SPE 36647

Separator Design and Operation : Tools for Transferring “Best Practice”

P.N.E.Lawson and L.M.Little, BP Exploration and Operating Co.Ltd., London, UK.

Copyright 1996, Society of Petroleum Engineers, Inc.

This paper was prepared for presentation at the 1996 SPE Annual Technical Conference
performance of a separation scheme. This method can be
and Exhibition held in Denver, Colorado, U.S.A., 6–9 October 1996. used to estimate the performance of a separation scheme and
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, how it will perform over a range of operating scenarios. A
as presented, have not been reviewed by the Society of Petroleum Engineers and are
subject to correction by the author(s). The material, as presented, does not necessarily
parallel activity has been the generation of a Separator
reflect any position of the Society of Petroleum Engineers, its officers, or members. Papers Database which contains both process and design data for
presented at SPE meetings are subject to publication review by Editorial Committees of the
Society of Petroleum Engineers. Permission to copy is restricted to an abstract of not more HP Production separators throughout BPX. The Database is
than 300 words. Illustrations may not be copied. The abstract should contain conspicuous
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, a method by which design and performance data can be
P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435. collated and a means by which operating experience can be
transferred between Assets.
The aim of this paper is to give an overview of these two
Abstract activities and to facilitate further discussion on the potential
Maintaining flexibility in the design of separation systems is for these developments.
a key consideration in coping with the uncertainty in fluid
properties, reservoir performance and production profiles.
There is an increasing need to improve our understanding of Separator Rating Programs
how different separation schemes perform over a range of BP have developed two separator design and rating
operating conditions. This paper outlines two recent programs (PROSEPARATOR and SSA).
approaches that BP Exploration have been developing in the PROSEPARATOR has been used to design separators for
area of separator design and operation. The first addresses new facilities and to provide valuable information on the
the need to understand the ‘operating envelope’ of a design/operation of existing separators. The SSA program
separator. In contrast to the conventional method of sizing a is still under development although it has been used to aid
separator for a number of design cases, the operating range our understanding of oil-water separation issues.
of a separator can be presented as an operating envelope.
This concept will be demonstrated as a potential method for These two programs have been used by BP and our
taking account of reservoir uncertainty and as a means of consultants to
identifying operating flexibility. A parallel development is • evaluate alternative production separation systems for
the construction of a database which captures information new fields
on BP Exploration’s Production Separators. In addition to • check third party separator designs for new fields and
design and current operating data, ‘case histories’, retrofits
incorporating details on retrofits and design changes, are • define the operating envelope of existing equipment
being collected as a means of transferring ‘Best Practice’ in (plant debottlenecking and troubleshooting studies).
separator design and operation across the BP Exploration • extend the operating range of a plant
operating Assets world-wide.
The two programs are described in more detail below. It
Background should be noted that the main aim of the programs is to
Maintaining flexibility in the design of three phase provide a tool for the preliminary assessment of separator
separation systems is a key consideration in coping with the system designs and equipment configuration options.
uncertainty in fluid properties, reservoir performance and
production profiles. There is an increasing need to improve PROSEPARATOR (Gas-Liquid Separation)
our understanding of separation schemes over a range of The gas-liquid separator rating program,
different operating scenarios. In common with other PROSEPARATOR, can be used to size horizontal and
operators there is also a drive to debottleneck existing vertical two phase separators. The key difference between
separation trains as the volumes of bulk fluids to be PROSEPARATOR and conventional separator rating
processed increase through the addition of tie-back methods such as API 12J, is that PROSEPARATOR
production. accounts for the creation of liquid droplets at the inlet to the
separator. Conventional sizing methods use a single critical
The paper outlines the development of the separator droplet size of ca.100 to 140µm to estimate the separator
Operating Envelope and its use to estimate the overall
2 P.N.E. LAWSON, L.M.LITTLE SPE 36647

diameter based on Stoke’s Law. In addition, these methods separator performance.

do not provide the user with any information on the
Flowrates and physical properties are entered, together with
performance of the separator. PROSEPARATOR continues
a PFD describing the process, to allow the shear history of
to use similar critical droplet sizes for separator
the oil/water emulsion to be modeled. Correlations
dimensioning but the main advance is the inclusion of a
developed by Hinze (for shear across valves/orifices) and
droplet size distribution.
Karabelas (for equilibrium droplet sizes in pipes) are used to
In practice, it is known that a range of liquid droplet sizes generate a characteristic droplet size, and a Rosin-Rammler
will exist in the separator due to the shear of the fluids at the distribution is applied to this to give the droplet size
inlet. PROSEPARATOR estimates the liquid droplet size distribution. The separator is modeled using Stokes law
distribution using an empirical correlation which takes into settling only, and droplet-droplet coalescence is not
account the fluid flowrates, physical properties and the modeled at present. The model assumes that all droplets
separator inlet dimensions and configuration. The estimated which reach the interface are separated. The effect of
droplet size distribution is used to determine the gravity emulsion breaking chemicals is modeled by applying a
separation performance of the separator and the liquid carry- factor to the calculated droplet size, based on bottle test
over from the vessel. The program can also estimate the results. Whilst the physical property data required for SSA
performance of separator secondary devices such as mesh can be generated using a process simulator, some test data
pads, vane packs and multicyclone bundles. are required to demonstrate that the operating conditions
selected for the separator (i.e. temperature, dosing of
PROSEPARATOR has been widely used within BP’s
demulsifier chemical) are sufficient for separation to take
operations for a number of years and has clearly
place.
demonstrated benefits for a number of Assets. One of the
main areas in which the program has found increasing value As with PROSEPARATOR, the program has been
is the conceptual design of new separators, including the developed as a spreadsheet for ease of use. The system is
assessment of third-party designs. The program allows a built using macros, allowing the engineer to select the
range of different separator configurations to be quickly process building “blocks” (valves, pipes, pumps etc.) to
assessed, and has demonstrated clear benefits in applications mimic the process. This allows the changes in the droplet
where there is a need to reduce the size/weight/number of size distribution through the system to be modeled, and
separators. In addition, the ability to quantitatively assess a hence separator performance. The building block approach
range of separator options proposed by third parties has also allows the easy addition of new technologies to SSA as
been successfully applied for a number of Assets. This is a they become available.
very powerful concept where the proposed designs can be
The absence of a droplet-droplet coalescence model has
reviewed and the likely separation performance estimated.
been recognized as a limitation for SSA. Coalescence is the
The program has also been successfully applied to a number subject of a JIP managed by IKU SINTEF, in which BP,
of debottlenecking applications where existing separators Shell and Statoil are members. This is intended to develop a
are experiencing operating problems or there is a model for droplet-droplet coalescence.
requirement to estimate the effect of additional fluid
throughputs. Operational data (e.g. measured liquid carry- Operating Envelope: Principle
over) can be rationalized using the program and this The conventional method of sizing a separator for a given
provides a sound basis for forecasting the effect of future application is to size the separator for a number of Design
production rates or the impact of design changes. Cases which aim to cover the likely range of operating
An exclusive license for PROSEPARATOR has been conditions (e.g. Maximum Oil, Maximum Gas etc.) over
granted to AEA Technology - Petroleum Services at field life. The design is based around the results of bottle
Harwell who are now supplying PROSEPARATOR to tests and/or extended well tests (i.e. a snapshot of early field
outside companies. behaviour).
The aim of the operating envelope is to identify the
SSA (Oil-Water Separation) operational range of a separator scheme in terms of the
The traditional methods for designing oil water separators potential fluid throughputs for the required product
are typically based on either a residence time, which is a specifications (e.g. liquid carry-over into the gas and oil-in-
function of crude density and the operating temperature, or water specification).
by using Stokes law and a single droplet size (100 to 140µm
A logical next step that follows from the operating envelope
as with gas-oil separation). Whilst these methods provide
concept is the suggestion that rather than designing a one-
vessel sizes, they are unable to predict the quality of the
off separator, fit-for-purpose, there could be substantial
product streams, or how they will change as operating
benefit in having a standard off-the-shelf unit with the
conditions change.
separation performance described by its operating envelope.
To overcome this, BP have developed SSA (Separation
The development of the Operating Envelope for a typical
Systems Analysis) to model oil-water separation systems.
separation scheme is illustrated below.
As with gas-liquid separation, the approach taken has been
to model the droplet size distribution and use this to predict
36647 SEPARATOR DESIGN AND OPERATION : TOOLS FOR TRANSFERRING "BEST PRACTICE" 3

Concept Development liquid carry-over from the scrubber does not exceed the
A typical ‘element’ of a gas/oil processing system was used typical carry-over limit of 0.1USgal/MMscf.
to develop and illustrate the concept of the system operating The GOR of the feedstream is plotted on the HP separator
envelope for gas-liquid separation (Figure 1). The separator OE (Figure 4) and indicates that the limiting gas flow to
sizes, process flow conditions and physical properties used achieve the required carry-over specification from the HP
in this exercise are typical of separators in current operation separator is 27MMscfd. This gas flow is equivalent to an
(Table 1). This study is based on gas-oil separation to oil production rate of 77mbd.
illustrate a principle but it will be extended to gas-oil-water
separation at a later date. The OE for the HP separator can be combined with that for
the downstream scrubber on the gas outlet as shown in
Construction of Operating Envelope Figure 5. This shows the predicted gas handling capacity of
The following describes the steps used to construct an the scrubber for inlet liquid flows of up to 70USgal/hr (note
Operating Envelope (OE) for the separation scheme detailed change in units). The main limit is to ensure that the liquid
above. PROSEPARATOR was used to generate the carry-over from the scrubber does not exceed the
required gas/oil separation performance data for both the 0.1USgal/MMscf specification. In addition, the liquid
horizontal separator and the downstream vertical scrubber. carry-over rate from the HP Separator are plotted on the
same axes.
Step 1 - HP Separator OE - Gravity Separation It can be seen that the limiting gas flow for scrubber
The first step is the construction of an OE for the HP operation (to the required gas outlet specification) is a much
separator. The curve (Figure 2) shows the gas handling higher 37MMscfd. This indicates that at these conditions,
capacity of the separator for feed oil flows of up to 150mbd. there is spare separation capacity available in the gas
The main performance limit is that the oil carry-over from scrubber. This could be utilized by relaxing the carry-over
the gravity section of the separator can be adequately specification from the HP separator by increasing the gas
handled by the downstream secondary separation device flow until it matches the limiting gas flow of the scrubber to
(mesh pad). maintain the 0.1USgal/MMscf carry-over specification. For
the current example this occurs at an inlet gas flow of
Step 2 - HP Separator OE - Addition of 34MMscfd which gives an optimum oil production rate of
97mbd. The links between the HP separator and
Secondary Separation Device downstream scrubber operating envelopes is summarized in
The next step considers the performance of the HP separator
Figure 6.
secondary separation device. Although there are many such
devices available, a mesh-pad was chosen, given its wide In order to maximize the benefits of this technique a
spread application and the availability of established composite system OE can be developed from the individual
performance prediction methods. The main constraint of operating envelopes as shown in Figure 7. This can be used
mesh-pads is a limiting gas velocity which is a function of to identify the operating boundaries of both the HP
the phase density ratio and the cross sectional area (CSA) of separator and downstream scrubber for a required gas carry-
the mesh-pad; it is less sensitive to the inlet oil loading. If over specification. The impact of different feed GORs on
the inlet gas velocity is exceeded, the probability of mesh- the given separation scheme can be quickly identified and
pad liquid flooding increases significantly and results in a the system limits identified. This is a very powerful concept
severe deterioration in separation performance. that allows different scenarios to be quickly screened and
operating limits identified. Work is continuing on the
The HP separator OE from Step 1 was modified to include
development of the concept with the aim of developing a
typical limits for the performance of a mesh-pad of
software method of generating operating envelopes for
appropriate cross sectional area (Figure 3).
different separator designs and flow conditions.
For this mesh pad flooding limit, it can be seen that the oil
carry-over from the gravity section can always be handled
by the downstream mesh-pad and meet the required liquid
carry-over specification from the horizontal separator. Separator Operation: Separator Database
Another tool currently being developed, aimed at improving
The exercise can be repeated for the vertical scrubber on the the dissemination of data and operating experience across
gas outlet of the separator in order to generate an OE for the the Assets, is the Separator Database. The database is a
complete separation scheme. This is illustrated in the detailed survey of BP Exploration Production Separators,
following worked example. recording the current designs, dimensions and internals of
production separators on both existing and emerging
Worked Example platforms. The database is currently in spreadsheet format,
To illustrate the operating envelope concept, the above and includes design and operating data for all of BP
methodology will be used to the determine the maximum oil Exploration’s production separators. In addition, GORs,
production rate for the scheme shown in Figure 1. The Gas- liquid levels, residence times and API gravities (Figure 8)
Oil Ratio (GOR) of the feedstream will be assumed to be are also being incorporated into the database, in order to
350scf/bbl and the main requirement is to ensure that the establish trends and correlations across the Assets.
4 P.N.E. LAWSON, L.M.LITTLE SPE 36647

The database provides an indication of the range of the data in the database provides some idea of typical
conditions over which the separator can operate, from separator dimensions, for a given set of flow conditions,
design conditions, through current operating conditions, to together with some indication of the more common inlet
assessing whether the separator can accommodate increased devices, secondary devices and internals. Correlations can
operating capacities. It can also be used to compare the then be established, for example, between fluid throughput
performance and internals of similar-sized separating and GORs, inlet nozzle diameter and inlet momentum
vessels on other Assets operating under similar conditions. values, and separator performance with internals and
secondary devices.
The database also includes several case histories of selected
separators. The case histories focus on separators that have
been debottlenecked and capture the changes made to the Conclusions
design and operation of the separator. Details of when and The tools described above facilitate the transfer of
why new internals, inlet devices and/or secondary devices performance data and operating experience across BP. The
were fitted are documented, together with relevant necessity to increase awareness (via Separator Database) is
performance data after modifications. Any operating becoming increasingly important as more Assets are facing
problems encountered during or after modifications are also similar issues with separator debottlenecking.
recorded. The case histories are a valuable method of The Operating Envelope concept can be used to estimate
sharing operating experience and providing feedback on separator performance over a range of operating conditions.
debottlenecking modifications and lessons learnt. The method can be applied to both existing separation
This type of information is also of significant interest to the equipment (identify operating flexibility) and to the
vendors of the internals and secondary devices. The specification and design of new facilities (taking account of
vendors provide the equipment to meet the design reservoir uncertainty).
specifications initially, but often receive little feedback
except when there is a problem or the equipment requires
6.0 Acknowledgements
debottlenecking. Vendors are recognizing the increasing
importance of feedback on the performance of their
The authors wish to thank BP Exploration and Operating
equipment, and the need to increase the interaction and
Company Limited for permission to publish this paper. In
transfer of information between customer and vendor.
addition we acknowledge the advice and assistance of Brian
The database is also a valuable tool in developing the Oswald, Lisa Hunt and Alastair Sinker.
concept of a standard off-the-shelf separator. Analysis of
TABLE 1 SEPARATOR GEOMETRY AND OPERATING CONDITION

HP Separator
Vessel Diameter 2.5m
Effective Length 12.5m
Inlet Nozzle Diameter 12 inch
Liquid Surface Level 50%
Mesh Pad Secondary Device
Vertical Gas Scrubber
Vessel Diameter 3m
Inlet Nozzle Diameter 16inch
Mesh Pad Secondary Device

Liquid Flow Range 0 → 150mbd (no water)

Operating Pressure Range 5 bar
Operating Temperature 60°C
40 API Crude
36647 SEPARATOR DESIGN AND OPERATION : TOOLS FOR TRANSFERRING "BEST PRACTICE" 5

Typical gas/liquid processing element

Dimensions: HP separator Ø = 2.5m L = 12.5m

Vertical gas scrubber Ø = 3m

Liquid flow range 0 - 150mbd Mesh Gas

Pad
Operating pressure 5bar
Vertical Gas
40API crude
Mesh Separator
Pad

Feed NNF
HP
Separator

Liquid

Fig. 1-Schematic of typical Separation Element

Inlet Gas Flow (M M scfd)

Constraints
60 Liquid outlet hydraulic lim it

50 Liquid carry-over spec.

40

30 Liquid Carry-Over Spec

20

10
Max Liquid Capacity

0
0 20 40 60 80 100 120 140 160
Inlet Liquid Flow (mbd)

Fig. 2- Construction of HP Separator Envelope - Gravity Separation

Inlet G as Flow (M M scfd)

Constraints
60 Liquid outlet hydraulic lim it
Mesh pad flooding lim it
50 Liquid carry-over spec.

40 M esh P ad Flooding Limit

30 Liquid Carry-Ov er S pec

20

10
M ax Liquid Capacity

0
0 20 40 60 80 100 120 140 160
Inlet Liquid Flow (m bd)

Fig. 3- Construction of HP Separator Envelope - Secondary Separation

6 P.N.E. LAWSON, L.M.LITTLE SPE 36647

Inlet Gas Flow (M M scfd)

60
Input: 350 scf/bbl GOR

50 Requirem ent: m ax liquid production rate for gas/liquid separation elem ent
and suitable liquid carry-over
40 Mesh Pad : Flooding Limit

27 MMscfd
30 Liquid Carry-Over Spec 1

20

10
Inlet GOR = 350 scf/bbl Max Liquid Capacity

0
0 20 40 60 80 100 120 140 160
Inlet Liquid Flow (mbd)

Fig. 4- Impact of Feed GOR on Separator Operating Envelope

Inlet G as Flow (M M scfd)

60

Liquid Carry-Ov er = 0.1 US gal/M M scf

50
37 M M scfd

40

30

20
27 M M scfd

10
Inlet OGR = HP S ep Liq Carry-Ov er S pec

0
0 10 20 30 40 50 60 70
Inlet Liquid Flow (USgal/hr)

Fig. 5- Construction of Downstream Scrubber Operating Envelope

HP Separator - Operating Envelope Gas Scrubber - Operating Envelope

Inlet Gas Flow Inlet Gas Flow
Increasing
Increasing Liquid C/O Inlet OGR
Liquid C/O Spec.
Spec. M atching
Gas Flows
Liquid C/O
= 0.1 USgal/M M scfd

Inlet Liquid Flow Inlet Liquid Flow

Optimised Oil
Production

Example Case
Optimised gas flow - 34 MMscfd

Optimised oil production - 97 mbd (from 77mbd)

Fig. 6-Summary of Links between HP Separator and Scrubber Operating Envelopes

36647 SEPARATOR DESIGN AND OPERATION : TOOLS FOR TRANSFERRING "BEST PRACTICE" 7

Inlet Gas Flow (MMscfd)

60

50 Inlet GLR
= 350 scf/bbl
40 System Liquid Carrry-Over = 0.1 USgal/MMscf

97mbd
30

Constraint : Constraint :
20
HP Sep Mesh Pad Flooding Limit Scrubber Performance

10

77mbd
Max Liquid Capacity
0
0 20 40 60 80 100 120 140 160
Inlet Liquid Flow (mbd)

Fig. 7-Composite Operating Envelope for Separation Scheme

Case histories. Easily accessible. Pooling in-house

Performance data. Continually updated. experience.

Separator : Inlet Device : Internals : Secondary Device :

Asset, Tag No. Vendor, Type Vendor, Type Vendor, Type

Inlet Nozzle :
Internal Diameter
Separator Dimensions :
I.D., Tan-Tan
Current Operating Conditions :
Gas, Oil, Water Flows
Temperature, Pressure Normal Operating Level
Gas, Oil Densities
GOR
API Gravity
K Factor
Slug Capacity Antifoaming Chemicals : Operating Target :
Residence Time Name, Dosage e.g. 175 mbd by 1999

Fig. 8-Typical Content of Separator Database