SPE-173598-MS A Simplified Approach To Sizing 2 and 3 Phase Separators PDF
SPE-173598-MS A Simplified Approach To Sizing 2 and 3 Phase Separators PDF
This paper was prepared for presentation at the SPE Production and Operations Symposium held in Oklahoma City, Oklahoma, USA, 1–5 March 2015.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.
Abstract
This paper provides a simplified approach to sizing 2 and 3 phase separators in low GOR (⬍2000
scf/STB) applications. The paper will provide the facility engineer with a straight forward method for
beginning the sizing of the separation system. Once the first pass sizing has been executed, the sizing can
be refined and adjusted to meet any specific requirements. The paper will also describe a simplified Stokes
equation to confirm that the retention time approach has a high probability of meeting process require-
ments. Finally, the methodology lends itself to building an excel spreadsheet for multiple vessel sizing
requirements.
   The oil should be ⱖ 25 API crude, although the application can be applied to heavier crudes providing
that additional safeguards are applied. There are no limits on the water cut, but the paper assumes that the
water cut is greater than 50%. The approach uses a retention time method which sizes the liquid section
of the separator. The recommended retention time will be approximately 2 times the API 12J values for
2 reasons:
        1. To account for hydraulic short circuiting in the separator
        2. To ensure that the separation process is in the Stokes or Laminar regime.
   The paper will also recommend using baffle plates in the 3 phase separation to facilitate plug flow. The
paper will recommend the use of either a mesh pad or vane pack in the gas section to minimize liquid
aerosols carried out with the gas.
   The sizing methodology is summarized as follows:
        1. Establish the actual oil, water and gas properties and rates.
        2. Select a retention time for water and oil.
        3. Select a Length to Diameter ratio or Height to Diameter ratio.
        4. Solve for the vessel diameter and length.
        5. The gas section is then sized.
        6. The liquid control volume and alarm heights are established.
        7. Inlet and outlet nozzles are sized.
        8. Stokes calculation is executed to determine separable droplet size, oil in water, water in oil and oil
2                                                                                               SPE-173598-MS
       in gas.
  The paper will discuss the merits of vertical and horizontal separators based on production environment
and environmental conditions.
Introduction
Domestic onshore oil production has dramatically increased over the past decade. Small and midsized
E&P companies rather than the majors have driven this development. The developments have been in
unconventional and or tight formations. The technical emphasis has been associated with downhole
processes. The surface facilities, separators and treaters, have in general been purchased as if thru a
catalogue whereas offshore systems are commonly designed based on production issues, risk and profiles.
The typical purchase of a separator in this environment is based on normal operating pressure and
temperature, an oil rate, a water rate and possibly a gas rate. The vessel design is left to a fabricator who
has been building vessels based on previous vessels which may have originally been sized on the basis
API 12J or another companies design which has been scaled up or down to match stated rates.
   This approach creates a number of number of problems for the end user which includes but are not
limited to inadequate retention times, design not based on worst case, poor separation, inadequate relief,
making bad oil, rerunning oil, and high oil concentrations in water. The remainder of the paper will review
the basic principles associated with the process design of 2 and 3 phase liquid dominated separators and
a sizing approach to generate desired separation results.
Application
Step 1
Obtain the data required for Table 1. The pressure and temperature data should be available from existing
field data and from production data. The temperature information must also consider the heat loss between
the well head and the production battery. As an example, many producers use polyethylene flow lines laid
SPE-173598-MS                                                                                                          3
                Pressure PSIG                        Minimum    Normal     Maximum      Pounds per Square Inch Gage
                Temperature °F                       Minimum    Normal     Maximum           Degrees Fahrenheit
                Gas Rate SCFD                        Minimum    Normal     Maximum      Standard Feet Cubed per Day
                Actual Gas Rate AFt3/S               Minimum    Normal     Maximum      Actual Feet Cubed per Second
                Actual Gas Density lbm/Ft3                      Nominal                    Pounds per Foot Cubed
                Oil Rate BPD                                    Normal     Maximum             Barrels per Day
                Oil Rate CFM                                               Maximum          Cubic Feet per Minute
                Oil Viscosity (cP/1488)              Minimum     Normal    Maximum         Pounds per Foot-Second
                Produced Water Rate BPD                                    Maximum             Barrel per Day
                Produced Water Rate CFM                                    Maximum          Cubic Feet Per Minute
                Produced Water Viscosity (cP/1488)              Nominal                   Pounds per Foot -Second
                Oil Density lbm/Ft3                             Nominal                    Pounds per Foot Cubed
                Water Density #/Ft3                             Nominal                    Pounds Per Foot Cubed
on the surface between the well head and the battery. In the winter the production fluids arrive at the
battery at or close to ambient temperature. The critical aspect of the temperature is its effect on viscosity.
The viscosity of 35 API gravity oil at 100°F at the well head is approximately 4cP. Based on heat loss
the well head fluid can easily arrive at the production battery at 40°F which changes the viscosity from
4cP to 16cP.1 The oil and water rates in many cases have a correlation based on how the well comes in.
In many cases facilities are designed on the basis of best case oil and historical water rates. The worst case
oil rate is also based on historical rates in the producing area. The producer ultimately has to decide on
whether the design basis is the optimistic or the realistic rate. This paper assumes that the optimistic rate
be defined as the maximum and the realistic rate is defined as normal. Most of the data required for the
table is easily obtained internally with the exception of viscosity. There are a number of correlations which
can be used to obtain reasonable values such as the Glaso correlation. Given the fact that these systems
operate at low pressure, less than 200 PSIG, the dead oil correlation is adequate since Gas in Solution
values are very low at these pressures. For example 35 API oil at 200 PSIA and 100°F has a live oil
viscosity value of 3.4cP versus a dead oil viscosity value of 4cP. Using the dead oil viscosity at low
pressure can be thought of as a safety factor when a separable droplet is calculated.
Step 2
Decide on whether the separator should be vertical or horizontal. As with most design decisions there is
not a single correct answer. General statements can be made:
     1. Horizontal is better for 3 phase separation because for the same design parameters the horizontal
        has better retention time and less steel.
     2. Horizontal is better for foamy crudes because increasing retention in the horizontal vessel still
        results in less steel than an equivalent vertical vessel.
     3. Sand and Wax control and removal is more easily addressed in a vertical vessel, especially one
        with a conical bottom.
     4. Liquid dominated 2 phase vessels may be either vertical or horizontal. In general, the horizontal
        vessel will result in less steel.
   Numerous texts such as Arnold and Stewart’s Surface Production Operations Volume 1 (2008) and
Manning and Thompson’s Oilfield Processing Volume 2 (1995) discuss the merits of vertical versus
horizontal separators.
   If the service is 2 phase degassing of a liquid load, the decision could be either a vertical or horizontal
and the deciding factors may be cost and other process issues. If the liquid load is substantial, greater than
5000 BPD then the most common decision is a horizontal separator. This tends to be an economic decision
4                                                                                                                           SPE-173598-MS
Figure 1—Drag Coefficient versus Reynolds Number from Chemical Engineers’ Handbook, McGraw Hill, New York, NY
   If the service is 3 phase separation, liquid dominated then the most common selection is a horizontal
separator. The decision is based on economics, less steel.
Step 3
The design criteria will be based on liquids in the laminar flow regime. This means that the Reynolds
number for the separable droplet of interest, i.e. a gas bubble out of the liquid phase, will be less than or
equal to 1. See Figure 1 from the Chemical Engineers’ Handbook
   The boundary between the Stokes (Laminar) flow regime and the Intermediate flow regime is a
Reynolds Number value between 1 and 2. This paper will use a Reynolds value of 1 to define that
boundary.
   The Reynolds Number Re ⫽ (DpV)/ ⬍ 1 for Laminar or Stokes flow
   Where:
    The vessel sizing approach assumes laminar or Stokes flow in the liquid section. The separable droplet
will be calculated on the basis of laminar flow. The Reynolds Number is then calculated on the calculated
droplet and terminal velocity which are determined by the vessel size. If the calculated Reynolds number
is less than 1 then the vessel is in the laminar or Stoke regime and the separable droplet is valid. This
calculation is used to confirm that the assumptions for the residence time sizing criteria are valid.
    The following steps will be segregated to address the sizing for the 2 most common applications:
     1. 3 phase oil water separator
     2. 2 phase gas liquid separator
SPE-173598-MS                                                                                               5
Figure 3—Fraction of area for gas, oil and water flow as a function of interface height
    5. Calculate the volume for oil, volume for water and the total liquid volume using Retention Times
       chosen in step 1:
       a. Vo ⫽ Qo ⫻ Tro
       b. Vw ⫽ Qw ⫻ Trw
       c. Vl ⫽ Vo ⫹ Vw
          Where
    6. Use a graph or table to obtain the percentage of vessel area available for Liquid. The 1987 GPSA
       Volume 1 Figure 6-22 has a complete table of partial volume of horizontal cylinders. Figure 3
       below describes the area available for Gas, Oil and Water. The M values used in the 3 phase
       horizontal vessel are obtained from the GPSA.
         a. The Area Available for Liquid is Ml which is equal to Mo ⫹ Mw
         b. The Area Available for Oil is Mo
         c. The Area Available for Water is Mw
         d. The Area Available for Gas is (1- Ml)
    7. The vessel dimension can now be calculated. The Volume for liquid is a function of the diameter
       cubed because the length is a function of the diameter from step 3 and the percentage of vessel area
       for liquid is defined by the height of liquid to diameter ratio from step 6.
          a.
         b.                              where L ⫽ C1D and Ml is the percentage of area for liquid
         c.
         d.                  where Diameter and Lenqth are in feet
          ii. and if the separable water droplet is ⱕ 400 microns then the retention time sizing is valid
       d. Steps a. thru c. are repeated for the separable droplet calculation for oil out of water
       e. Vt for oil out of water ⫽ Hw/(60 ⫻ Trw) where time is in seconds
       f. Using Stokes Law in the laminar regime calculate the separable oil droplet
          i.                                            where g ⫽ 32.2 ft/ sec2
       g. Confirm that the Reynolds Number based on the separable droplet calculated in step g. and the
          terminal velocity calculated in Step f. is less than 1.
         i. If Re ⫽ (Vtoiw ⫻ Doiw ⫻ pw)/w ⬍ 1 then the flow is laminar and if the separable oil
             droplet is ⬍ 200 micron then the retention time sizing is valid
   14. In order to mitigate hydraulic short circuiting, the designer should consider the addition of 2 or 3
       baffle plates/flow straighteners (see figure below).The plates should also extend a 4 to 6 inches
       into the gas section to break any surging or wave action. The author has good success with cutout
       area which slows the fluid velocity thru the cutout area to one half of the vessel fluid velocity. The
       cutouts can be circular or elongated circles
   15. The gas section is now addressed. This paper assumes that a 6⬙ standard mesh pad is used. The
       sizing of the gas space uses API 12J (1987) recommendations for determining the vessel Ksb.
       Assuming that the vessel is longer than 10 feet then Ksb will be between 0.7 and 0.9 feet per
8                                                                                                 SPE-173598-MS
       second. Because the vessel has been sized for liquid, the gas section may be a compromise. The
       vessel Ksb uses the standard Souders Brown equation in API 12J (1987).
       a.
       b.                   where the Gas Flow rate is in Actual Feet Cubed per Second
       c. Area for Gas ⫽ (/4)D2 ⫻ (1 ⫺ Ml)
       d. If the vessel Ks is between 0.7 and 0.9 then the mesh pad can be installed across the horizontal
          cross section and can be liquid wetted. If the vessel Ks is below 0.7 to 0.9 then the designer
          can either use a gas dome sized for the desired Ks or fabricate a box with an internal area inside
          the vessel which will satisfy the vessel desired Ks.
    16. The final components to consider are the inlet and outlet nozzles. This paper assumes that
        conventional impact or diverter plate is used. The inlet nozzle should precondition the flow for
        separation and as such it should reduce momentum. Manning (1995) states that erosional velocity
        should be the limiting factor. This paper does not agree. Stewart and Arnold (2008) suggest that
        inlet and gas outlet nozzles should be sized so that the velocity is less than 60 divided by the square
        root of the stream density. This paper suggests a more conservative approach for the inlet nozzle.
        The inlet nozzle should be sized on the basis of inlet velocity equal to 30 to 40 divided by the
        square root of the inlet mixture density. This allows for the fluid stream to slow down before
        entering the vessel and minimizes droplet shattering. The liquid outlet nozzles are sized to
        minimize gas carryunder and to minimize restrictions due to scale and other deposits. This paper
        recommends a liquid outlet velocity of 4 to 6 feet per second.
        a.
       b.
       c. Voil or V water ⫽ 4 to 6 feet per second
    17. The designer must make a decision on what is the worst case overpressure event and the relief
        volume associated with the event. In many cases, this reduces to a decision on sizing the relief
        valve based on vapor only or a vapor and liquid. The designer is responsible for this decision but
        this paper recommends using vapor and liquid as the basis for sizing the relief valve which is the
        most conservative approach.
    18. Process controls play a critical role in obtaining the design performance. The interface control is
        the most critical because it controls the operating residence time of both the oil and water. The
        suitability of a control is partially dependent on the how the vessel designer has designed the
        vessel. There are 3 possibilities:
        a. No weir, the oil simply sits on the water on top and the oil is a drawn from the vessel via an
            outlet pipe set at a unique elevation. This paper is not going to discuss this approach because
            of the inherent issues and poor control associated with this design.
        b. The liquid level in the vessel is set by a weir. This is the most common design. The oil spills
            over the weir into an isolated compartment. In this case the oil level in the isolated section is
            easily controlled by a float controlled mechanical control valve. The interface level controller
            is more problematic. The conventional float control depends on the density difference between
            the oil and water. As a result it tends to have a wide operating range. More importantly, when
            it actuates, the water level falls dramatically. This means that the relative retention times of the
            water and the oil vary in accordance with the water level at the lowest point when the valve has
            actuated to the normal interface level just before the valve actuates. The float travel is normally
            set to 12 to 18 inch and the level falls in accordance with the float travel. The second issue with
            this type of interface controller is how the float is affected by changing temperature. In the
SPE-173598-MS                                                                                                               9
          winter or seasonal change, the vessel, the oil and the water cool dramatically. The temperature
          change can be a 50°F swing. The oil viscosity increases and the quality or sharpness of the
          gravity break at the interface deteriorates. The smaller the difference in gravity and the
          thickness of the interface emulsion alters the reliability of the conventional float style interface
          controller. The author has good results with the newer generation of controllers using a more
          sensitive float (Teflon) and a more sensitive controller.
       c. The bucket and weir design uses an oil bucket and a weir which controls the water interface
          level. This approach allows the oil to be in its unique compartment and the water to be in its
          unique compartment. The interface level is physically controlled by the water weir. This allows
          for the satisfactory use of the conventional float style control valves in both the oil bucket and
          water compartment.
        c. Confirm that the Reynolds Number based on the separable droplet calculate in steps. and
           terminal velocity is Step a. is less than 1.
          i.                                                                  1 confirming that
              the flow is laminar and the sepable water droplet is ⬍ 400 micron confirming that the
              retention time sizing is valid
        d. Steps a. thru c. are repeated for the separable droplet calculation for oil out of water
        e. Vt for oil out of water ⫽ Hw/Trw ⫽ 1.94/300 ⫽ .0065ft/sec note retention time converted to
            seconds
        f. Using Stokes Law in the laminar regime calculate the separable oil droplet
           i.
        g. Confirm that the Reynolds Number based on the separable droplet calculate in step i and in
           Step g. is less than 1.
          i. If Re ⫽ (Vtoiw ⫻ Doiw ⫻ w)/w ⫽ (0.0065 ⫻ .000368 ⫻ 69)/(1/1488) ⫽ .245 ⬍ 1
             confirming the flow is laminar and the separable oil droplet is ⬍ 200 micron confirming that
             the retention time sizing is valid
     14. Two or three flow conditioners would be designed as discussed above. The decision to use holes
         or elongated slots would be a fabrication decision.
     15. The gas section is now addressed. A 6⬙ standard mesh pad is used. The vessel is16 feet long then
         Ksb should be between 0.52 and 0.65 based on API 12J (1989). Because the vessel has been sized
         for liquid, the gas section may be a compromise. The vessel Ksb uses the standard Souders Brown
SPE-173598-MS                                                                                            11
(2008) is reasonable. This paper also recommends that the separable gas bubble in the liquid section is less
than or equal to 200 micron for good degassing quality. The liquid section will use a retention time
sufficient to ensure laminar flow using the lowest operating temperature.
   Finally the authors experiences suggest that the economics of a vertical separator are limited to 1000
liquid barrels per day assuming there are no mitigating circumstances.
   The method for sizing the vertical 2 phase liquid dominated separator will:
     a. Use a simplified version of droplet settlement theory to size the vessel diameter (D) based on
        separable oil droplet less than or equal to 140 micron. A critical point is that the gas section
        operates in the intermediate flow regime because gas viscosity is small.
     b. The height (H) of the vessel will be based on retention with flow in the laminar regime. The sizing
        will be confirmed by using the simplified Stokes equation in the laminar regime to confirm that
        the separable gas bubble out of oil is less than 200 micron.
     c. After the vessel Diameter and Height have been calculated. The Vessel Souders Brown coefficient
        Ksb is calculated. The Ksb for the vessel will be smaller than the recommended value in API 12J
        (1989). A fabrication detail with an area calculated to speed up the velocity which satisfies the
        desired Ksb will be calculated
SPE-173598-MS                                                                                                           13
   The sizing procedure will use a modified form of the 1987 GPSA Guidelines for Vertical Separator
Dimensions. The sizing procedure also includes High Level Shutdown and a Low Level Shutdown for
safe operating practices. See Figure 4.
   Steps 1and 2 are same as the horizontal separator. The sizing method will begin at step 3.
Step 3
     1. Arbitrarily select a value of 10 for the Reynolds number in the intermediate flow regime (see
        Figure 1 below).
Figure 1—Drag Coefficient versus Reynolds Number from Chemical Engineers Handbook, McGraw Hill, New York, NY
     2. Calculate the Terminal Velocity Vt based on 140 micron (460 ⫻ 10⫺6ft). The terminal Velocity
        will remain constant thru this process. Viscosity is in units of Pounds per Foot-Second.
        a. Re ⫽ (Vt ⫻ (460 ⫻ 10⫺6) ⫻ g)/g ⫽ 10 where the regime is intermediate if Re ⬎ 1
        b. Vt ⫽ (10 ⫻ g)/((460 ⫻ ⫺6) ⫻ g)
     3. Calculate the Drag Coefficient based on the Reynolds Number (Cdre). There are a variety of ways
        to evaluate the relationship between the Reynolds number and the drag coefficient (Cd). The drag
        coefficient calculation shown on Figure 1. is straight forward. Given that the Reynolds number
        will be greater than 1 and the gas section will be in the intermediate regime.
        a. Cdre ⫽ (18.5)/Re0.6 the reynolds number raised to the 0.6 power
     4. Calculate the Drag Coefficient (Cdge) using the general equation. The general equation will use
        the velocity calculated in a.ii. and a droplet size of 460 ⫻ 10⫺6ft. (140 microns).
        a.                                                     where g is 32.2 ft/sec2 the equation can be
          simplified to
       b. Cdge ⫽ (43 ⫻ (460 ⫻ 10⫺6)/(Vt)2) ⫻ ((o — g)/g)
14                                                                                               SPE-173598-MS
      5. If the drag coefficient (Cdre) calculated using the Reynolds number is ⱕ the drag coefficient
         (Cdge) using the general equation then the separable droplet will ⱕ 140 microns. If there is desire
         to calculate the exact droplets then the 2 drag coefficients are iterated using progressively smaller
         separable droplets until agreement is obtained. This method does not iterate a solution. The fact
         that the performance is better than required is viewed as conservative design.
         a. if Cdre ⱕ Cdge then the vessel will separate oil droplets in the gas space less than 140 microns.
      6. The Vessel Diameter is calculated using the Velocity in a.ii.:
         a.
     Where:
Step 4
      1. Select a liquid retention time. API 12J (1988) recommends minimum retention time for the liquid
         to degas. The retention times are:
         a. Above 35 °API 1 minute
         b. 20 to 30 °API 1 to 2 minutes
         c. 10 to 20 °API 2 to 4 minutes
         The paper is only concerned with oils greater than 25° API and believes that operating temperature
         should be part of the decision making process because it will influence when equilibrium is
         reached between the gas and the liquid. Low operating temperature increases the oil viscosity and
         therefore increases the size of the separable droplet. This recommends the following retention
         times:
        i. Above 35 ° API 2minutes
        ii. 30 to 35 ° API 3 minutes
        iii. 25 to 30 ° API 4 minutes
         Arnold and Stewart (2008) make the following points: if foam is present increase retention time
         by a factor of 2 to 4 and if high CO2 exists use a minimum retention time of 5 minutes. The author
         has seen foam with seven minute collapse time so Arnold and Stewarts comment is well taken. The
         author would suggest that unless the foam characteristics are known, a factor of 4 is better than
         2 because the need for a chemical defoamant will be less.
      2. Calculate the Volume for Liquid. This volume provides space for both degassing and control. The
         retention for oil and water is the same.
         a. VI ⫽ (Qo ⫹ Qw) ⫻ Tr
         Where:
      3. Calculate the Height of the Volume for Liquid (Hl). This height should be greater than or equal
         to18 inches so the level controllers movement is not compromised.
SPE-173598-MS                                                                                              15
       a. HI ⫽ Vl/((/4) ⫻ D2)
          Where:
     8. The inlet nozzle, the gas outlet nozzle and liquid outlet nozzle are sized exactly the same as in the
16                                                                                                                 SPE-173598-MS
          ii. Calculate the separable gas bubble in the gas section assuming laminar flow.
             1.
          iii. Confirm laminar flow in the oil section by calculating the Reynolds number for the oil
               section. If the Reynolds number is less 1 then the flow is laminar.
             1. If Re ⫽ (Vtgio ⫻ Dgio ⫻ o)/o ⬍ 1 and the flow is laminar and if the separable water
                droplet is ⱕ 200 microns then the retention time sizing is valid
     1. Arbitrarily select a value of 10 for the Reynolds number in the intermediate flow regime.
        a. Calculate the Terminal Velocity Vt based on 140 micron (460 ⫻ 10⫺6/t). The terminal Velocity
           will remain constant thru this process. Viscosity is in units of Pounds per Foot-Second.
          i. Re ⫽ (Vt ⫻ (460 ⫻ 10⫺6) ⫻ g)/g ⫽ 10 where the regime is intermediate if Re ⬎ 1
          ii. Vt ⫽ (10 ⫻ (8.7 ⫻ 10⫺6))/((460 ⫻ 10⫺6) ⫻ 0.5) ⫽ 0.38 ft/sec
       b. Calculate the Drag Coefficient based on the Reynolds Number (Cdre). There are a variety of
          ways to evaluate the relationship between the Reynolds number and the drag coefficient (Cd).
          The drag coefficient shown on Figure 1. is straight forward. Given that the Reynolds number
          will be greater than 1 and the gas section will be in the intermediate regime.
         i. Cdre ⫽ (18.5)/Re0.6 ⫽ 18.5/100.6 ⫽ 4.6
SPE-173598-MS                                                                                            17
       c. Calculate the Drag Coefficient (Cdge) using the general equation. The general equation will use
          the velocity calculated in a.ii. and a droplet size of 460 ⫻ 10⫺6ft. (140 microns).
         i.                                                     where g is 32.2 ft/sec2 the equation can be
             simplified to
         ii. Cdge ⫽ (43 ⫻ (460 ⫻ 10⫺6)/(0.38)2) ⫻ ((51 ⫺ 0.5)/.5) ⫽ 13.8
       d. If the drag coefficient (Cdre) calculated using the Reynolds number is ⱕ the drag coefficient
          (Cdge) using the general equation then the separable droplet will ⱕ 140 microns
         i. 4.6 ⱕ 13.8 the vessel will separate oil droplets in the gas space less than 140 microns.
      e. The Vessel Diameter is calculated using the Velocity in a.ii.:
         i.                                                       round up to 3.5 ft
   where
     5. The height required for the high level shutdown and the low level shutdown can be calculated
        (Hsd). The height for each will be the same because they both use the same retention time of 1
        minute or have a minimum of 1 foot spacing between the normal liquid space and the shutdown
        device.
        a.
       b. If Hsd ⱖ 1ft then use the calculated value of HSD, if Hsd ⬍ 1 ft then Hsd ⫽ 1 ft
     6. The Height of the Vessel associated with the gas space (Hg) is the height from the inlet nozzle to
        the mesh pad. This space allows for the gas to develop plug or piston like flow. The height is a
18                                                                                               SPE-173598-MS
b.
        c. The vessel Ksb is much less than the API 12J (1987) recommended values between 0.18 to 0.35
           ft/sec. Selecting a value of 0.3 ft/sec, the required gas velocity thru the mesh pad is 3 ft/sec. A
           fabrication with an area of 1.12 ft2 would house the mesh pad.
      9. The vessel can be dimensioned per Figure 4. Figure 5 below illustrates the first pass dimensions.
         The vessel diameter and height can be optimized on the basis of API 12J (1987). Standard heights
         are in 2.5 foot increments and diameters increase in 0.5 ft. increments.
     10. The inlet nozzle, the gas outlet nozzle and liquid outlet nozzle are sized exactly the same as in the
         Horizontal Separator Step16.
         a.                                              which would require a 6⬙ inlet nozzle
         b.                                                which would require a 4⬙ nozzle
        c. VI ⫽ 4 to 6 feet per second ⫽ 0.065/4 ⫽ 0.02ft2 which requires a 2⬙ nozzle. To avoid issues
           with scaling, sediment and wax the designer should consider increasing the size to 3⬙
     11. A simplified Stokes procedure confirms that the liquid section will separate out a gas bubble of
         200 micron or less. Although the liquid section is a mix of oil and water, the confirmation process
         uses oil only because it is the most conservative approach.
SPE-173598-MS                                                                                         19
       a. Oil Section
         i. Calculate the Terminal Velocity for the gas bubble rising.
                1.
          ii. Calculate the separable gas bubble in the gas section assuming laminar flow.
                1.
2.
          iii. Confirm laminar flow in the oil section by calculating the Reynolds number for the oil
               section. If the Reynolds number is less 1 then the flow is laminar.
                1. If Re ⫽ (Vtgio ⫻ Dgio ⫻ p)/o ⬍ 1 and the flow is laminar and if the separable water
                   droplet is ⱕ 200 microns then the retention time sizing is valid
20                                                                                              SPE-173598-MS
Nomenclatures
 C1         Numerical value of the Length to Diameter ratio for a vertical vessel (dimensionless)
 C2         Numerical value of the Height of Liquid to Diameter ratio (dimensionless)
 Cdre       Drag Coefficient based on the Reynolds number calculation (dimensionless)
 Cdge       Drag Coefficient based on the Stokes General Equation calculation (dimensionless)
 D          Vessel Diameter (ft)
 Dgio       Droplet of Gas in Oil (ft)
 Doig       Droplet of oil in gas (ft)
 Doiw       Droplet of Oil in Water (ft)
 Dp         Diameter of the Droplet in the dispersed phase in the Reynolds number calculation (ft)
 Dwio       Droplet of water in oil (ft)
 g          Gravitational Constant (32.2 ft/sec2)
 H          Heightof Vessel (ft)
 Hg         Height of the gas space (ft)
 Hl         Height of Liquid (ft)
 Hsd        Difference in Height between the High or Low shutdown and height of Liquid (ft)
 Ksb        Souders Brown Coefficient (ft/sec)
 L          Vessel Length (ft.)
 Ml         The percentage of area available for liquid in a horizontal vessel expresses as a decimal
              (dimensionless)
 Mo         The percentage of area available for oil in a horizontal vessel expresses as a decimal
              (dimensionless)
 Mw         The percentage of area available for water in a horizontal vessel expresses as a decimal
              (dimensionless)
 Qg         Gas Volumetric rate (ft3/sec)
SPE-173598-MS                                                                                        21
Acknowledgement
The author would like to thank Mahmood Mosphfegian for his help in both reviewing formatting the
paper.
References
     1. Glaso Dead Oil Correlation; PetroWiki published by SPE International
     2. Arnold, K. and Stewart, M. 2008, Surface Production Operations Vol 1, third edition, Burlington
        Ma. : Gulf Publishing
     3. Manning, F and Thompson, R. 1995, Oilfield Processing Vol 2 Crude Oil, Tulsa Ok. : Penwell
        Corporation
     4. Lapple, C. 1950, Chemical Engineers’ Handbook, Ney York, NY : McGraw Hill
     5. Engineering Data Book Vol 1, 1987 tenth edition, Tulsa Ok., Gas processors Association
     6. Specifications for Oil and Gas Separators, API Specification 12J, 1989 seventh edition, Wash-
        ington DC, American Petroleum Institute
     7. Specifications for Vertical an Horizontal Emulsion Treaters, API Specification 12L, 1987 third
        edition, Washington DC, American Petroleum Institute