EXAMPLE 1: SIZE A 2-PHASE VERTICAL SEPARATOR

JOB SPECIFICATIONS:
GAS
Flow, MMSCFD 12 (shaded cells require input)
MW 22
Temp, deg F 120
Pres, PSIG 600
compressibility factor 0.9
viscosity, cp 0.012
ATM PRES
PSIA 14.7
LIQUID
Flow, BPD 50
specific gravity 0.5
minimum level, in. 8
SEPARATION
remove drops >__micron 150
Flow Character (slug, free, entrained, mist) free liquid
APPLICATION TYPE: intercept
TYPE OF VESSEL: knockout
VESSEL CONFIGURATION: vertical
MIST EXTRACTOR: no

CALCULATIONS:
1. Calculate design specification information
pg = (P+Pa)(MW) 2.41 lb/cu ft
10.73*(T+460)*(z)
pl = 62.4(sp. gr.) 31.20 lb/cu ft
Dp= 0.00003937(micron)/12 0.000492 ft
m=MMSCFD(1e6)(MW) 8.05 lb/sec
379.4(24)(3600)
Qa=m/pg 3.34 acfs
Ql=42W/7.481/86400 0.0032 cu ft/sec
Qm=Qa+Ql 3.34 cu ft/sec
pm=(pl*Ql+pg*Qg)/Qm 2.44 lb/cu ft
2. Calculate minimum diameter for gas capacity
Method 1a: Equation 10 and Figure 8
C
D
Re^2 (Eq. 10) 5464.84
C
D
from Fig 8 1.70
V
t
= (4gD
p
2
(r
l
-r
g
)/3C
D
r
g
)^0.5 0.38 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 39.9 in 3.5 ft
Method 1b: Stokes' Law, Newton's Law, Intermediate
Stokes' Law Stokes' Law Not Applicable
Re = 1488(D
p
V
t
r
g
)/m 227.85
V
t
= 1488gD
p
2
(r
l
-r
g
)/18m 1.546 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 19.9 in 2 ft
Newton's Law Newton's Law Not Applicable
Re = 1488(D
p
V
t
r
g
)/m 111.43
V
t
= 1.74(gD
p
(r
l
-r
g
)/r
g
)^0.5 0.756 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 28.4 in 2.5 ft
Intermediate Range - Iteration Intermediate Range Is Applicable
Trial No. 1 2 3 4 5
Assume C
D
0.34 0.80 0.96 1.00 1.01
V
t
= (4gD
p
(r
l
-r
g
)/3C
D
r
g
)^0.5 0.86 0.56 0.51 0.50 0.50
Re = 1488(D
p
V
t
r
g
)/m 126.82 82.90 75.51 73.84 73.43
Calculated C
D
0.80 0.96 1.00 1.01 1.02
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 35.0 in 3 ft
3. Calculate vessel liquid capacity requirements
Method 3a: Arnold-Stewart
Vessel Diameter, dv 36 in
Residence Time, t 3 min
Liquid Height, h 0.965 in
Lss = (h+76)/12 6.4 ft
Lss = (h + dv + 40)/12 6.4 ft
Vessel height S/S 6.4 ft 6.5 ft
L/D 2.167
Method 3b: Svrcek-Monnery
Vessel Diameter 3 ft
hold up time, t1 3 min
hold up volume, Vh=60Ql*t1 0.585 cu ft
surge time, t2 3 min
surge volume, Vs=60Ql*t2 0.585 cu ft
low liquid level, Hlll 8 in
norm liq level, Hh = Hnll-Hlll = 4*12Vh/pDv^2 0.993 in
high liquid level, Hs = Hhll-Hnll = 4*12Vs/pDv^2 0.993 in
inlet nozzle, dn=(4Qm/(p*60/pm^0.5))^0.5*12 3.99 in
centerline inlet, Hlin-Hhll=12+dn 15.99 in
disengagement, Hd-Hlin=36+dn/2 38.00 in
mist extractor, Hme 0.00 in
Vessel height, Ht=Hlll+Hnll+Hlin+Hdme 63.98 in 5.5 ft
L/D 1.833
Method 3c. GPSA Engineering Databook
Vessel Diameter 36 in
Mist Extractor Depth 0 in
Inlet Nozzle Diameter 4 in
Mist Extractor Btm to Top Seam 0 in
Disengagement Area = Greater of Dv or 24" 36 in
inlet nozzle area, 2*(4Qm/(p*60/pm^0.5))^0.5*12 8 in Time
Level Gauge to Hi-Level SD (12-inch Min.) 12 in 36.3 min
Level Gauge & Controller (12-inch Min.) 12 in 36.3 min
Lo-Level SD to Level Gauge (12-inch Min.) 12 in 36.3 min
Minimum Level 8 in
Vessel height S/S 88 in 7.5 ft
L/D 2.500
Newton's Law Not Applicable
Intermediate Range Is Applicable
6
1.02
0.50
73.33
1.02
EXAMPLE 2: COMPARE 4 METHODS FOR DETERMINING DIAMETER
JOB SPECIFICATIONS:
GAS
Flow, MMSCFD 12 (shaded cells require input)
MW 22
Temp, deg F 120
Pres, PSIG 600
compressibility factor 0.9
viscosity, cp 0.012
ATM PRES
PSIA 14.7
LIQUID
Flow, BPD 50
specific gravity 0.5
SEPARATION
remove drops >__micron 150
Flow Character (slug, free, entrained, mist) free liquid
APPLICATION TYPE: intercept
TYPE OF VESSEL: knockout
VESSEL CONFIGURATION: vertical
MIST EXTRACTOR: no

CALCULATIONS:
1. Calculate design specification information
pg = (P+Pa)(MW) 2.41 lb/cu ft
10.73*(T+460)*(z)
pl = 62.4(sp. gr.) 31.20 lb/cu ft
Dp= 0.00003937(micron)/12 0.000492 ft
m=MMSCFD(1e6)(MW) 8.05 lb/sec
379.4(24)(3600)
Qa=m/pg 3.34 acfs
Ql=42W/7.481/86400 0.0032 cu ft/sec
Qm=Qa+Ql 3.34 cu ft/sec
pm=(pl*Ql+pg*Qg)/Qm 2.44 lb/cu ft
2. Calculate minimum diameter for gas capacity
Method 1: Equation 10 and Figure 8
C
D
Re^2 (Eq. 10) 5464.84
C
D
from Fig 8 1.30
V
t
= (4gD
p
2
(r
l
-r
g
)/3C
D
r
g
)^0.5 0.44 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 37.3 in 3.5 ft
Method 2: Souders-Brown with and without demister
With Demister
K (From Table) 0.18
V
t
=K((pl-pg)/pg)^0.5 0.622 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 31.4 in 3 ft
Without Demister
K (From Table) 0.09
V
t
=K((pl-pg)/pg)^0.5 0.311 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 44.4 in 4 ft
Method 3: Newton's Law Newton's Law Not Applicable
Re = 1488(D
p
V
t
r
g
)/m 111.43
V
t
= 1.74(gD
p
(r
l
-r
g
)/r
g
)^0.5 0.756 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 28.4 in 2.5 ft
Method 4: Stokes' Law Stokes' Law Not Applicable
Re = 1488(D
p
V
t
r
g
)/m 227.85
V
t
= 1488gD
p
2
(r
l
-r
g
)/18m 1.546 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 19.9 in 2 ft
Intermediate Range - Iteration Intermediate Range Is Applicable
Trial No. 1 2 3 4
Assume C
D
0.34 0.80 0.96 1.00
V
t
= (4gD
p
(r
l
-r
g
)/3C
D
r
g
)^0.5 0.86 0.56 0.51 0.50
Re = 1488(D
p
V
t
r
g
)/m 126.82 82.90 75.51 73.84
Calculated C
D
0.80 0.96 1.00 1.01
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 35.0 in 3 ft
(shaded cells require input)
Newton's Law Not Applicable
Stokes' Law Not Applicable
Intermediate Range Is Applicable
5 6
1.01 1.02
0.50 0.50
73.43 73.33
1.02 1.02
EXAMPLE 3: EXISTING SEPARATOR
JOB SPECIFICATIONS:
GAS
Flow, MMSCFD 12 (shaded cells require input)
MW 22
Temp, deg F 120
Pres, PSIG 600
compressibility factor 0.9
viscosity, cp 0.012
ATM PRES
PSIA 14.7
LIQUID
Flow, BPD 50
specific gravity 0.5
SEPARATION
diameter, ft 3

CALCULATIONS:
1. Calculate design specification information
pg = (P+Pa)(MW) 2.41 lb/cu ft
10.73*(T+460)*(z)
pl = 62.4(sp. gr.) 31.20 lb/cu ft
m=MMSCFD(1e6)(MW) 8.05 lb/sec
379.4(24)(3600)
Qa=m/pg 3.34 acfs
Ql=42W/7.481/86400 0.0032 cu ft/sec
Qm=Qa+Ql 3.34 cu ft/sec
pm=(pl*Ql+pg*Qg)/Qm 2.44 lb/cu ft
2. Calculate actual velocity
Vt = Qa/A 0.47 ft/sec
3. Assume C
D
and calculate Dp until converged
Trial No. 1 2 3 4
Assume C
D
0.34 2.14 0.78 1.27
Dp = 3C
D
p
g
V
t
2
/4g(pl-pg) 0.000148 0.000933 0.000341 0.000553
Re = 1488(D
p
V
t
r
g
)/m 20.90 131.82 48.15 78.11
Calculated C
D
2.14 0.78 1.27 0.99
Dp 0.000466 ft
dm 142 micron
(shaded cells require input)
5 6 7 8 9 10 11
0.99 1.12 1.05 1.09 1.07 1.08 1.07
0.000429 0.000488 0.000457 0.000472 0.000464 0.000468 0.000466
60.65 68.90 64.52 66.72 65.58 66.16 65.86
1.12 1.05 1.09 1.07 1.08 1.07 1.07
EXAMPLE 4: SIZE A 2-PHASE HORIZONTAL SEPARATOR
JOB SPECIFICATIONS:
GAS
Flow, MMSCFD 12 (shaded cells require input)
MW 22
Temp, deg F 120
Pres, PSIG 600
compressibility factor 0.9
viscosity, cp 0.012
ATM PRES
PSIA 14.7
LIQUID
Flow, BPD 5
specific gravity 0.5 API 151.5
minimum level, in. 8
SEPARATION
remove drops >__micron 150
residence Time, min 3
Flow Character (slug, free, entrained, mist) free liquid
APPLICATION TYPE: intercept
TYPE OF VESSEL: Inlet sep
VESSEL CONFIGURATION: horizontal
MIST EXTRACTOR: yes

CALCULATIONS:
1. Calculate design specification information
pg = (P+Pa)(MW) 2.41 lb/cu ft
10.73*(T+460)*(z)
pl = 62.4(sp. gr.) 31.20 lb/cu ft
Dp= 0.00003937(micron)/12 0.000492 ft
m=MMSCFD(1e6)(MW) 8.05 lb/sec
379.4(24)(3600)
Qa=m/pg 3.34 acfs
Ql=42W/7.481/86400 0.0003 cu ft/sec
Qm=Qa+Ql 3.34 cu ft/sec
pm=(pl*Ql+pg*Qg)/Qm 2.42 lb/cu ft
2. Calculate minimum diameter for gas capacity
Method 1a: Equation 10 and Figure 8 Souders-Brown
K (From Table) 0.4
V
t
=K((pl-pg)/pg)^0.5 1.381 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 21.0 in 2 ft
Stokes' Law Stokes' Law Not Applicable
Re = 1488(D
p
V
t
r
g
)/m 227.85
V
t
= 1488gD
p
2
(r
l
-r
g
)/18m 1.546 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 19.9 in 2 ft
Newton's Law Newton's Law Not Applicable
Re = 1488(D
p
V
t
r
g
)/m 111.43
V
t
= 1.74(gD
p
(r
l
-r
g
)/r
g
)^0.5 0.756 ft/sec
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 28.4 in 2.5 ft
Intermediate Range - Iteration Intermediate Range Is Applicable
Trial No. 1 2 3 4
Assume C
D
0.34 0.80 0.96 1.00
V
t
= (4gD
p
(r
l
-r
g
)/3C
D
r
g
)^0.5 0.86 0.56 0.51 0.50
Re = 1488(D
p
V
t
r
g
)/m 126.82 82.90 75.51 73.84
Calculated C
D
0.80 0.96 1.00 1.01
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 35.0 in 3 ft
3. Calculate vessel liquid capacity requirements
Leff and Lss for Gas Capacity
Vessel Full - beta 50%
alpha 0.50
dvLeff 102.10
Leff 2.91
Lss 5.9 6 ft
Leff and Lss for Liquid Capacity
d^2*Leff 21.4
Leff 0.02
Lss 0.02 0.5 ft
Lss 6
Lss/Dv 2
(shaded cells require input)
Stokes' Law Not Applicable
Newton's Law Not Applicable
Intermediate Range Is Applicable
5 6
1.01 1.02
0.50 0.50
73.43 73.33
1.02 1.02
EXAMPLE 4: SIZE A 3-PHASE HORIZONTAL SEPARATOR
Gas Flowrate (MMSCFD) 12.00 Gas MW 22
Oil Flowrate (BOPD) 500 Oil S.G. 0.5
Water Flowrate (BWPD) 500 Water S.G. 1.1
Total Liquid (BPD) 1000.00
ATM Press. 14.7
Op Press (psig) 600.00
Op Temp (F) 120
Gas Compressibility Z 0.90
Retention Time (min) t 3.00
Remove drops >__micron from gas 150
Remove H2O drops >__micron from oil 500
Remove oil drops >__micron from H2O 200
Vessel Liquid Level - beta 50%
1. Calculate design specification information
rg = (P+Pa)(MW) 2.41 lb/cu ft
10.73*(T+460)*(z)
rl = 62.4(sp. gr.) 31.20 lb/cu ft
rw = 62.4(sp. Gr H2O.) 68.64 lb/cu ft
Dp= 0.00003937(micron)/12 0.000492 ft
Dw= 0.00003937(micron)/12 0.001640 ft
Do = 0.00003937(micron)/12 0.000656 ft
m=MMSCFD(1e6)(MW) 8.05 lb/sec
379.4(24)(3600)
Qa=m/rg 3.34 acfs
Ql 0.0325 cu ft/sec
Qw 0.0325 cu ft/sec
Qm=Qa+Ql+Qw 3.40 cu ft/sec
pm=(rl*Ql+rg*Qg+rw*Qw)/Qm 3.32 lb/cu ft
Fractional area of liquids - alpha 0.50
2. Calculate C
D
and min diameter
Trial No. 1 2 3
Assume C
D
2.01 1.22 1.06
V
t
= (4gD
p
(r
l
-r
g
)/3C
D
r
g
)^0.5 0.35 0.46 0.49
Re = 1488(D
p
V
t
r
g
)/m 52.16 67.07 71.69
Calculated C
D
1.22 1.06 1.03
Minimum dia.= 12*(TZQ
g
/2.4V
t
(P+P
a
))^0.5 35.1 in 36
3. Determine the fractional height of water in the vessel
Fractional area of water aw=atQw/t(Qw+Ql) 0.250
Fractional height of water bw 0.298 change until above matches below
Fractional area of water aw 0.250
4. Calculate max vessel diameter for water settling
Vtw = 1488gDw2(pw-pl)/18ml 0.03 ft/sec
Max Height of Oil Pad, Ho 57.93 in max
Maximum diameter = Ho/(b-bw) 287 in max
5. Calculate max vessel diameter for oil settling
Vtw = 1488gDw2(pw-pl)/18mw 0.0429 ft/sec
Max Height of water, Hw 92.68 in max
Maximum diameter = Hw/bw 311 in max
Maximum Vessel Diameter 287 282
6. Calculate vessel gas and liquid capacity requirements
dvLeff (for gas capacity) 102.12
dv^2*Leff (for liquid capacity) 4286
7. Determine appropriate diameter and S-S length
Diameter (in) 36 42 48
Leff (gas) 2.84 2.43 2.13
Lss (gas) 5.84 5.93 6.13
Leff (liquid) 3.31 2.43 1.86
Lss (liquid) 4.41 3.24 2.48
Lss (ft) 6 6 7
L/D 2.00 1.71 1.63
Gas Viscosity m 0.012 cp
Oil Viscosity ml 10 cp
H2O Viscosity mw 1 cp
4 5 6
1.03 1.02 1.02
0.49 0.50 0.50
72.89 73.20 73.27
1.02 1.02 1.02
in
change until above matches below
in
54 60 66
1.89 1.70 1.55
6.39 6.70 7.05
1.47 1.19 0.98
1.96 1.59 1.31
7 7 8
1.44 1.40 1.36