Designing oil and gas production systems How to size and select two-phase separators Ken Amold, Senior Project Engineer, Paragon Engineering Services, Ine., Houston, and Maurice Stewart, Jr., Re: gional Petroleum Engineer, Minerals Management Service, Metairie, La. 20-second summary Although there are many varieties of two-phase sepa- rators, most oil field units are conventional designs, bull in horizontal or vertical configurations. Horizontal ‘saparators ate more size-efficiont than vertical types, but have limited surge capability and are sometimes auvkward to fit onto offshors platforms. Vertical separe- | tors often are specified for high or low GOR applice- | tions. Both configurations employ similar hardware, in- | cluding inlet diverters, mist eliminators and voriex breakers. Authors provide formulas for liquid drop ve- locity, drop diameter and liquid retention time as well as step-by-step procedures for selecting both horizontal and vertical units. Tables simplify calculations and ves- sal sizing. PRODUCED WELLITKAD FLUIDS are complex mixtures of hydrogen and carbon compounds with differing densities, vapor pressures and other characteristics. ‘The wellstream undergoes continuous pressure anc temperature reduction sit leaves the reservoir, Gases evolve from liquids, water vapor condenses and part of the well stream changes from a liquid to bubbles, mist and free gas. Gas carries liquid bub= bles and the liquid carries gas bubbles. Physical separation of these phases is one of the basic operations in production, processing and treatnient ef cil and eas. Oil and gas separators mectianically separate liquid and. ges components that exist ata specific temperature and pre sure, for eventual processing into salable items. A separation vessel normally is the initial processing vessel in any facility, and improper design of this component ean Boltlouck and re, duce capacity of the encire facility Separators are classified as two piase if they separate gas from the total liquid stream and dre phase if they also sepa- fate the liquid stream into its crude oil and water compo eats, This article deals with two-phase separators. [n addi- tion, it discusses requirements of good separation design and how various mechanical devices take advantage of physical the produced siream to achieve good separation. Separators are sometimes called gas scrubbers when the ra: fio ol gas raic to liquid rate is very high. Some operators use the term traps 10 designate separators that handle flow di rectly from wells. In any case, they all have the same confi uration and are size in uccordzmee with the same proce: dures. EQUIPMENT DESCRIPTION | Horizontal separators. Fluid enters the separator (Fi Cpcesa si Fig. 1—Horlzontal separator employs tour basio machaniems to Ib ‘exaie oes from lguld. Inlet Gverter imposes a surksen direction ang moienium change on the flonsiream, causing neavier Nquics to ‘drop out, Grevity settling soction crovides opporturity for sree srepate jo iaave gas stream, and mislenrator colesces weaning liquids as gas exis vassel. In accition, entrained ges eccapes in lq. uid collection section. mentum and the initial gross separation of liquid and vapor, Gravity causes liquid droplets to fall out of the gas stream to the' bottom of the vessel for collection. This liquid collection section provides retention time required for entraised gas (0 evolve out of the oil and rise to the vapor space. It also pro- vides surge volume, ifnecessary, co hancle intermittent slugs of liquid. Liquid then leaves the vessel through the liquid dump valve, which is regulated by a level controller. The level controller senscs changes in liquid level and controls the dump valve accordingly. Gas flows over the inlet diverter and then. horizontally through the eravity setting section above the liquid. As gas flows through this section, small drops of liquid that were not separated by the inlet diverter are separated by gravity and fall to the gas-liquid interface. Some drops are of such small diameter that they are nox easily separated in the grav- ity settling section. ‘Thus, before gas leaves the vessel, it passes through a coalescing section, or mist climinator. This section employs vanes, wire mesh or plates 10 coalesce and remove the very small droplets. A controller opens and closes the pressure control valve at the gas outlet to maintain desired vessel pressure, Normally, horizontal scpazators are operated half fall of liquid to maxi. mize the gas-liquid interface area, Vortical separators, Fig. 2is a schematic of a vertical separa- (or: In this configuration inlet flow encers the vessel through the side, As in the horizontal separator, the inlet diverter does the initial gross separation. Liquid flows down to the liguid eollection section of the vessel, then down to the liquid, outlet. As liquid reaches equilibrium, gas bubbles flow counter to the direction of liquid flow and eventually mi- grate to the vapor space. The level controller and liquid dump valve operate in the same manner as in a horizontal separator. Ckk Fier cheb Fak WES eT easTiusgne riarace auld collection ‘eaten Fig. 2—Vertcal separators effective in low or very High GOR api- fans ara often ined on oven lets rors osoe 9530618 at Sperm, > Fig. 3—Spherical separator can be thought of asa vertical separator ‘without a eylindrical shell otweer the two heads, Bocause of inted Sarge copay and laostonciteates, sich Soperators tc Ho usein tne of eld, downward, counter 19 gas flow. Gas goes through the coalescing/mist extractor section before leaving the vessel. Pressure anc level are maintained as in @ horizontel separa: Spherical separators. Atypical spherical separator is shown ii fig. 3 The same fou Sections described previously are preset in this ves. Spherical separators can be consigered Ripecal cate of vertical separators witout cylindrica! sell between the two heads. This design my be very elicit froma preure comuainizent standpoint, ove becatse of im Hed liquid surge, capability and fabrication dificulties, Spoercal separators are no longer specified for ol field ape Clvons and wil not be cacoaned father Other configurations. Some separators operatc by eentrifi- gal Jorce. Although centrifugal separators are space-efficient, they are not commonly uscd in production operations be- cause they are sensitive to flowrate and require greater pres- sure drops than the standard configurations, ‘Another type of separator used in certain high-gas/low- liquid flow applications isa jill separatr "These can be either: horizontal or vertical in configuration. Fig. 4 shows a hori- zontal design. Filter tubes in dhe inidal separation section €o~ ‘alesce liquid mist into larger droplets as gas passes thromgh the tubes. A secondary section, consisting of vanes or other scatiih ecttemrtcw dhomamana: dlactieime viseiaak GADMMIBAR CEBEAeE.- Fig, 4-—F lr separate car rrove all pats lego han aut: Imigions and 9269 of hose as siral as 0.5 micron. These unis, als. Available in vertical conf guratione, ere used at comprossorinlots ane inaiher high GOR applications. ‘§-—Double-barral seperators isolate colacted iguids In lowe {9 plevent gas re-enlrainrent during surges. Configuration rarely seen today eines fi expeneive to buld and advamagos st more theoretical than prectical ‘ ‘This vessel can remove 160% of all particles larger cha about 2 microns and 99% of those down to about 0.5 m cron, Filter separators are commonly used on compressor it Jets in field compressor stations, as final scrubbers upstreat of gyleol contact towers and in instrument/fuel gas applic: tions. Design is proprietary and dependent upon type of fi, ter clement employed. ‘Two-barrel separators were common at one time. In the: designs ges anc! liquid chambers ace separated as shown i Fig. 9. Flow enters the vesse] in the upper barrel and strik the inlet diverter, Free liquid fall to the lower barrel throuc a llow pipe. Gas flows through the gravity seiting sectic and encounters a mist extractor enroute to the gas outle Liquids drain through a flow pipe into the lower barre Sinall amounts of gas entrained in the liquid are liberated the liquid eolleetion barrel and flow up through the flo pipes. In this manner, liquid accumulation is separated fro: the gas stream so that there is no chance of gas surges {lov ing over and re-entraining the liquid. Tworbarrel units a no longer widely used because of their additional cost ar because of the absence of problems with single-barrel separ. tors For applications in which there is very litte liquid flow horizontal separator often. will include a liquid sump on ‘outlet end to provide required liquid retention time, This ‘eelta isi a wnalice Gvevall vented diameter,Fig, 6—Datiecor battle separates oll and gas by forcing dlrsctionel and velocity changes on flowstroam. Cyclone inlet achieves same ro suttwith eantifugal farce. HORIZONTAL VERSUS VERTICAL Horizontal separators normally are more efficient at han- dling large volutes of ges than vertical types since liquid droplets all perpendicular tothe ges flow inthe gravity set ling seetion, and are moze easily Setiled out ofthe gas cor ‘inuous phase. Also, since interface area ip larger in'a hor zontal separator, fi easier for gaa bubéles, which come out of solution a liquid approaches equilibrium to reach the ver por space Tn terms ofthe gasliquid separation process, horizontal separators would be preferred, However, they do ave draw- backs that could lead to a preference fora Vertical separator in certain situations * Horizontal separators do not handle solids as well as vertical separators, The liquid dump on a vertical separator can be placed at the center of the bottom head so that solids, which would otherwise build up in the separator, can be passed to the next vessel in the process. As an alternate, a drain can be placed at this location so that solids could be disposed of periodically, while liquid leaves the vessel ct a slightly higher clevation. It is necessary to place several drains along the length of a horizontal vessel and since solids hhave an angle of repose of 45° to 60°, drains must be spaced at very close intervals. Attempts to lengthen the distance be- {ween drains, by providing sand jets te fluidize solids while drains are in operation, are expensive and have been only marginally successful in the field ‘¢ Horizontal vessels require more plan area than equivar len veri! vesea Wile his nay not be of mportarse for land locations, it can be very important offshore. © Horizontal vessels have less liquid surge capacity. For a given change in liquic surface elevation, there is typically & larger increase in liquid volume for a horizontal separator than for a vercical separator sized for the same flowrate However, horizontal vesse! geometry requires the high level shutdown device to be located close to the normal operating, level. In a vertical vessel, the shutdown can be placed much, higher, allowing the level controller and dump valve more time to react to the surge, In addition, surges in horizontal vessels can create internal waves that eould activate the shut- ‘own device. Ik should be pointed out that vertical vessels also have non-process-related drawbacks that must be considered in making a selection, including: «© Relief valve and some controls may be difficule to ser- vice without special ladders and placorins * Vessel may have to be removed from its skid for truck- ng due to height restrictions, Overall, horizontal vessels are more economical for nor- ‘ual oil and gas separation, particularly where there may be oblems with emulsfons, foun or high gas ol aos, Verte sal vessels work more eflectively in. cither love or very high BER gnedinalinne: sash ai stckteccs, Fig. 8 Vertex breaker hep prevent gas fe-entrainment when lsu sonirol valve opens. VESSEL INTERNALS Inlet diverters. Fig. 6 shows two basic types of diverters that are commonly used. The firstis a dejledor baffle. This can be a spherical dith, flat plate, angle iron, cone or about any cb= struction that will accomplish an abrupt change in fluid di rection and velocity. The design of the balfle is governed principally by structural supporis required to resist the im- pact-momentum load. The advantage of devices such as the half sphere or cone is that they eveate less disturbance than plates or angle iron, cutting down on re-entrainment and emulsification problems ‘The second device shown is a cyclone inlet that uses centeif- tugal force, rather than mechanical agitation, to disengage oil and gas. This inlet can have a eyelonie chitnney, as shown, ‘or may use a tangential fluid race around walls. Designs are proprietary, but most use an inlet nozdle sized to create a Fluid velocity of about 20 fps around a chimney whose diam= cter is wwo-thirds the vessel diameter. Wave breakers. In long horizontal vessels it is necessary to install wave breakers, whieh are simply vertieal baffles span sing the gas-liquid interface perpendicular to the flove Dofoaming plates. Hoam a: the interface may occur as gas bubbles break out of the liquid. Foam can be stabilized with addition of chemicals at the inlet. Often a more effective s0- lution is to force foam to pass through a scrics of inclined Pzallet plates or tbes Fig. 7) that help coalesce the ube les. vod! idea to include a sime &, to prevent a vortex Vortex breaker, It is normally a ple vortex breaker, as shown in Eee NOveN Organs, a8 sown fhFig. 9—Thios popular mist al minator designs are wire mesh pads, vane eliminstors and arch plates. Wire mean i leeet expensive, but Yelbely genstive. Vane elfminatore impose laminar fow anc direc. ‘Tonal changes on gas stream. Arch plates, conssting of evincars of Detrugated piao, function much lks vane-ype eliminator, vortex could draw gos out ofthe vapor space and re-entrain Jin the liquid one iit ellminater. Fig. 9 shows three of the most common mise extraction devices: wire mesh pads, arch plates and vanes. A. tine sh pad ie made of finely woven mats Of states stecl crite wrapped into. tighlly packed eyinder. Liquid droplets impinge on the thatted whren and coalesce. Effeciveness of wire mesh depends largely on gas being in the proper veloc- ity range. If velocities are too high, liquids knocked out will bd ferentrainel, If velocities are lem, vapor just drifix through the mesh element without droplets impinging. and coalescing. Construction is often specified by calling for a certain thickness (nsvally3 to 7 ny) and mesh density (usually 10 %0 12 Tbfie), Experience indicates that a properly sized wire meth eliminator can remove 99% of idamicron and larger roplete, Although vsire mesh elimina:ors are inexpensive, they ate rove casly plugged than other types. Tene eiminatrs force gas flow to undergo. directional changes ar it passes between parallel plates: Droplets im- pinge on plate surfaces, coalesce and fall to a liquid collect- Ing per for routing tothe liquid collection accion ofthe vee- Se) Wane-type elhminators are sized by their manufacturers to atsure a cercain minimum pressure drop. ‘Arch pats are corragated concentric cylinders arranged so that gas impinges on the corrugations anc coalsces Contig! must eliminairs separate hqvid drops by eenteif sal force. These can be more efficient than eituer wire mesh Sr mist eliminators, ard sre the lenst susceptible to plugging, Fiowever, they are notin common use in producsion 02ere tions because cemoval efficiencies exz sensitive t sal changes in flow. In addition, they require relatively large presuce drops to create the centrifugal force THEORY Settling, Liquid drops will setde in the gravity seitling sec mn at a velccity determined by equating gravity force on the drop with drag force caused by its motion relative to the gas ‘continuous phase, ‘Drag force is determined from the equation: Fo = CoAp(V*/2g) o Drag foree Drag coefficient ‘A = Cross-sectional area of drop p= Density of continuous phase Velocity of drop Gravitational constant. If flow around the drop were laminar, then Stokes’ Law ‘would govern and: Gp = 2K, @ Where R, = Reynolds number. Tt-can be shown that in such a gas, drop setding velocity would be given by V = [1,78 « 10-*(48.6.\4,Vu a Where AS.G. ~ Difference in specific gravity, eelative © water, between drop and gas d,, = Drop'diameter, micron i = Viscosity of gas, ep. ‘Unfortunately for production facility design, it can be shown that Stokes’ Law does ast govern, and the following more complete formula for drag coefficient must be uses: lp = (RHR) + GIR) + 0.34 ® Equating drag and buoyant forees, seuling velocity is given by: ¥ = QO119[(4/Co)(e: ~ Py)ing]”® & Where py = Density of liquid, bf?” Py = Density of gas ar separator temperature and pres sure, Ibe, Eqs. 4 and 5 can be solved by am iterative solution Drop size, The purpose ofthe vessel's gas separation section is to condition gas for final polishing by the mist eliminatcr From field experience, it appears that if 100-micron dropt are removed in this section the eet eliminator wil not Be Come flooded arid will be able to remove those drops be tween 10 and 100-micron diameter, ‘Gas capacity design equations in this article are all based oon 100-mierom removal In some cases, this wil give a0 Overly conservative solution, Techniques used here can be ‘modified easly for any deop size. Retention time, Liquid must be held in the separator fora certain time for gas and liquid to reach equilibrium undet pressure. Retention dane is defined es the averag: time a molecule of liquid is retained in the vessel under pu Foye Thus, retencion cme is the volume of liquid storage vieled by liquid flowrate For most applications, retention times of 30 sec 10 3 mis are suificient. When foaming crude is present, retentic mes up to four times longer may be needed. SEPARATOR SIZING Horizontal separators. ‘Ib size = horizontal separator, it necessary to choose seam-to-searn vessel length and a di ter. This choice must satisfy conditions for gas capacity allow liquid drops to fall from the gas to the liquid volume: gas traverses the effective length of the vessel, The desi ust also provide sufficient retention time to allow liquid reach equilibrium. For separation of 100-micron liquid drops in a vessel 50Fig, 10—Chart prove anproxmate vals for des gn constant K. Sylecpoatia groiy of ge er = 4) Pispossure, sis end is ore Brat, “Urol demote of 100 mfsore sasino full of liquid, the following equations apply: Gas capacity Dilg = 22KC7RYP) © Where Pi + Mosel 1D ins s ive len vessel where separation Md ~ Goes Ch dow Bria nea oa outlet nozzle location, effective length ean be approximated as at 0.75 times the aeam-to- G2 Sota een = Se ee a ei ete tie K = [Coldydo,on ~ 6,3)" @ vtass ¢, < meee SHEE, cad in elie 2: eee art oi Revere i ale todos cuca xcs Liguid capacity fi | Déby = T.Qu/0.1 q @) Where, = Desired retention time for liquid, min @; = Liga flowrate, bpa arators require a minimum diameter to allow Liquid drops to separate kom vertically moving gar. "The liq uid retention time reqviitement specifies a combination of cl- ameter and liquid volume height. Any diameter greater than minimum required for gaé capacity can be chosen. Gas capacity Di = 500K TRIP) @ Liquid expecty DBA = T,Qs/0.12 (10) Where k= Height of liquid volume, in Seam-to-seam vessel Jength should be determined from the geometry once liquid volume diameter and height are known, ‘As shown in Fig. 11, allowance must be made for the ges separation section, mist eliminator and for any space below ‘he liquid ouder. For screening purposes the following an. proximation has been proven useful Lo = G4 TEN «ay et Fig. 11—For vertical soparato, vertoal space availabe olquis Setimlosean ong oes aps tot mi oaacioy es Sbiion and wut Slareren TABLE 1—Liquid capacity constraint—Vertical separator example 7 3 i a i im ® 2) Lo, a 23) 008 ae oa 2 se Ho oh \ gs) ane 38 32 Sieeo cH a 2 BBE lee 2 a are We \ 58 5 300 3 as 3 287 as 23 i 2 fag . 38 1 & 2s i aa 2 as m 2 & ee ta 25 EXAMPLES Sizing a vertical soparator, Give: Flowmnte is 10 MMscid of 0.5 specific gravity gas and 2,000 bpd of 40°API oil. Operating pressure is 1,000 psa and operating eanperatute is 60°F, Selation # Calculate & SPIT ~ (0.6)0,000/(460 + 60) = 1.1598 Prom Fig. 10, & = 0,903 © Gas capacicy constraint DP = 900 (FQUP) = (500),0.303)1620}(10y (1,000) D = tin, © Liquid capacity constraint Dib = (Tig, 0.12 cominFig. 12—Itie holptul to construct e graph basoc on comp.ted valuse ‘nal sizing selection. This graph, drawn fort eon vertical separator sizing, indicates that a S6-n diameter by 1Oft-Iong \veseel wil provido retoivon time (T) of mare than © mi sepatalon, shons tial a 80 Fig, 19—Graph drawn or a borizon bj 0st separator wil give about 2.Srn cud retention time. Note ‘tat in tno horizontal vassel axampo tho gas capaatty dose nct co. Combinations of:D, A and Ly. for various 7, values are computed (Table 1). Next, the slendernen ratio (12 Z, /D) is caletlated. Choices in the range of 8 to 4 are most comrcion (Tabie 3), Plot results and choose a.reasonatle size with a diameter greater than that determined by gas capacity line, fg 12: en this emer, = S6vin, by TOR separator provioes igbily more than 3 min recention time, a 30-in, by 10-f separator provides about 2 min and a 36in. by 7'-fe vessel provides about 1 min Sizing # horlzontal separator. Givex: Flowrate is 10 MMIscfa of 0.6 specific gravity gas 22,000 bopd of API ol. Operating presure is 1,600 psia and operating temperature is 60°F Solution © Calculate K TABLE 2—Gas capacity 1 constraint—Horizontal separator example a Le Lae in ® it 16 ait 3a 2 303 408 2a 206 357 ‘TABLE 3—Liquid capacity i constraint—Horizontal separator example 5, D ; In wt 2) ts 3 PI 128 29 ot 2 tr Br 28 Fok 23 2 8s 3 2 & 12 oe i Ba 3a s 53 20 1 Pa bs aa i e re 2a SPIT = (0.6X1,000)(460 + 60) = 1.1538 From Fig. 10, K = 0.303 © Gas capacity constraint Dilyg = (42X0.303)1(620)(10)/(1,000)] = 66.18 © Compute seam-to-seam length for various values of D, (Table 2) and the liguid capacity constraint, (D,)'Lig. Next, compute combinations of D; and L for various 7 and slen- derness ratios, 22, /1); Table 3), Choices in the range of 3 to 4 are common. Plot results and choose reasonable size swith a diameter and length combination above both gas and guid capacity constraint lines, In Fig. 13, a 36-in by 7 ‘or 30-in. by 10-ft separator provides about 2,5 min retention fime,, while « 30m. by Tft vessel provides sigh le than’ 2 min, ‘The authors Ken Amoid 's « senior project engineer for Fer- {agen Engineshg Serves, Heuston, wher ho fis been invohaed ite Gesign, coneustan ‘anagemant ar startup of numb of or Shoe and ef shore feces. Prof ing Par agar 1 {500, ha had 16 years of spoons ‘thi Sl Of a torn sore fly a f\ Girear, project enginees, and fn rasearcin ant! are Gesrg mansgemen if: Arold teaches Pe dhction Facity Dasign and Oparton, which fan mast ae) pevoieun enghsering course a the Univestyof Hater Maurice |. Stowart J Isa regional staff petro." aur enginaer forthe Gulf of Mexico OCS fie. {107 of tha Minorals Management Sarvice (U.S. Department ofthe Interior: @ registered profes: ‘ional engines, an associate professor of pate: eum anginearing at Tulane University and an active member of SPE-AIME, and ADO. He ab- i {tained his BS end MS dogress in chi, mochani- cal end petrolaum anghtesrng from Lousiana ‘State University end his PhO in petroleum engi: nesting tom Tulane University az Stewart's work experience includes eling, well completans and workovers, production facilly design land construc duties onshore end cffshors n bon domestic end foreign arsas. Mr. Stawart has Gone consulting for major compari sorved as an expert yriness on ding end production Issues end fas ‘ugh industry short courses ip various areas of petroleum englnce- ing. Ma is kectuer Ia the SPE Continulng Edueatlon Program