1 of 26

Calculation Cover Sheet

JOB NO. CALCULATION NO. REV. PAGE NO.

JU-11805D JU-11805D-CAL-P-009 B
CUSTOMER
NAME: Ithaca Energy

CONTRACT
NAME: Greater Stella Area Development

CTR TITLE: CTR

Equipment Sizing for Datasheet Production No.

Calculation Summary
CALCULATION LP Separator, V-0152, Sizing Calculation
TITLE :

FILE REF : 'file:///conversion/tmp/activity_task_scratch/ CRITICALITY

LEVEL :
828736343.xls'#$CalcCover
AIM / OBJECTIVE:

Calculate vessel dimensions, required nozzle sizes etc and equipment information for datasheet
generation.

ASSUMPTIONS:

1.
2.
3.

REFERENCES (INCLUDE REVISION / AMENDMENT / EDITION NUMBERS / SOFTWARE USED):

1. H&MB Case Jan 2015; FPF1-ST-G00001-B-CAL-0012

2. H&MB Cases Jan 2014/16/17/18/19/20/21 (7 off); FPF1-ST-G00001-B-CAL-0011/13/14/15/16/17/18
3. FPF1-ST-G00001-B-CPID-0009 Rev B01 Crude Oil, LP Separator
4. Stella, Harrier & Hurricane Development Production Chemistry Issues, STE-XS-IT-PC-RE-0001, Rev D1
5. STE-HO-EP-MD-SP-0001 Function Spec. Updated Table 4.1 (TQ-XXX) Peak Capacity Design Requir'mts

RESULTS AND CONCLUSIONS:

1. Separator Sized for an Oil Inlet Flowrate of 25,000 bbl/day which includes a 0 % design
2. margin.
Oil, Gas and Water Inlet Flowrates are 118,923; 16,311 and 573 kg/hr respectively.
3. Oil viscosity taken as approximately 2.8 cP.
4. Separator Dimensions are 2.59 m in diameter and 7.50 m T/T.
5. Allowance for Slug Volume of approximately 1.4 m3 equal to approximately 10 % of vessel
6. volume.
Separator Inlet and Gas Outlet Nozzle Sizes are 16 inch and 10 inch respectively.
7. Design Pressure and Corrosion Allowance are 3.5 bar(g) and 3.0 mm respectively.
8. Vessel Weight (Dry) is approximately 5,783 kg including a margin of 20%.
9. Vessel Weight (Operating) is approximately 26,898 kg.

© Petrofac Engineering Ltd Business Management System

 2 of 26

Revision History

Self Checked
Sign In-Discipline Check Approval Check
Rev. Reason for Revision
Date Sign Date Sign Date
A Original MHT 26/01/12 RL 26/01/12

B Weight Reduction Update GPM 15/06/12 AG 15/06/12

C H&MB Reissue 05/07/2012

© Petrofac Engineering Ltd Business Management System

 3 of 26

Calculation Sheet
JOB NO. CALCULATION NO. REV. PAGE NO.
JU-11805D JU-11805D-CAL-P-009 B
CUSTOMER
NAME: Ithaca Energy
CONTRACT
NAME: Greater Stella Area Development

Ref. CALCULATION Rev.

A. SIZING: LP Separator, V-0152

B. HYSYS Model Data Used:

Production Year Gas Oil Water Total

Stream 0114 0117 0123 -
kg/hr kg/hr kg/hr kg/hr
(2) 2014_01 11 Bar(a) 8,989 129,087 55 138,131
(1) 2015_01 11 Bar(a) 17,603 128,340 618 146,561 (Sizing Case)
(2) 2016_01 11 Bar(a) 10,363 87,396 408 98,167
(2) 2017_01 11 Bar(a) 7,113 64,175 286 71,574
(2) 2018_01 11 Bar(a) 2,919 30,892 107 33,918
(2) 2019_01 11 Bar(a) 2,245 23,144 65 25,454
2020_01 11 Bar(a) 1,345 15,453 24 16,822
2021_01 11 Bar(a) 1,238 12,851 26 14,115

C. OPERATING CONDITIONS AND FLUID PARAMETERS:

(1) Operating Pressure = 2.0 bar(a)

(3) Design Pressure = 3.5 bar(g)
(1) Operating Temperature = 85 °C

(1) Oil Mass Flowrate = 128,340 kg/hr

= 26,980 bbl/day
(1) Water Mass Flowrate = 618 kg/hr
97 bbl/day
(1) Vapour Mass Flowrate = 17,603 kg/hr
= 8,450 STD m3/hr
= 7.2 mmscfd
Total Flow = 146,561 kg/hr

Total Liquid
Composition %mass %mass
Oil = 87.6 99.5
Water = 0.4 0.5
Vapour = 12.0
Total = 100.0 100.0

(1) Oil Density = 718.0 kg/m3

© Petrofac Engineering Ltd Business Management System Form: PEL-BMS-STF-X-1252 Rev 0

 4 of 26

Calculation Sheet
JOB NO. CALCULATION NO. REV. PAGE NO.
JU-11805D JU-11805D-CAL-P-009 B
CUSTOMER
NAME: Ithaca Energy
CONTRACT
NAME: Greater Stella Area Development

Ref. CALCULATION Rev.

(1) Water Density = 960.0 kg/m 3

(1) Vapour Density = 3.3 kg/m3 (Calculated)

(1) Gas Molecular Weight = 48.0 kg/kgmole

Gas Constant, R = 8.314 kJ/kgmole K
(1) Compressibility, Z = 0.975 -

Inlet Mixture Density = 26.6 kg/m3

Inlet Liquid Density = 718.9 kg/m3

(4) Oil Viscosity = 2.8000 cP

(1) Water Viscosity = 0.3300 cP
(1) Vapour Viscosity = 0.0100 cP

J. SIZING FLOW RATES:

Required Gas Flow Rate = 0 mmscfd

Pro Rating Factor for Required Gas Flow Rate = 0.00 -

(5) Required Oil Flow Rate = 25,000 bbl/day

Pro Rating Factor for Required Oil Flow Rate = 0.93 -

Pro Rating Factor Required 0.9

Design Margin = 0%

Oil Mass Flowrate = 118,923 kg/hr

= 25,000 bbl/day
165.6 m3/hr
Water Mass Flowrate = 573 kg/hr
= 90 bbl/day
0.60 m3/hr
Vapour Mass Flowrate = 16,311 kg/hr
= 7,830 STD m3/hr
= 6.6 mmscfd
4,930.8 Am3/hr
Total Flow Rate = 135,807 kg/hr

K. SLUG VOLUME:

Assumed Length of Slug = 123 m

© Petrofac Engineering Ltd Business Management System Form: PEL-BMS-STF-X-1252 Rev 0

 5 of 26

Calculation Sheet
JOB NO. CALCULATION NO. REV. PAGE NO.
JU-11805D JU-11805D-CAL-P-009 B
CUSTOMER
NAME: Ithaca Energy
CONTRACT
NAME: Greater Stella Area Development

Ref. CALCULATION Rev.

(3) Diameter of Inlet Piping = 16 in.
Slug Volume Calculated = 15.98 m3
Slug Volume Factor = 10% -
Slug Volume Allowance = 1.39 m3

L. LIQUID-LIQUID INTERFACE DETAILS:

Maximum liquid-liquid interface height HIL = 28.96 % of diameter

Weir Height = 0.950 m
Weir Position from Tan = 0.750 m
HHILL to Weir 0.100 m
HIL to HHILL = 0.100 m

Minimum LIL = 0.350 m

Allowance for Sand Collection = 0.100 m
Estimated LIL = 0.450 m

Interface low-low to interface low (LLIL to LIL) = 0.100 m

Water outlet nozzle minimum = 0.100 m

M. VAPOUR-LIQUID INTERFACE DETAILS:

Maximum Vapour Liquid Interface Height HHLL = 71.43 % of diameter

HHLL to HHHLL = 0.100 m
HLL to HHLL = 0.100 m
LLL to HLL = 0.600 m
LLLL to LLL = 0.100 m
Minimum Distance LLLL to HIL = 0.300 m

N. VESSEL SIZING PARAMETERS:

Minimum Oil Residence Time = 5 mins

Minimum Water Residence Time = 5 mins
Vessel L/D ratio = 2.9 -

Estimated Vessel Diameter = 2.59 m

= 8 6 ft in

P. DROPLET CHARACTERISTICS:

© Petrofac Engineering Ltd Business Management System Form: PEL-BMS-STF-X-1252 Rev 0

 6 of 26

Calculation Sheet
JOB NO. CALCULATION NO. REV. PAGE NO.
JU-11805D JU-11805D-CAL-P-009 B
CUSTOMER
NAME: Ithaca Energy
CONTRACT
NAME: Greater Stella Area Development

Ref. CALCULATION Rev.

Maximum Water Droplet Size = 300 μm

Maximum Oil Droplet Size = 150 μm
Liquid Droplet Terminal Velocity Margin = 100 %

Q. THREE PHASE SEPARATOR CALCULATION OUTPUT:

Estimated Vessel Length T/T = 7.50 m

= 24 7 ft in

(2) R. NOZZLE SIZES:

d Act d Calc ρ v act v calc ρv2 Act ρv2 Calc ρv2 Max
in in kg/m3 m/s m/s
Inlet = 16 14 26.6 10.91 14.26 3174 5415 6000 OK
Gas Outlet = 10 10 3.3 27.03 27.03 2417 2417 3750 OK
Oil Outlet = 12 10 718.0 0.63 0.91 285 592 1000 OK
Water Outlet = 2 #N/A 960.0 1.00 #N/A 958 #N/A 1000 #N/A

L. INSTRUMENT LEVELS: WATER SIDE

Water Flowrate = 0.6 m3/hr Diameter of Vessel = 2.59 m

Alternative Flowrate = 7.3 m3/hr Vessel Radius = 1.30 m
Selected Flowrate = 7.3 m /hr
3 L/d = 2.90
= 6,996 kg/hr Section Length = 6.75 m
= 1,100 bbl/d

Summary of Volumes LLILL LILL NILL HILL HHILL Weir

Liquid Height (m) 0.350 0.450 0.600 0.750 0.850 0.950
x/D 0.14 0.17 0.23 0.29 0.33 0.37
f(Ze) 0.05 0.08 0.14 0.20 0.25 0.30
a 0.75 0.86 1.00 1.14 1.22 1.30
Volume of Head (m3) 0.11 0.18 0.31 0.46 0.57 0.69
Part Area of Vessel (m2) 0.43 0.61 0.92 1.27 1.50 1.75
Cylindrical Volume (m ) 3
2.87 4.14 6.24 8.54 10.16 11.82
Total Drum Volume (m3) 2.99 4.32 6.55 9.00 10.73 12.52

© Petrofac Engineering Ltd Business Management System Form: PEL-BMS-STF-X-1252 Rev 0

 7 of 26

Calculation Sheet
JOB NO. CALCULATION NO. REV. PAGE NO.
JU-11805D JU-11805D-CAL-P-009 B
CUSTOMER
NAME: Ithaca Energy
CONTRACT
NAME: Greater Stella Area Development

Ref. CALCULATION Rev.

Residence Time (min) 23.66 10.39 17.34 18.94 13.30 13.70

Hold-Up Volume (LILL-HILL) = 4.69 m3 Hold-Up Time = 38.6 mins

HHLL Height /D Ratio = 0.33

L. INSTRUMENT LEVELS: OIL SIDE

Oil Flowrate = 165.6 m3/h Diameter of Vessel = 2.59 m

Alternative Flowrate = m /hr
3 Vessel Radius = 1.30 m
Selected Flowrate = 165.6 m3/hr L/d = 2.90 -
= 118,923 kg/hr Section Length = 7.50 m
= 25,000 bbl/d

Summary of Volumes LLLL LLL NLL HLL HHLL HHHLL

Liquid Height (m) 1.050 1.150 1.527 1.750 1.850 1.950
x/D 0.41 0.44 0.59 0.68 0.71 0.75
f(Ze) 0.36 0.42 0.63 0.75 0.80 0.85
a 1.38 1.46 1.75 1.93 2.01 2.10
Volume of Heads (m3) 1.64 1.89 2.88 3.42 3.65 3.85
Part Area of Vessel (m2) 2.00 2.26 3.23 3.79 4.03 4.26
Cylindrical Volume (m3) 15.03 16.95 24.24 28.41 30.20 31.91
Total Drum Volume (m3) 16.66 18.84 27.12 31.83 33.84 35.77
Residence Time (min) 5.44 0.70 2.64 1.51 0.65 0.62

Hold-Up Volume (NLL-LLL) = 8.28 m3 Hold-Up Time = 3.0 mins

HHLL Height /D Ratio = 0.71

Hold-Up Volume (NLL-Weir) = 14.61 m3 Hold-Up Time = 5.3 mins

Slug Volume (HLL-LLL) = 12.99 m3 Hold-Up Time = 4.7 mins

M. VESSEL WEIGHTS:

Material Allowable Stress = 18,750 psi

Material Density = 7,900 kg/m3

© Petrofac Engineering Ltd Business Management System Form: PEL-BMS-STF-X-1252 Rev 0

 8 of 26

Calculation Sheet
JOB NO. CALCULATION NO. REV. PAGE NO.
JU-11805D JU-11805D-CAL-P-009 B
CUSTOMER
NAME: Ithaca Energy
CONTRACT
NAME: Greater Stella Area Development

Ref. CALCULATION Rev.

Corrosion Allowance = 3.0 mm
Allowance for Nozzles & Trim = 20%

Estimated Vessel Weight (Dry) = 5,783 kg

Water Volume (NIL) = 6.55 m3

Water Mass (NIL) = 6,290 kg

Oil Volume (NLL) = 20.57 m3

Oil Mass (NLL) = 14,769 kg

Total Vessel Volume = 44.06 m3

Liquid Volume, HHLL = 30.20 m3
Liquid Volume, Normal = 27.12 m3
Gas Volume, Normal = 16.94 m3

Gas Mass = 56 kg

Estimated Vessel Weight (Operating) = 26,898 kg

© Petrofac Engineering Ltd Business Management System Form: PEL-BMS-STF-X-1252 Rev 0

 CALCULATION WORKSHEET
Horizontal three phase separator sizing - Sheet 1 of 4 - rev 01

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. Calc No.

Date Project
Originator Client
Checker Location
Approver Subject

SHEET 1 - VESSEL SIZING AND INTERFACE LEVELS

OPERATING CONDITIONS AND FLUID PARAMETERS CALCULATED VARIABLES

Operating pressure (bara) 2.0 Separation volume required for oil (m3) 13.803
Operating temperature (oC) 85 Separation volume required for water (m3) 0.050
Slug volume (m3) 1.385
Oil mass flowrate (kg/hr) 118,923 Separation volume (m3) 15.237
Water mass flowrate (kg/hr) 573 Vessel fill (% by volume) 76.42
Vapour mass flowrate (kg/hr) 16,311 Approximate vessel volume based on minimum vessel diameter (m³) 19.94
Approximate minimum vessel diameter (m) 2.062
Oil density (kg/m³) 718.00
Water density (kg/m³) 960 Vessel diameter (m) 2.590
Vapour density (kg/m³) 3.31 Vessel length (m) 7.500
Vessel cross section area (m²) 5.269
Oil viscosity (cP) 2.8 Separation length (m) 6.750
Water viscosity (cP) 0.33 Weir height (m) 0.950
Vapour viscosity (cP) 0.01
Vapour area available (based on NLL) (m²) 2.039
LIQUID-LIQUID INTERFACE DETAILS Liquid-liquid interface height HIL (m) 0.750
Normal liquid-liquid interface level NIL (m) 0.600
Maximum liquid-liquid interface height HIL (% of diameter) 28.96 Low-Low liquid-liquid interface level LLIL(m) 0.350
HIL to weir (m) 0.100 Water outlet nozzle minimum (m) 0.100
Estimated LIL (m) (note, a minimum of 0.35m is required) 0.450
Interface low-low to interface low (LLIL to LIL) 0.100 Vapour-liquid interface height maximum HHLL (m) 1.850
Water outlet nozzle minimum (m) 0.100 Vapor liquid interface height HLL (m) 1.750
Normal vapor-liquid interface level NLL (m) 1.527
VAPOUR-LIQUID INTERFACE DETAILS Vapour liquid interface height LLL (m) 1.150
Vapour liquid interface height minimum LLLL (m) 1.050
Maximum vapour liquid interface height HHLL (% of diameter) 71.43
HLL to HHLL (m) 0.100
LLL to HLL (m) 0.600
LLLL to LLL (m) 0.100

VESSEL SIZING PARAMETERS

Minimum oil residence time (mins) 5

Minimum water residence time (mins) 5
Vessel L/D ratio 2.90
Estimated vessel diameter (m) 2.590

Distance between LIL and HIL greater than 0.3m - OK Distance between LIL and HIL (m) 0.300
LIL greater than 0.35m - OK Low liquid-liquid interface level LIL (m) 0.450
Water residence time OK Water residence time (mins) 626.50
Distance between vessel top and HHLL OK Distance between vessel top and HHLL 0.740
Distance between LLLL and HIL greater than 0.3m - OK Distance between LLLL and HIL(m) 0.300
Oil residence time less than required Oil residence time (mins) 5.64

ONE OR MORE PROCESS DESIGN CRITERIA NOT MET, CHECK INPUTS

3.000

2.500

2.000
1.850
1.750

1.500 1.527

1.150
1.050
1.000
0.750
0.600
0.500 0.450
0.350

0.000
1 1.5 2 2.5 3 3.5 4 4.5

-0.500
Horizontal Three Phase Separator - Liquid Levels

-1.000
 CALCULATION WORKSHEET
Horizontal three phase separator sizing - Sheet 2 of 4 - rev 01

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. Calc No.

Date Project
Originator Client
Checker Location
Approver Subject

SHEET 2 - DROPLET SEPARATION CHECKS

DROPLET CHARACTERISTICS Droplet separation checks are carried out to ensure that
droplets can disengage adequately from the continuous
Max water droplet size (Micron) 300 phase. Three checks are carried out. These are:
Max oil droplet size (Micron) 150
Liquid droplet terminal velocity margin (%) 100 1. Droplet separation in the vapour phase. This is based upon
the time required for the oil phase to settle out from the
vapour phase. The calculation is carried out for the normal
Liquid droplet settling in vapour phase (based upon oil droplet properties) liquid level (NLL) and for the HH and LL liquid levels. This
covers the full range of operating conditions.
Based upon Based upon Based upon
NLL LLLL HHLL 2. Water settlement in the oil phase. This is based upon the
K 9.22 9.22 9.22 time required for the water to settle through the oil phase to
the liquid liquid interface. The calculation is carried out for the
A 18.50 18.50 18.50
full range of possible oil layer depths.
N 0.60 0.60 0.60
Liquid droplet terminal velocity (m/s) 0.36 0.36 0.36 3. Oil separation from the water phase. This is based upon
Vapour volumetric flowrate (m³/hr) 4930.8 4930.8 4930.8 the time required for the oil to rise through the water layer to
Vapour velocity (m/s) 0.6718 0.420 1.103 the liquid liquid interface. The calculation is carried out at NIL,
Time for vapour to travel from inlet to outlet (s) 9.7 15.5 5.90 HIL and LLIL to cover the full range of water layer depths.
Settling time for droplet from vessel top to liquid level (s) 3.0 4.3 2.06
For each of these cases, the droplet settling time/rise time is
Droplet separation OK OK OK calculated and compared to the residence time for the
continuous phase. Droplet separation is deemed to be
Water droplets settling in oil phase adequate if the continuous phase residence time is greater
than the required settling/rise times.
Based upon Based upon Based upon
NLL-NIL HHLL-LLIL LLLL-HIL
K 1.804 1.804 1.804
A 24.000 24.000 24.000
N 1.000 1.000 1.000
Water droplet terminal velocity (m/s) 0.0042 0.0042 0.0042
Oil volumetric flowrate (m³/hr) 165.63 165.63 165.63
Oil velocity (m/s) 0.0199 0.0128 0.0622
Separation length (m) 6.750 6.750 6.750
Time for oil to travel to weir (s) 338.5 528.6 108.6
Water droplet settling time in oil phase (s) 218.7 353.9 70.8
Droplet separation OK OK OK

Oil droplets rising through water phase

Based upon Based upon Based upon

NIL HIL LLIL
K 4.134 4.134 4.134
A 18.500 18.500 18.500
N 0.600 0.600 0.600
Oil droplet terminal velocity (m/s) 0.0073 0.0073 0.0073
Water volumetric flowrate (m³/hr) 0.60 0.60 0.60
Water velocity (m/s) 0.0002 0.0001 0.0004
Separation length (m) 6.750 6.750 6.750
Time for water to travel to weir (s) 37589.8 51575.9 17250.4
Oil droplet rise time to interface (s) 81.9 102.3 47.8
Droplet separation OK OK OK

ALL DROPLET SETTLING CRITERIA MET, DESIGN OK!

 CALCULATION WORKSHEET
Horizontal three phase separator sizing - Sheet 3 of 4 - rev 01

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. Calc No.

Date Project
Originator Client
Checker Location
Approver Subject

SHEET 3 - ADDITIONAL DESIGN PARAMETERS

DEMISTER REQUIREMENTS NOZZLE SIZING REQUIREMENTS

Horizontal demister type (select from drop down list) Wire-mesh Inlet device type (choose from drop down list) Schoepentoeter
Demister thickness (mm) 200
Correction factor for operating pressure 0.80

Demister sizing Inlet nozzle sizing

K 0.135 Kv 6000
Critical velocity (m/s) 2.627 Mixed phase density (kg/m3) 26.64
Required demister area (m2) 0.521 Inlet velocity (m/s) 15.01
Vessel chord length at top of demister (mm) 1658 Total volumetric flowrate (m3/second) 1.416
Space allowed above demister (mm) 300 Minimum nozzle diameter (m) 0.347
Demister minimum diameter (mm) 815 Recommended nozzle size to use (in) 14
Clearance between HHLL and bottom of demister (mm) 240
Insufficient clearance between HHLL and demister Vapour outlet nozzle sizing
Demister diameter less than chord length -OK
Outlet vapour velocity (m/s) 33.67
VESSEL WEIGHT CALCULATION INPUTS Minimum nozzle diameter(m) 0.228
Minimum nozzle size to use (in) 10
Type of vessel head (choose from drop down list) 2:1 Ellipsoidal
Vessel design pressure (bara) 3.50 Oil outlet nozzle sizing
Allowable stress (psi) 18,750
Corrosion allowance (mm) 3 Minimum nozzle diameter(m) 0.242
Vessel material density (kg/m3) 7,900 Minimum nozzle size to use (in) 10
Weld efficiency factor 0.85
Water outlet nozzle sizing
Vessel weight
Minimum nozzle diameter(m) 0.015
Estimated vessel thickness (mm) 7.1 Minimum nozzle size to use (in) #N/A
Area of vessel (m2) 77.9
Estimated vessel weight (kg) 4819
 CALCULATION WORKSHEET
Horizontal three phase separator sizing - Sheet 4 of 4 - rev 01

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. Calc No.

Date Project
Originator Client
Checker Location
Approver Subject

INLET VAPOUR OUTLET

SHEET 4 - CALCULATION SUMMARY

VESSEL DIAMETER
WEIR HEIGHT
HHLL = 1850
HLL = 1750
NLL = 1527
LLL = 1150 OIL OUT
WATER OUT
LLLL = 1050

SEPARATION LENGTH
HIL = 750
T-T LENGTH
NIL = 600
LIL = 450
LLIL = 350

SUMMARY VESSEL DESIGN DESIGN CHECKS

Vessel diameter (mm) 2590 Distance between LIL and HIL>0.3m OK

Vessel T-T length (mm) 7500 LIL greater than 0.35m OK
Separation length (mm) 6750 Water residence time OK
Weir height (mm) 950.0 Distance between vessel top and HHLL OK
Estimated vessel wall thickness (mm) 7.1 Distance between LLLL and HIL>0.3m OK
Estimated vessel weight (kg) 4819 Oil residence time OK
Demister clearance above HHLL Not OK
Inlet nozzle diameter (in) 14 Chord length above demister OK
Vapour outlet nozzle diameter (in) 10
Water outlet nozzle diameter (in) #N/A Liquid droplet settling in vapour phase OK
Oil outlet nozzle diameter (in) 10 Water droplet settling in oil phase OK
Oil droplet rise in water phase OK
Demister type Wire-mesh
Demister thickness (mm) 200
Demister diameter (mm) 815
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

Introduction

This spreadsheet gives preliminary vessel dimensions for a horizontal three phase Gas-
Oil-Water separator. The calculations are based on various industry standards and are
referenced within the worksheets. Applicability is limited to submerged weir type designs.

Use of this spreadsheet

The spreadsheet is a read-only file and is password protected. Once it has been opened
from the approved programs directory, then it must be saved under a new name in a project
directory. Use of the spreadsheet is straightforward. Inputs are allowed only in the yellow
cells. These must all be completed before vessel dimensions can be obtained. Various
comments and recommendations are included in the spreadsheet (denoted by a small red
triangle) to aid in selecting values for different parameters.

Please note that the vessel sizing does not take account of the volume attributable to the
heads, therefore the results are conservative. However, the heads are included in the
calculation of vessel weight.

The following sections give the background to the sizing methodology.

Overview of spreadsheet

Sheet 1 gives an estimate of required separator dimensions based upon user input values
of residence times. Residence times for the oil and water layers are input by the user and
are assumed to be "typical" values for the specific application. Although this approach gives
estimated vessel dimensions which meet the residence time requirements, there is no inherent
guarantee that the required droplet separation characteristics will be met by the assumed
times. Droplet separation checks are provided on sheet 2. If the droplet separation checks
show that droplet separation criteria are not fully met, then it is necessary to go back to Sheet 1
and revise the vessel dimensions and/or residence times. Sheets 3 and 4 provide further design
calculations.

The purpose of this spreadsheet is to provide typical dimensions for a three-phase separator
which meets the separation criteria defined by the inputs. The calculations are considered
appropriate to study/FEED work and are sufficiently detailed to provide input into equipment
lists, plot plan/layout considerations and FEED level estimates. Most of the necessary
inputs are provided by the user, but there are some inherent assumptions in the spreadsheet.
These are:

- Slug volume is 10% of the total inlet liquid flow

- The separation length is 90% of the T-T length of the vessel
- Inlet and outlet nozzles are assumed to be 500mm from the tan lines
- A 10% margin is added to the estimated vessel weight to account for nozzles, internals,
manways and other fittings.
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

The calculations are contained on four worksheets as follows:

Sheet 1: Vessel Sizing and Interface Levels

Sheet 2: Droplet Separation Checks
Sheet 3: Additional Design Parameters
Sheet 4: Calculation Summary

The flow diagram given below outlines the basic functionality of this spreadsheet.
Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

Sheet 1:
Input P,T, flowrates and fluid
physical properties

Sheet 1:
Input oil and water residence times
and L/D ratio.

Sheet 1:
Input estimated vessel diameter
based upon calculated minimum
vessel diameter.

Sheet 2: NO
All design
criteria met?

YES

Sheet 2:
Input maximum droplet sizes. Input
fractional % of terminal velocity to
use.

Sheet 2: NO
Droplet settling
criteria met?

YES

Sheet 3:
Input demister/nozzle requirements

Sheet 3: NO
Demister
clearance OK?

YES

Sheet 4:
Summary calculations and final
check on all design criteria
 clearance OK?

YES

Sheet 4:
Summary calculations and final
check on all design criteria
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

Sheet 1 - Vessel Sizing and Interface Levels

The process of calculating vessel dimensions is iterative in nature. This involves making a 'guess'
of certain key variables, and then adjusting the values of these key variables in order to satisfy
a number of design criteria. Sheet 1 involves the input of a large number of variables. The key
variables which must be estimated are the vessel L/D ratio and its diameter. Other key variables
which may need to be adjusted in order to satisfy all design criteria are the oil and water
residence times, the maximum vapour-liquid interface height (HHLL), the maximum liquid-liquid
interface height (HIL), and the low interface level (LIL). Other dimensions and parameters
can be adjusted, but those listed here are generally those which need to be fixed so as to
ensure all design criteria are met.

Vessel diameter can be estimated by using a value at least equal to the approximate minimum
vessel diameter. This is calculated by the spreadsheet and is given in the results output box
entitled "Calculated variables".

Typical values for input variables (key variables shown in bold) are:

Liquid-Liquid Interface Details

- Maximum liquid-liquid interface height HIL (% of diameter) - 40-50%

- Distance between High Interface level (HIL) and the top of the weir - 0.1m
- Estimated LIL (m) - A minimum of 0.35m is required)
- Interface low-low to interface low (LLIL to LIL) - 0.15m
- Water outlet nozzle minimum - 0.15m

Vapour-Liquid Interface Details

- Maximum vapour liquid interface height HHLL - 50% - 70% of diameter

- HLL to HHLL - 0.25m
- LLL to HLL - 0.15m
- LLLL to LLL - 0.15m

Vessel sizing parameters

- Minimum oil residence time (mins) - Between 5 and 10 minutes

- Minimum water residence time (mins) - Between 5 and 10 minutes
- Vessel L/D ratio - between 2 and 5. 3 is a good starting point
- Estimated vessel diameter (m) - User inputs a value, based upon the approximate
minimum vessel diameter calculated by the spreadsheet

These variables can be adjusted until the following six design criteria are all met:

- Distance between LIL and HIL greater than 0.3m

- LIL greater than 0.35m
- Water residence time OK
- Distance between vessel top and HHLL OK
- Distance between LLLL and HIL too low
- Oil residence time OK
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

Sheet 2: Droplet separation checks

As stated in the introduction, Sheet 1 calculates the vessel dimensions based upon a simple
iterative approach to achieve minimum vessel residence time requirements. This approach has
no inherent guarantee that the times required for droplet separation are met. The purpose of
sheet 2 is to carry out further checks to ensure that adequate droplet separation times are being
achieved. If the droplet separation checks show that droplet separation times are not adequate,
then it is necessary to go back to Sheet 1 and revise the vessel dimensions and/or residence
times.

Inputs required from the user are maximum droplet sizes for the oil and water, and the
liquid droplet terminal velocity margin. This latter parameter serves as a design margin and
is defined as a percentage of terminal velocity to use in the droplet settling calculations.

Three checks are carried out, one for each layer (vapour/oil/water). These are:

1. Droplet settling in the vapour layer. Droplets are assumed to be oil, as this gives the most
conservative result.

2. Water droplet settling in the oil layer

3. Oil rise in the water layer

In each case, the time required for the droplet to settle (settling/rise time) across the maximum
extent of the continuous layer is compared to the transit time for the layer. If the settling time
is less than the transit time, then droplet separation is deemed adequate.

For all cases, the transit time is given by:

LA
t T=
V
Where:
tT Transit time for the layer (s)
L Length of the layer (m). For the vapour layer this is the distance between the inlet
nozzle and the outlet nozzle. For the oil and water layers this is defined as the
distance between the tan line closest to the inlet nozzle and the weir.
A Cross sectional area of the layer (m2)
V Volumetric flowrate of the layer (m3/hr)

The settling or rise time is given by:

Note that this expression gives a settling time in the case of

D
t S= droplets settling in the either the vapour or oil layers, or a rise
vt time in the case of oil droplets rising through the water layer.

Where:
vt Terminal velocity of the droplet(m/s)
D Depth of the layer (m)

Hence, if tS < tT for each of the three layers, then all droplet settling criteria are met.
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

The generalised expression for droplet terminal velocity is estimated as follows:

[ 4 gDNp +1|ρ p − ρf | ( 2−N )

]
1

v t=
3 Aμ N ρ(f 1−N )
Where:

g Gravitational acceleration (9.81 m/s2)

Dp Droplet diameter (m)
rp Droplet density (kg/m3)
rf Continuous phase density (kg/m3)
m Continuous phase viscosity (kg/m.s)
|ρ p −ρf | Positive value of the density difference (kg/m3)

Note that the above expression applies equally to droplets settling in the vapour and oil layer,
or to oil droplets rising through the water layer.

A & N are constants, which are determined from the following table:

Law K A N
Stokes K< 3.3 24 1
Intermediate 3.3 < K < 43.6 18.5 0.6
Newton’s K > 43.6 0.44 0

Where:

[ ]
1/ 3
gρf |ρ p − ρf|
K =D P
μ2

In the spreadsheet calculations, the transit time and settling/rise time is calculated for each layer
at the normal layer depth, the maximum layer depth and the minimum layer depth as follows:

Vapour layer depth Oil layer depth Water layer depth

Normal Diam-NLL NLL-NIL NIL

Maximum Diam-LLLL HHLL-LLIL HIL

Minimum Diam-HHLL LLLL-HIL LLIL

Droplet sizing criteria are considered to be fully satisfied if the settling/rise time is less than the
transit time for each of these nine cases.
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

Sheet 3: Additional design parameters

Sheet 3 calculates additional design parameters. These are:

- Demister dimensions
- Nozzle sizes
- Approximate vessel weight

Demister

The user is required to input the demister type (either wire mesh, vane or none) from a drop
down menu, the demister thickness and a constant k1, chosen from the table below.

k1 Correction factor for operating pressure as follows (%)

Pressure (bara) k1
atm 1
10 0.9
20 0.85
40 0.8
80 0.75

The demister is sized based upon a critical velocity Vc. The required demister area is determined
from:

mg
A=
ρg V c
Where:

A Required demister area (m2)

mg Vapour mass flowrate (kg/s)
rg Vapour density (kg/m3)
Vc Demister critical velocity (m/s)

The demister critical velocity is calculated from:

v c=0 . 5355 k 1 KL 0 . 56
Where:
√ ρl−ρ g
ρg

K An empirical constant (m/s), which depends on separator type:

0.135 for horizontal wire-mesh demisters
0.20 for vane type mist extractors
rl Liquid density (kg/m3); oil density is used for more conservatism
L Vessel length (m)
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

The demister sizing is then checked against the following two criteria:

Separation distance from HHLL and demister bottom should be greater than the required
minimum. This is set at 300mm or 15% of the vessel diameter, whichever is the greater.

The vessel chord length above the demister should be greater than the demister diameter.

The vessel chord length, CL, is calculated as follows:

(
CL=2 r sin cos−1
r ))
( r−h
Where:

CL Vessel chord length above the demister (m)

h Height above demister (m)
r Vessel radius (m)

h
Chord Length CL

Ddemister
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

Nozzle sizings

The only input required from the user is the type of input device where appropriate. The options
are no inlet device, half open pipe or schoepentoeter/other vane pack device. Nozzles are sized
according to the following criteria:

Feed inlet nozzle

For the feed inlet nozzle, the mixture velocity is calculated from:

V m=
Where:
√ Kv
ρm

Vm Mixture velocity (m/s)

rm Mixture density (kg/m3)

Kv=1000 if there is no inlet device

Kv=1500 if half open pipe is used

Kv=6000 if Schoepentoeter or other vane pack inlet device is used

( m o +m w +m v )
ρm=

( )
mo mw mv
+ +
ρo ρw ρv
Where

ρo , ρw , ρv Oil, water and vapour density respectively (kg/m3)

mo,mw,mv Oil, water and vapour mass flowrate respectively (kg/hr)

The inlet nozzle minimum diameter is then calculated from:

d min =

Where:
√ 4V
πV m

V Total (oil, water and vapour) volumetric flow entering the vessel (m3/sec)

dmin Minimum nozzle diameter (m)

Following the calculation of minimum diameter, the spreadsheet then rounds up to the next
available normal line size.
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

Vapour outlet nozzle

The vapour outlet nozzle is sized in exactly the same way as the inlet nozzle, except that
vapour properties are used throughtout. The value of the constant K v is taken as 3750.

Oil and water outlet nozzles

The basis for sizing both oil and water outlet nozzles is that the velcity is limited to a
value of 1m/s. For low liquid flow systems, the nozzle has a minimum diameter of 2".
 Application Horizontal Three-Phase Separation

Assigned owner P M Birchenough/L.Yassin

Rev No. Revision Date Originator Checker Approver
01 First Issue 1/6/2009 PMB GM RL

Vessel weight

A preliminary estimate of the vessel weight is provided by the spreadsheet. The user is required
to provide the following inputs:

Type of head: 2:1 ellipsoidal or hemispherical heads are available options. The user selects from
a drop down list.
P Design pressure of vessel (bara)
S Maximum allowable stress (psi)
C Corrosion allowance (mm)
ρM Material density (kg/m3)
E Weld efficiency factor, determined from the table below. The default value is 0.85

Double-welded butt joints Single-welded butt joints

Full radiographed 1 0.9
Spot radiographed 0.85 0.8
No radiograph 0.7 0.65

The vessel thickness is then estimated from:

7231 PD
T= +C
SE−8 . 7 P
Where:

T Thickness of vessel (mm)

D Inside diameter of vessel (m)

Vessel weight is then estimated as follows:

Weight= ρM T ( π DL+ K H D 2 ) Note that in this expression, T is

in metres
Where:

L Vessel T-T length (m)

KH Constant taking a value of 0.8 for ellipsoidal heads and 1 for hemispherical heads

An arbitrary margin of 10% is added to the vessel weight to account for nozzles, internals,
manways etc.
NOTE, INFORMATION FOR DROP-DOWN LISTS IS GIVEN ON CALCULATIONS SHEET 3, COLUMNS P TO S

Area of vessel 1.527 h= 4

77.885 m2 if 2:1 Ellipsoidal heads are used 1.527 k= 1.295
82.100 m2 if Hemispherical heads are used a= 0.32375
0.600 b= 1.295
Law K A N 0.600
Stokes K<3.3 24 1
Intermedia3.3<K<43.6 18.5 0.6 1.181495 0.967861
Newton's K>43.6 0.44 0 4.318505 0.967861
1.226824 0.711975
0.76834 0.175143 0.922748 3.8
0.864865 0.080375 0.42346 x1 x2 y
0.96139 0.01413 0.074447 4 1.5 0 0.00
4.064425 1.435575 0.0259 0.04
4.09065 1.40935 0.0518 0.08
0.285676 0.764217 1.242232 4.026297 4.110455 1.389545 0.0777 0.12
0.324286 0.718694 1.482068 3.786461 4.126884 1.373116 0.1036 0.15
0.410363 0.613043 2.038693 3.229837 4.141119 1.358881 0.1295 0.19
0.555946 0.429259 3.006968 2.261561 4.153773 1.346227 0.1554 0.23
0.594556 0.380812 3.262212 2.006317 4.165208 1.334792 0.1813 0.26
4.175662 1.324338 0.2072 0.29
4.185303 1.314697 0.2331 0.33
0.710425 0.24031 1.266079 4.19425 1.30575 0.259 0.36
4.202596 1.297404 0.2849 0.39
4.210413 1.289587 0.3108 0.42
0.826255 0.115676 0.609445 4.217756 1.282244 0.3367 0.45
4.224674 1.275326 0.3626 0.48
6.228549 4.231204 1.268796 0.3885 0.51
21.8014 4.237377 1.262623 0.4144 0.54
4.243222 1.256778 0.4403 0.56
Min nozzle sizes 4.248761 1.251239 0.4662 0.59
in m 4.254015 1.245985 0.4921 0.62
2 0.0508 4.259 1.241 0.518 0.64
3 0.0762 4.263732 1.236268 0.5439 0.66
4 0.1016 4.268224 1.231776 0.5698 0.69
6 0.1524 4.272489 1.227511 0.5957 0.71
8 0.2032 4.276536 1.223464 0.6216 0.73
10 0.254 4.280376 1.219624 0.6475 0.75
12 0.3048
14 0.3556 4.284016 1.215984 0.6734 0.77
16 0.4064 4.287464 1.212536 0.6993 0.79
18 0.4572 4.290727 1.209273 0.7252 0.81
20 0.508 4.293811 1.206189 0.7511 0.82
22 0.5588 4.296722 1.203278 0.777 0.84
24 0.6096 4.299464 1.200536 0.8029 0.86
30 0.762 4.302043 1.197957 0.8288 0.87
36 0.9144 4.304463 1.195537 0.8547 0.88
42 1.0668 4.306726 1.193274 0.8806 0.90
48 1.2192 4.308838 1.191162 0.9065 0.91

7 14 0.3556
5 10 0.254
5 10 0.254
#N/A #N/A #N/A

0
0
0 0
0 0
0 0
0 0 0
0 0
0 0
1 0 0
1 0

Diameter 2.590 2.8 Diameter

HHLL 1.850 1.9 HHLL
HLL 1.750 1.9 HLL
NLL 1.527 3 NLL
LLL 1.150 1.9 LLL
LLLL 1.050 1.9 LLLL

Weir height 0.950 3.8 Weir height

HIL 0.750 2 HIL
NIL 0.600 3 NIL
LIL 0.450 2 LIL
LILL 0.350 2 LILL

0.950 3.8
0 3.8

0.000 1.5 4.3108 1.1892 0.9324 0.92

0 4 4.312616 1.187384 0.9583 0.93
4.314288 1.185712 0.9842 0.94
2.590 1.5 4.315818 1.184182 1.0101 0.95
2.590 4 4.317209 1.182791 1.036 0.96
4.318462 1.181538 1.0619 0.97
4.319579 1.180421 1.0878 0.97
4.320562 1.179438 1.1137 0.98
4.321411 1.178589 1.1396 0.99
4.322127 1.177873 1.1655 0.99
4.322712 1.177288 1.1914 0.99
4.323167 1.176833 1.2173 1.00
4.323491 1.176509 1.2432 1.00
4.323685 1.176315 1.2691 1.00
4.32375 1.17625 1.295 1.00
4.323685 1.176315 1.3209 1.00
4.323491 1.176509 1.3468 1.00
4.323167 1.176833 1.3727 1.00
4.322712 1.177288 1.3986 0.99
4.322127 1.177873 1.4245 0.99
4.321411 1.178589 1.4504 0.99
4.320562 1.179438 1.4763 0.98
4.319579 1.180421 1.5022 0.97
4.318462 1.181538 1.5281 0.97
4.317209 1.182791 1.554 0.96
4.315818 1.184182 1.5799 0.95
4.314288 1.185712 1.6058 0.94
4.312616 1.187384 1.6317 0.93
4.3108 1.1892 1.6576 0.92
4.308838 1.191162 1.6835 0.91
4.306726 1.193274 1.7094 0.90
4.304463 1.195537 1.7353 0.88
4.302043 1.197957 1.7612 0.87
4.299464 1.200536 1.7871 0.86
4.296722 1.203278 1.813 0.84
4.293811 1.206189 1.8389 0.82
4.290727 1.209273 1.8648 0.81
4.287464 1.212536 1.8907 0.79
4.284016 1.215984 1.9166 0.77
4.280376 1.219624 1.9425 0.75
4.276536 1.223464 1.9684 0.73
4.272489 1.227511 1.9943 0.71
4.268224 1.231776 2.0202 0.69
4.263732 1.236268 2.0461 0.66
4.259 1.241 2.072 0.64
4.254015 1.245985 2.0979 0.62
4.248761 1.251239 2.1238 0.59
4.243222 1.256778 2.1497 0.56
4.237377 1.262623 2.1756 0.54

( ( ))
4.231204 1.268796 2.2015 0.51
r−h
4.224674 1.275326 2.2274 0.48 A=2 r×sin cos−1
4.217756 1.282244 2.2533 0.45 r
4.210413 1.289587 2.2792 0.42
4.202596 1.297404 2.3051 0.39
4.19425 1.30575 2.331 0.36
4.185303 1.314697 2.3569 0.33
4.175662 1.324338 2.3828 0.29
4.165208 1.334792 2.4087 0.26
4.153773 1.346227 2.4346 0.23
4.141119 1.358881 2.4605 0.19 water
4.126884 1.373116 2.4864 0.15
4.110455 1.389545 2.5123 0.12
4.09065 1.40935 2.5382 0.08
4.064425 1.435575 2.5641 0.04
4 1.5 2.59 0.00