Design & Sizing Calculations Separators

(API 12J)

1
Sizing of Two phase oil Gas Separators
Sizing should be based on the maximum expected instantaneous rate.
A - Theory and Equations: Gas Capacities of separators may be determined
by a modified Stokes Law. When using stokes Law the capacity is based on
the principle of the minimum droplet size that will settle out of a moving
gas stream at a given velocity. The maximum allowable superficial
velocity of the gas at operating conditions is calculated by the following
formula:
Va = K (dl dg)/dg (1)
Where:
Va = Maximum allowable superficial velocity in feet per second through the
secondary separation section.
Dl = Density of the liquid in pounds per cubic foot at operating conditions
DG = Density of the gas in pounds per cubic foot at operating conditions
K = A Constant depending up on design and operating conditions

2
K FACTORS FOR DETERMINING MAXIMUM ALLOWABLE SUPERFICIAL VELOCITY

Type Separator Height or Length Typical K Factor

L (Feet) Range
Vertical 5 0.12 to 0.24

10 0.18 to 0.35

Horizontal 10 0.40 to 0.50

Other Lengths 0.40 to 0.50 x

(L/10)0.58
Spherical All .2TO 0.35

3
B - The maximum allowable superficial velocity
calculated from the above factors is for separator
normally having a wire mesh mist extractor. This rate
should allow all liquid droplets larger than 10 microns
to settle out of the gas.
The maximum allowable superficial velocity or other
design criteria should be considered for other type
mist extractors.
NOTE: Mist extractor manufacturers recommend
minimum distances upstream and downstream of the
wire mesh between gas inlet and outlet nozzles
should be provided for full utilization of this mist
extractor.

4
C - The oil capacity of a separator is a function of
retention time and gas oil interface area. The
basic requirement is to retain the oil long
enough and provide sufficient interface area
for entrained gas to break out of the oil.
Separator liquid capacity is normally based on
one minute retention time for non-foaming oils
having a gravity of 35o APl and above.
A gravity lower than 35o API may require a
greater retention time.

5
D - Foaming crudes offer a special problem in sizing
separator. Foam is a mixture of gas dispersed in a liquid
and having a density less than the liquid but greater than
gas. Greater interface area & longer retention time are
needed to remove the gas form the liquid.
Horizontal separators normally give the largest interface
area. Retention times of as high as 15 minutes may be
necessary. However a retention time of 2 to 5 minutes is
sufficient in most cases for the separators to handle
foaming crudes. Where the well can be sampled in a test
unit. More accurate estimate of required retention time
can be determined. Defoaming separator designs often
include a variety of proprietary internal configuration to
improve capacity. These are beyond the scope of this
specification.
6
 E - In addition to the well stream properties the gas
capacity is influenced by the following:
Operating temperature being above the cloud
point of oil
Operating temperature being above the hydrate
point of oil
Foaming tendency of liquid
Uniformity of flow
Defoaming chemicals, if used

7
 F - The liquid capacity of a separator is primarily
dependent upon the retention time of the liquid in
the vessel. Good separation requires sufficient time
to obtain an equilibrium conditions between the
liquid and gas phase at the T & P of separators. The
liquid capacity of a separator of the settling volume
required based on retention can be determined from
the following equations:
W=(1440 x V)/t or t=(1440 x V)/W or V=(W x t) / 1440
Where:
W = Liquid capacity, bbl/day at flowing conditions
V = Liquid settling volume bbl
T = Retention time, minutes

8
G - Basic design criteria for liquid retention time in two
phase separators are generally as follows:

Oil Gravity, 0 API Time (Minutes; Typical)

Above 35 1

20 to 30 1 to 2

10 to 20 2 to 4

9
H - The settling volumes may be used in the above
equations of a particular vessel.
For proper sizing both the liquid capacity & gas
capacity should be determined. It may be noted that
an most high pressure gas distillate wells the GOR is
high and the gas capacity of a separator is usually the
controlling factor. However, the reverse may be true
for low pressure separators used on well streams with
low GOR.
The liquid discharge or dump valve on the separator
should be sized based upon the pressure drop
available, the liquid flow rate and the liquid viscosity.

10
 Sizing of Three phase Separators
(Oil, Gas & Water)
The basic principle of oil and gas separation have been covered under
sizing of two phase oil gas separators. The following portion will cover
the separation of free water and oil:
1. All of the basic separators ( vertical, horizontal, Spherical ) may be used
for three phase separation. Regardless of shape all three - phase vessels
must meet the following requirements.
a. Liquid must be separator from a primary separating section.
b. Gas velocity must be lowered to allow liquids to drop out.
c. Gas must be scrubbed through an efficient mist extractor
d. Water and oil must be diverted in a turbulence free section of the
vessel
e. Liquids must be retained in the vessel long enough to allow separation
f. The water oil interface must be maintained
g. Water and oil must be removed from the vessel at their respective
outlets.

11
2 - Sizing a three phase separator for water removal is mainly a
function of retention time. Required retention time is related
to the volume of the vessel, the amount of liquid to be
handled & the relative specific gravities of the water and oil.
The effective retention volume in a vessel is that portion of the
vessel in which the oil and water remain in contact with one
another. As far as oil water separation is concerned, once
either substance leaves the primary liquid section, although it
may remain in the vessel in a separator compartment, it
cannot be considered as a part of the retention volume.
There are two primary considerations in specifying retention
time:
a. Oil settling time to allow adequate water removal from oil.
b. Water settling time to allow adequate oil removal from
water.

12
The usual approach in design is to allow equal retention times
for oil and water. This is accomplished with a wide range
interface level controller or variable water . Basics design
criteria for liquid retention time in three phase separator are
generally as follows:

Oil Gravity, 0 API Time (Minutes; Typical)

> 35 3 to 5
<35
100 + 0F 5 to 10
80 +0F 10 to 20
60 +0F 20 to 30

13
 Separator Selection
Following procedure may be used when selecting a separator for a
particular application:
Determine which shape fits the particular installation best
considering space, mounting, and the ease of access for
maintenance. Consider both present and future operating
conditions.
Determine whether unusual well stream conditions (foam, sand,
etc.) would make the vessel selected difficult to operate or
maintain.
Determine whether over-all economics is affected by the
installation or portability of the shape selected.
Make certain that all design requirements such as heating coils for
paraffin or hydrates and three phasing for water removal have
been considered and area compatible with the shape selected.
Consider possible liquid slugging of the separator.

14
 Separator sizing (Num.)
Design Conditions:

Gas flow rate 25MMSCFD

Oil flow rate 3000 BPD
Operating Pressure 800 psig
Operating Temperature 80 0F
Flowing gas density dG 3.40 lbs/ft3
(for 20.3 mol. Wt. gas)
Flowing oil density dG 51.5 lbs/ft3
(for 40o API oil)
Separator type Vertical , two phase

(Tentatively assume 10 feet shell height 30 % liquid full and use

K of 0.3)

15
 DATA SHEET
(SEPARATOR DESIGN INFORMATION)
I Operating Conditions
A. Liquid Volumes
1. Oil/condensate ____________BPD, Gravity __________ 0API, Viscosity _________cp
2. Water ____________ Barrels/Day, Sp. Gravity_______ (Water 1.0)
B. Oil/Condensate Characteristics
1. Foaming: Nil __________ Moderate___________________ Severe ____________
2. Paraffin Problem: No. _______Yes____(If , Yes give cloud point ________oF)
Slug Flow: No ___ Yes __ (If yes give details such as maximum liquid rate, slug
volume etc., or suggest surge factors, _______________________________
______________________________________
C. Gas: ___________MMSCFD , Sp. Gr:____________________(Air = 1)

D. Operating Temperature oF ____________Max. ____________ Min. ____________

E. Operating Pressure, psig ___________ Max. _____________ Min. _____________

F. H2 S Content __________Mole % , CO2 Content __________Mole%

G Geographical Location________________________________________ 16
II Design Requirement
A. Type:_________ Vertical ___________ Horizontal ___________ Spherical
Manufacturers Recommendation________________________________
____________________Two Phase _______________Three Phase
B. Design Pressure _______ psig at Temperature_______________ o F

C. Type Mist Extractor (Specify) _______________________________

D. Liquid Retention Time_______________________________________

E. Corrosion Allowance_________________________(inches)
F. Corrosion Allowance for Non-Pressure Internal Parts________(inches)
G. NACE MR 01-75: Required: No _______ Yes ________
H. Special Stress Relieving No __________ Yes ________
I. Specify, if Yes________________________________________________

J. API RP 14C Safety Systems: Required No _________ Yes ________

17
III Coating
A.External Mfgr. Std _________ Other ________
Specify, if other ___________________________
B. Internal : (Specify) ________________________
C. Cathodic Protection: (Specify) ___________________

18
IV Special Instructions:

A. Radiographic Inspection: ASME Code ___________ Other_______

Specify if other________________________________________
_____________________________________________________

B. Hydrostatic Testing Pressure: ASME Code ________ Other ______

Specify, if other ____________________________________________________
______________________________________________________________

C. Hardness Testing Requirement (Specify) ___________________________________

D. Lifting Lugs: (Specify) ___________________________________ _______________

E. Skid Mounting: (Specify) ___________________________________ ____________

F. Welding Requirement: ASME Code _______Other _____________

Specify, if other ______________________________________________

G. Sand Removal Systems System: (Specify)_____________________________________

_________________________________________________________

H. Any Other______________________________________________________________
______________________________________________________________________

19
Best wishes for end-sem. examination

20