiddensity,lbm/ft3
g=gasdensity,lbm/ft3
CD=dragcoefficient.(Seebelowforcalculation)
Forbubblesorliquiddropsinliquidphase:
(/File%3AVol3_page_041_eq_001.PNG)................(2)
where
dm=bubbleordropdiameter,m
hc=continuousliquidphasespaceheight,in.
Fc=fractionalcontinuousphasecrosssectionalarea
d=dispersedliquidphasedensity,lbm/ft3
c=continuousliquidphasedensity,lbm/ft3
Qc=continuousliquidphaseflowrate,B/D.
ForlowReynoldsnumberflow,Eq.3canbefurtherreducedto
(/File%3AVol3_page_041_eq_002.PNG)................(3)
where
trc=continuousphaseretentiontime,minutes
c=continuousphasedynamicviscosity,cp
=specificgravitydifference(heavy/light)ofcontinuousanddispersedphases.

Verticalvessels
Settlingtheoryresultsinthefollowingrelationship.Forliquiddropsingasphase,
(/File%3AVol3_page_042_eq_001.PNG)................(4)
Forbubblesorliquiddropsinliquidphase,
(/File%3AVol3_page_042_eq_002.PNG)................(5)
AssuminglowReynoldsnumberflow,Eq.5canbefurtherreducedto
(/File%3AVol3_page_043_eq_001.PNG)................(6)

Drop/bubblesizes
Ifdroporbubbleremovalisbeingusedforsizing,consultTable1forguidelines.Sizingthewaterphasebyoildropremovalisusuallynoteffective.Thewatereffluentquality
ismorelikelydictatedbytheaddedchemicals.Hence,thewaterphasevolumeistypicallydeterminedbyaretentiontime,basedonexperience.

(/File%3AVol3_Page_052_Image_0001.png)

Table1

Theoildropstoberemovedfromthegasstreamalsodependuponthedownstreamequipment.Flarescrubbersaretypicallydesignedforremovalofdropsthatareafew
hundredmicronsinsize.

Retentiontime
Horizontalvessels
TherelationshipofvesseldiameterandlengthisgivenbyEq.7.
(/File%3AVol3_page_045_eq_001.PNG)................(7)
where
tro=oilretentiontime,minutes
trw=waterretentiontime,minutes
Qo=oilflowrate,B/D
Qw=waterflowrate,B/D
Fl=fractionofvesselcrosssectionalareafilledbyliquid.

Verticalvessels
Similarlyforverticalvessels,therelationshipofvesseldiameterandliquidpadheightsisgivenbyEq.8.
(/File%3AVol3_page_045_eq_002.PNG)................(8)
where
ho=oilpadheight,in.
hw=waterpadheight,in.

Demistersizing
Asdiscussedpreviously,manytypesofdemistersarelimitedbyamaximumvelocitygivenby
(/File%3AVol3_page_045_eq_003.PNG)................(9)
where
Kd=demistercapacityfactor,ft/secanddependsuponthedemistertype
Vm=maximumvelocity,ft/sec
L=liquiddensity,lbm/ft3
g=gasdensity,lbm/ft3
Forhorizontalvessels,therequireddemisterarea(Ad)isgivenby

(/File%3AVol3_page_046_eq_001.PNG)................(10)

(/File%3AVol3_page_024_eq_001.PNG)................(11)
Forverticalvessels,Eq.11isalsovalid.Thevesseldiameteristhenobtainedas

(/File%3AVol3_page_046_eq_002.PNG)................(12)

Fordemisters(horizontalorverticalvessels)sealedinagasbox,inadditiontothedemisterarea,someheightmustbemaintainedbetweenthebottomofthedemisterandthe
highestliquidlevelforthedemistertodrain.Apressuredropexistsacrossthedemister.Iftheliquidlevelistoohigh,thedemisterwillnotdrain,andliquidsiphoningcanoccur.
Asmallholeissometimesdrilledintothedrainpipeasasiphonbreaker.
Whenusingsettlingtheoryordemistersizinginhorizontalvessels,oneshouldalsoconsiderthegasvelocityforreentrainment.Toohighofagasvelocitywillresultinliquid
reentrainmentfromtheliquidsurface,whichmayfloodthedemisterandcausecarryover.TypicalgasvelocitiesforreentrainmentareshowninTable2.

(/File%3AVol3_Page_052_Image_0002.png)

Table2

Seamtoseamlength
HorizontalVessels
Theseamtoseamlength,Lss,forthehorizontalvesselshouldbedeterminedfromthegeometryonceadiameterandeffectivelengthhavebeendetermined.Lengthmustbe
allottedforinletdevices,gasdemisters,andcoalescers.Forscreeningpurposes,thefollowingapproximationscanbeused.

(/File%3AVol3_page_047_eq_001.PNG)................(13)

Theratiooflengthtodiameteristypicallyinthe3to5range.

Verticalvessels
Theseamtoseamlengthoftheverticalvesselshouldbedeterminedfromthegeometry,onceadiameterandheightofliquidvolumeareknown.Allowancemustbemadefor:
theinletnozzle
spaceabovetheliquidlevel
gasseparationsection
mistextractor
foranyspacebelowthewateroutletasshowninFig.1

(/File%3AVol3_Page_051_Image_0001.png)
Fig.1Approximateshelllengthforvertical
vessels(courtesyofCDSSeparationTechnologies
Inc.).

Forscreeningpurposes,thefollowingapproximationscanbeused,wheredisthevesseldiameter).

(/File%3AVol3_page_048_eq_001.PNG)................(14)

Theratioofheighttodiameteristypicallyinthe3to5rangefortwophaseseparators.Forthreephaseseparators,theratioisinthe1.5to3range.
Additionalconsiderationshouldbegivenforinstallationoftheinternalsaswellasmanwayaccess.Inglycoldehydrationtowers,amanwayistypicallyinstalledabovethe
packing/traysandthedemister.Accessspacemustbeallottedforinstallationoftheequipment.

Nozzlesizing
Nozzlesaregenerallysizedbymomentumorvelocities.Table3givesguidelinesthatcanbeusedforsizingnozzles,wheremisthebulkdensityandVmthebulkvelocity.

(/File%3AVol3_Page_052_Image_0003.png)

Table3

Inaddition,theAPIRP14E[1]onerosionvelocityshouldbeincluded.ThisrelationshipisalsogivenbyaninletmomentumcriterionasmVm2=C2,whereCisgivenas100for
continuousserviceand125forintermittentservice.ThevalueofCcanalsovarywithpipematerial,solidsloading,andservice.SeethechapteronPipingandPipelinesinthis
sectionoftheHandbook.Vortexbreakersaregenerallyrequiredontheliquidoutlets.Thesearetypicallyperpendicularplates,asshowninFig.2.

(/File%3AVol3_Page_053_Image_0001.png)
Fig.2Typicalvortexbreaker(courtesyofCDS
SeparationTechnologiesInc.).

Examplesofseparatorsizing
Example1:verticaltwophaseseparatorwithameshpaddemistergivenvalues
ThegivenvaluesforExample1arelistednext.
Gasrate

10MMscf/D

Gasspecificgravity

0.6

Gaszfactor

0.84

Gasdensity

3.7lbm/ft3

Oilrate

2,000B/D

Oildensity

50lbm/ft3

Operatingpressure

1,000psia

Operatingtemperature 60F
OperMeshpadKfactor 0.35ft/sec
Meshpadthickness

6in.

Liquidretentiontime

1minute

Inletnozzle

4in.

Step1.CalculatetherequiredmeshpadareawithEq.10.Thismeshareawillresultinavesselinternaldiameterof15in.
Step2.CalculatetheheightforliquidretentiontimewithEq.2.13.ho=74in.
Step3.ComputeseamtoseamlengthwithEq.9.
TheLeff/D(D=d/12)is9.2andislargerthanthetypical3to5range.Therefore,theinternaldiametermustbeincreasedtoreducetheLeff/Dratio.Table4showsLeff/Dfor
threedifferentvesselIDs.A24in.IDvesselhastheappropriateLeff/Dratio.Theselectedvesselwouldthenbe24in.8ftSStall(afterroundinguptheheight).

(/File%3AVol3_Page_053_Image_0002.png)

Table4

Themeshpadcanbeinstalledintwoways,ifthe1.15ft2istobemaintained.One,afulldiametermeshpadcanbeinstalledwithablankingannularplateontop.Two,a
cylindricalboxwitha15in.diametercanbeinstalledaroundthegasoutlet.

Example2:Horizontaltwophaseseparator
Sizeahorizontalseparatortoremove100mdropsinthegasphase.
GivenValues.ThegivenvaluesforExample2arelistednext:
Gasrate

10MMscf/D

Gasspecificgravity

0.6

Gaszfactor

0.84

Gasdensity

3.7lbm/ft3

Gasviscosity

0.012cp

Oilrate

2,000B/D

Oildensity

50lbm/ft3

Operatingpressure

1,000psia

Operatingtemperature 60F
MeshpadKfactor

0.35ft/sec

Meshpadthickness

6in.

Liquidretentiontime

1minute

Inletnozzle

4in.

Vesselfill

50%(Therefore,Fg=0.5andhg=0.5d.)

Step1.CalculatevesseldiameterandlengthwithEq.1forgascapacity.
(/File%3AVol3_page_054_eq_001.PNG)................(15)
Assumehg=0.5dsothatFg=0.5.
(/File%3AVol3_page_054_eq_002.PNG)................(16)
FromAppendixA,usingagasviscosityof0.012cp,CD=1.42.
(/File%3AVol3_page_054_eq_003.PNG)................(17)

(/File%3AVol3_page_054_eq_004.PNG)................(18)
Step2.CalculateLeffandLss=Leff+d/12fordifferentvaluesofd.
Step3.CalculatethevesseldiameterandlengthforliquidretentiontimewithEq.7.
(/File%3AVol3_page_054_eq_005.png)
Step4.CalculateLeffandLss=Leff+d/12fordifferentvaluesofd.
Step5.Selectvesselthatsatisfiesbothgasandliquidcapacity.
AcomparisonofTables5and6showsthattheliquidcapacityisthedominantparameter.Hence,a24in.6.6ftvesselissufficient,asithasaslendernessratiowithinthe
typical3to5range.Thissizeshouldberoundedupto24in.7ft.

(/File%3AVol3_Page_054_Image_0002.png)

(/File%3AVol3_Page_054_Image_0001.png)

Table5

Table6

Example3:Verticalthreephaseseparator
Givenvalues.ThegivenvaluesforExample3arelistednext:
Gasrate

5MMscf/D

Gasspecificgravity

0.6

Gaszfactor

0.84

Gasdensity

3.7lbm/ft3

Oilrate

5,000B/D

Oildensity

50lbm/ft3

Oilviscosity

10cp

Waterrate

3,000B/D

Waterdensity

66.8lbm/ft3

Operatingpressure

1,000psia

Operatingtemperature 60F
Liquidretentiontime

10minuteseachphase

Inletnozzle

12in.

Dropremovalfromgas 100m
Step1.CalculatevesseldiameterbasedongascapacityfromEq.4.
(/File%3AVol3_page_055_eq_001.PNG)................(19)
Fromthepreviousexample:
(/File%3AVol3_page_055_eq_002.PNG)................(20)

(/File%3AVol3_page_055_eq_003.PNG)................(21)
(/File%3AVol3_page_055_eq_004.PNG)................(22)
Step2.CalculatethevesseldiameterbasedonwaterdropremovalfromEq.6fora500mdrop.
(/File%3AVol3_page_055_eq_005.PNG)................(23)
(/File%3AVol3_page_055_eq_006.PNG)................(24)
Atthispoint,weknowthatthewaterdropremovalisthedominantsizingparameterincomparisontothegascapacity.
Step3.CalculateliquidlevelsforretentiontimebasedonEq.8.
(/File%3AVol3_page_056_eq_001.PNG)................(25)
Table7showsliquidlevelsfordifferentvesseldiameters.

(/File%3AVol3_Page_056_Image_0001.png)

Table7

Step4.CalculatevesselheightfromEq.13.ValesforLssaregiveninTable8.Valuesfor12Lss/dshouldbeinthe1.5to3range.

(/File%3AVol3_Page_036_Image_0001.png)
Table8

Step5.Selectavesselsizethatsatisfiesgascapacity,waterdropremoval,andliquidretentiontimerequirements.An84in.13.4ftseparatorsatisfiestherequirements,soyou
wouldrounduptoan84in.13.5ftvessel.Similarly,a90in.12.5ftseparatorwouldalsobesatisfactory.

Dragcoefficients
Thebalanceofdragandbuoyancyisgivenas
(/File%3AVol3_page_058_eq_001.PNG)................(26)
where
VT = terminalvelocity,cm/sec
CD = dragcoefficientofdrop/bubble
c = continuousphasedensity,g/cm3
d = dispersedphasedensity,g/cm3
g = gravitationalconstant,981cm/sec2
and
dv = dispersedphasedrop/bubblesize,cm.
Eq.26canberewrittenas
(/File%3AVol3_page_058_eq_002.PNG)................(27)
where
c = continuousphaseviscosity,g/(cm/sec)=poise,
Re = Reynoldsnumber,VTdvc/c,
and
Ar = Archimedesnumber.
ThedragcoefficientisafunctionoftheReynoldsnumber,Re,andisgivenbyacurvefitofdata(uptoaReynoldsnumberof5,000)fromPerrysChemicalEngineers
Handbook.[2]
(/File%3AVol3_page_058_eq_003.PNG)................(28)
TheformofEq.28waschosentoallowforaneasysolutionofEq.28fortheReynoldsnumberasoutlinedbyDarbyinDarby[3].
(/File%3AVol3_page_058_eq_004.PNG)................(29)
TheprocedurethentocalculatethedragcoefficientistocalculatetheArchimedesnumber,Ar,asdefinedinEq.27solveEq.29fortheReynoldsnumber,ReandsolveEq.28
forthedragcoefficient,CD.

Nomenclature
Ad = requireddemisterarea
C

= APIRP14Eerosionconstant,(lbm/ftsec2)1/2

CD =
d =
dh =
dm =

dragcoefficient(seeAppendixAforcalculation)
vesselinternaldiameter,in.
hydraulicdiameter,in.(orconsistentunitsforEq.11)

Fl =
h =
hc =
hg =

fractionofvesselcrosssectionalareafilledbyliquid
liquidheight,in.
continuousliquidphasespaceheight,in.

bubbleordropdiameter,m
dpp = perpendicularspacingofplates,m
D = vesseldiameter,ft
Fc = fractionalcontinuousphasecrosssectionalarea
Fg = fractionalgascrosssectionalarea

gasphasespaceheight,in.
ho = oilpadheight,in.
hw = waterpadheight,in.
K = meshcapacityfactor,m/sorft/sec
Leff = effectivelengthofthevesselwhereseparationoccurs,ft
Lss = seamtoseamvessellength,ft
P = operatingpressure,psia
Qc = continuousliquidphaseflowrate,B/D
Qg = gasflowrate,MMscf/D
Qo = oilflowrate,B/D
Qw = waterflowrate,B/D
Re = Reynoldsnumber
T = operatingtemperature,R
trc = continuousphaseretentiontime,minutes
tro = oilretentiontime,minutes
trw = waterretentiontime,minutes
V = bulkvelocity,m/sec
Vc = continuousphasevelocity,m/s(orconsistentunitsforEq.11)
Z = gascompressibility
= inclinationangle,degrees
= specificgravitydifference(heavy/light)ofcontinuousanddispersedphases
c = continuousphasedynamicviscosity,cp
= constant,3.14159
= density,kg/m3orlbm/ft3
m = bulkdensity,kg/m3orlbm/ft3
c = continuousliquidphasedensity,kg/m3orlbm/ft3
d = dispersedliquidphasedensity,kg/m3orlbm/ft3
g = gasdensity,kg/m3orlbm/ft3
l = liquiddensity,kg/m3orlbm/ft3
o = oildensity,kg/m3orlbm/ft3
w =
Ar =
CD =
dv =

waterdensity,kg/m3orlbm/ft3
Archimedesnumber
dragcoefficientofdrop/bubble
dispersedphasedrop/bubblesize,cm

g = gravitationalconstant,981cm/sec2
Re = Reynoldsnumber,VTdvc/c
VT = terminalvelocity,cm/sec
c = continuousphaseviscosity,g/(cm/sec)=poise
c = continuousphasedensity,g/cm3
d = dispersedphasedensity,g/cm3

Subscripts
m = bulkproperties

References
1.APIRP14E,RecommendedPracticeforDesignandInstallationofOffshoreProductionPlatformPipingSystems,fifthedition.1991.Washington,DC:API.
2.Perry,R.H.andGreen,D.W.1984.PerrysChemicalEngineersHandbook,fifthedition,566.NewYorkCity:McGrawHillBookCo.
3.Darby,R.1996.DeterminingSettlingRatesofParticles.ChemicalEngineering(December):109.

NoteworthypapersinOnePetro
Olotu,C.O.andOsisanya,S.2013.DevelopmentofaUserFriendlyComputerProgramforDesigningConventionalOilfieldSeparators.SPE167578MSPresentedattheSPE
NigeriaAnnualInternationalConferenceandExhibition,Lagos,Nigeria,57August.http://dx.doi.org/10.2118/167578MS(http://dx.doi.org/10.2118/167578MS).
Laleh,A.P.,Svrcek,W.Y.andMonnery,W.2013.ComputationalFluidDynamicsBasedStudyofanOilfieldSeparatorPartII:AnOptimumDesign.OilandGasFac.2(1):
5259.SPE161036PA.http://dx.doi.org/10.2118/161036PA(http://dx.doi.org/10.2118/161036PA).

Externallinks
UsethissectiontoprovidelinkstorelevantmaterialonwebsitesotherthanPetroWikiandOnePetro

Seealso
PEH:Oil_and_Gas_Separators(/PEH%3AOil_and_Gas_Separators)
Oilandgasseparators(/Oil_and_gas_separators)

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