Production Facilities Design

Unit outline (MS)

 Overview of oil and gas surface systems and facilities .
 Overview of Petroleum Surface Operations including types.
 Application and Design of two and three Phase Separators
 Oil treatment equipment
 Vapour Recovery Processes:
 Gas Treatment processes and equipment
 Produced Water treatment and Disposal.
 Flow lines: gathering lines and transportation.
 Oil water and gas metering.
 Laboratory session cover design principles of production facilities leading to the
complete design of one basic production unit .
Assessment
Final exam 60%
Mid term Exam 30%
10% including: (Quiz, HW)
References
Arnold, K; Stewart, M. (2008) Surface production operations. Vol. 1.
(3rd Ed ) G lf P b C Ed.) Gulf Pub. Co.
 Abdel-Aal,H.K., Mohamed Aggour, M.A. (2003) Petroleum and gas
field processing. (3rd Ed.) Marcel Dekker
McCabe, W.L; Smith, J.C. & Harriott, P. (2005). Unit operations of
chemical engineering (7th Ed.) McGraw-Hill
Phase Equilibrium
The phase equilibrium diagram is a useful tool to visualize phase behavior. Equilibrium is a
theoretical condition that describes an operating system that has reached a “steady-state”
condition whereby the vapor is condensing to a liquid at exactly the same rate at which liquid
is boiling to vapor. Simply stated, phase equilibrium is a condition where the liquids and
vapors have reached certain pressure and temperature conditions at which they can separate.

reservoir fluids can be either a liquid,

a vapor or a mixture
of the two depending on :
 reservoir pressure,
 temperature,
 fluid composition.

re 1.1 Phase equilibrium phase diagram for a typical production system.

Factors Affecting Separation
Characteristics of the flow stream will greatly affect the design and operation of a
separator. The following factors must be determined before separator design:
 Gas and liquid flow rates (minimum, average, and peak),
Operating and design pressures and temperatures,
 Surging or slugging tendencies of the feed streams,
 Physical properties of the fluids such as density and compressibility factor, •
Designed degree of separation (e.g., removing 100% of particles greater than 10
microns),
 Presence of impurities (paraffin, sand, scale, etc.),
 Foaming tendencies of the crude oil,
 Corrosive tendencies of the liquids or gas.
Functional Sections of a Gas-Liquid Separator
Regardless of the size or shape of a separator, each gas-liquid separator contains
four major sections. Figures 4-2 and 4-3 illustrate the four major sections of a
horizontal and vertical two-phase separator, respectively.

Figure 2 Horizontal separator schematic.

1.Inlet Diverter Section
The inlet stream to the separator is
typically a high-velocity turbulent mixture
of gas and liquid. Due to the high velocity,
the fluids enter the separator with a high
momentum. The inlet diverter, sometimes
referred to as the primary separation
section, abruptly changes the direction of
flow by absorbing the momentum of the
liquid and allowing the liquid and gas to
separate. This results in the initial “gross”
separation of liquid and gas.

Figure 3 Vertical separator schematic.

2. Liquid Collection Section
The liquid collection section, located at the bottom of the vessel, provides the
required retention time necessary for any entrained gas in the liquid to escape to the
gravity settling section. In addition, it provides a surge volume to handle
intermittent slugs.
The degree of separation is dependent on:
 The retention time provided. Retention time is affected by the amount of liquid
the separator can hold, the rate at which the fluids enter the vessel, and the
differential density of the fluids. Liquid-liquid separation requires longer retention
times than gas-liquid separation.
3.Gravity Settling Section
As the gas stream enters the gravity settling section, its velocity drops and small
liquid droplets that were entrained in the gas and not separated by the inlet diverter
are separated out by gravity and fall to the gas liquid interface. The gravity settling
section is sized so that liquid droplets greater than 100 to 140 microns fall to the
gas-liquid interface while smaller liquid droplets remain with the gas. Liquid
droplets greater than 100 to 140 microns are undesirable as they can overload the
mist extractor at the separator out .let
4.Mist Extractor Section
Gas leaving the gravity settling section contains small liquid droplets, generally
less than 100 to 140 microns. Before the gas leaves the vessel, it passes through a
coalescing section or mist extractor. This section uses coalescing elements that
provide a large amount of surface area used to coalesce and remove the small
droplets of liquid. As the gas flows through the coalescing elements, it must make
numerous directional changes. Due to their greater mass, the liquid droplets cannot
follow the rapid changes in direction of flow. These droplets impinge and collect on
the coalescing elements, where they fall to the liquid collection section.
Overview of Petroleum Surface Operations including types.

Surface Production Facilities - Introduction

Surface production facilities are used to:

1.Separate the well stream into three components (phases): Oil, gas and water.

2. Process these components into marketable products or dispose of them.

 They can be categorized as follows:

1. Main process
2.Secondary process
3.Auxiliary systems
 Main Process:
 Separation of the oil, gas, water and solids; treat the oil to meet sales
specification and deliver it to transportation system .

Oil treatment usually includes dehydration, desalting, sweetening and

stabilization .

The gas must be treated for sales or disposal (flaring or venting). Nowadays
gas that can’t be transported is usually compressed for 6 reinjection to the
reservoir. Gas treatment may include dehydration, sweetening (removal of
contaminants such as H2S) and condensation of heavier components that can
be transported as a liquid.
Secondary process:

The produced water and solids are treated for disposal or any application.

Water treating usually includes removal of dispersed and dissolved hydrocarbons, filtration
and deionization. The water can be disposed of overboard in offshore areas. But usually
this is used for water flooding.

 If treating of solids is required, it may include water washing, agitation the solids to
remove the oil, and the water removal.
Auxiliary systems/facilities:

1. In addition to the process systems, auxiliary processes heating and cooling are
required Surface Production Facilities - Introduction are required.

2. Power generators and electrical systems are necessary for large or complex
facilities or for living quarters provided for personnel.

3. Safety systems required for all facilities, including safety instrumentation and
shutdown system; fire and gas detection; fire-fighting equipment; etc.
Composition of Crude Oil ?
Two-phase gas-oil separation
1. Introduction

 At the high pressure existing at the bottom of the producing well, crude oil
contains great quantities of dissolved gases.

 When crude oil is brought to the surface, it is at a much lower pressure. So the
dissolved gases tend to come out from the liquid.

 Two-phase separators are used to separate gas from oil in oilfields and water
from gas in gas fields. If water is produced with the oil a three-phase separator is
required.

 Crude oil usually goes through two or more stages of separation.

2. Theory of gas-oil separation
 Crude oil hydrocarbon components can be classified into three
groups :
2. Theory of gas-oil separation
The main target of gas-oil separation is to achieve the following objectives:
1.Separate C1 and C2 light gases from oil.
2. Maximise the recovery of heavy components of the intermediate group
(C5/C6) in oil.
3. Save the heavy group components in oil.

Some of heavy components of intermediate group are unavoidably lost in

the gas stream. To minimise this loss two methods are used:
1. Differential or enhanced separation
2. Flash or equilibrium separation
2.Theory of gas – oil Separation

In differential separation the light gases are

separated as soon as they are liberated due
to reduction in pressure; they are not in
contact with heavier components.

In flash separation, gases liberated from

the oil are kept in intimate contact with the liquid Feed 1 2 n Feed Gas Liquid 15
phase; a thermodynamic equilibrium is established.
Then the separation takes place at the required
pressure.
2.Theory of gas oil separation
Differential separation minimises the loss of heavy HCs but requires too many
stages, is costly and so not practical.

On the other hand, in flash separation, some loss of heavy HCs in gas stream is
inevitable but it’s viable as a few stages (4 to 5) would provide a close
approach to differential separation.
No. of flash stages % Approach to Differential

2 0
3 75
4 90
5 96
6 98.5
2.Theory of gas oil separation
3. Methods of gas-oil separation
 Conventional method is a multistage flash separation system. Recommended
for high pressure fluids .

Modified methods have been developed due to increasing demand for

recovering of natural gas (C1/C2) and NGLs. The modification may include:

 Adding vapour recompression units to recompress the separated gas from

each flash stage 18 separated gas from each flash stage.

 Replacing the conventional method by stabilizer columns (with interstage

reboilers and feed preheaters) and a recompression unit.
3.Method of gas – oil separation

The number of stages in conventional method is a function of following:

 The API gravity of the oil

 The gas-oil ratio (GOR)

 The flowing pressure

 Higher API gravity oils with high GOR flowing under high pressure would
require the greatest number of stages (3 to 4) .
3.Method of gas-oil separation
4.Gas-oil separation equipment : Separator
The essential characteristics of the conventional separator are:
 decreasing in the flow velocity, permitting separation of gas and liquid by
gravity.
operating at a temperature above the hydrate point of the flowing gas.
5. Functional components of a gas-oil separator
 Regardless of their configuration, they usually consist of four functional
sections.
5. Functional components of a gas-oil separator
In separating the gas/oil, a mechanical mechanism could be suggested which
implies the following two steps:
To separate oil from gas: Gravity separation. Suitable for particles larger than
100 μm. For smaller ones mist extractors are needed.
 To remove trapped gas from oil: Collecting any non solution gas that may be
locked or entrained in the oil. Recommended methods are settling, agitation,
and applying heat and chemicals.
6.Commercial types of Gas-Oil separator
Based on the configuration, the most common types of separator are
horizontal, vertical and spherical.
Horizontal Separator

Large horizontal separators are used almost exclusively in the Middle

6.Commercial types of Gas-Oil separator

Spherical
Separator
Vertical Separator
6.Commercial types of Gas-Oil separator
Which separator to use?
 Spherical separators are efficient in pressure
containment ,but have limited liquid surge capability and
exhibit fabrication difficulties, so normally not used in
oilfields.

 Vertical separators work most effectively with low GORs

(or high GORs where only fluid mists are being removed).
Problems are likely due to height restrictions (e.g., service of
valves and control devices).
6. Commercial types of gas-oil separator
Horizontal separators are the most economical (smaller and less
expensive than vertical ones for a given gas capacity) for normal
gas Two-phase gas-oil separation oil separation, particularly for
high GORs and when foaming is a problem. Higher liquid
capacity and interfacial area means easier gas bubbling and
liberation.
Problems:
 Solid handling (several solid drains required along the length of
the separator) .
 More space (problem in offshore oilfields) .
6. Commercial types of gas-oil separator

Separators for specific applications:

 Test separators: For separating and measuring (using flow meters)

Two-phase gas-oil separation the well fluids at the same time.

 Low-Temperature separators: Lowering the temperature of a high

pressure gas stream before separator effectively separates the light
hydrocarbons by condensation.

 For gas stream with very high GOR; cyclone separators, two-barrel
separators, filter separators and scrubbers are also used .
Design Theory
Settling In the gravity settling section of a separator, liquid droplets are removed
using the force of gravity. Liquid droplets, contained in the gas, settle at a terminal
or “settling” velocity. At this velocity, the force of gravity on the droplet or
“negative buoyant force” equals the drag force exerted on the droplet due to its
movement through the continuous gas phase. The drag force on a droplet may be
determined from the following equation:
Fd= Cd Ad ρ[] …………………..(4-3)
where FD = drag force, lbf, CD = drag coefficient, Ad = cross-sectional area of the
droplet, ft2, ρ= density of the continuous phase, lb/ft3 , Vt = terminal (settling
velocity) of the droplet, ft/s),
g = gravitational constant, 32.2 lbmft/s2 m/s 2 .
If the flow around the droplet were laminar, then Stokes’ law would govern and:
CD = ,
Where Re = Reynolds number, which is dimensionless. It can be shown that in such a
gas the droplet settling velocity would be given by :
where Dm = droplet diameter, ft (m), µ= viscositylb-sec/ft2
FD = 3 ∏µ” VDm (Stokes’ law). VDm (Stokes’ law).

The buoyant force on a sphere from Archimedes’ principles is :

FB = (ρl – ρg)
When the drag force is equal to the buoyancy force, the droplet’s acceleration is
zero so that it moves at a constant velocity. This is the terminal velocity.
where ΔSG = difference in specific gravity relative to water of the droplet and the
gas, dm = droplet diameter, microns,
µ= viscosity of the gas, cp.

Equations (4-5a) and is derived as follows: for low Reynolds number flows, i.e.,
Re < 1,
CD =
The drag force is then
Re = =
where Dm = droplet diameter, ft (m),
µ = viscosity lb-sec/ft2 kg-s/m2 ,
FD = 3 π µ VDm (Stokes’ law).
The buoyant force on a sphere from Archimedes principles is :
FB = (ρl – ρg)
where Dm = droplet diameter, ft (m),
µ = viscosity lb-sec/ft2 kg-s/m2 ,
FD = 3 ∏ µ VDm (Stokes’ law).
Figure 4-41. Coefficient of drag for varying magnitudes of the Reynolds number.
When the drag force is equal to the buoyancy force, the droplet’s acceleration is
zero so that it moves at a constant velocity. This is the terminal velocity.

Where
dm = diameter, micron,
ρl = 62.4×SG,
ρg = 62.4×SG
where SG = specific gravity relative to water
dm = diameter, micron,
ρl = 62.4×SG,
ρg = 62.4×SG
where SG = specific gravity relative to water
 Figure 4-41. Coefficient of drag for varying magnitudes of the Reynolds number.

Unfortunately, for production facility designs it can be shown that Stokes’ law does not govern, and
the following more complete formula for drag coefficient must be used (refer to Figure 4-41):
CD = + + 0.34
Equations Vt = 0.0119[(………(4-6) can be solved by an iterative process. Start
by assuming a value of CD, such as 0.34, and solve Eq. (4-6) for Vt. Then, using Vt, solve
for Re. Then, Eq. (4-6) may be solved for CD. If the calculated value of CD equals the
assumed value, the solution has been reached. If not, then the procedure should be
repeated using the calculated CD as a new assumption. The original assumption of 0.34 for
CD was used because this is the limiting value for large Reynolds numbers. The iterative
steps are shown below:
Field Units:

1. Start with Vt = 0.0119[( , assume CD = 0.34 then Vt will be

Vt = 0.0204[(
2. Calculate Re 0.0049
3. From Re, calculate CD using : CD = + + 0.34
4. Re calculate Vt = 0.0119[(………(4-6)
5. 5. Go to step 2 and iterate .
Droplet Size
The purpose of the gravity settling section of the vessel is to condition the gas for
final polishing by the mist extractor. To apply the settling equations to separator
sizing, a liquid droplet size to be removed must be selected. From field experience,
it appears that if 140-micron droplets are removed in this section, the mist extractor
will not become flooded and will be able to perform its job of removing those
droplets between 10- and 140-micron diameters. The gas capacity design equations
in this section are all based on 140-micron removal. In some cases, this will give
an overly conservative solution. The techniques used here can be easily modified
for any droplet size.
Retention Time
To assure that the liquid and gas reach equilibrium at separator pressure, a certain
liquid storage is required. This is defined as “retention time” .
Liquid Re-entrainment
Liquid re-entrainment is a phenomenon caused by high gas velocity at the gas-
liquid interface of a separator. Momentum transfer from the gas to the liquid causes
waves and ripples in the liquid, and then droplets are broken away from the liquid
phase. The general rule of thumb that calls for limiting the slenderness ratio to a
maximum of 4 or 5 is applicable for half-full horizontal separators. Liquid re-
entrainment should be particularly considered for high-pressure separators sized on
gas-capacity constraints. It is more likely at higher operating pressures (>1000 psig
or >7000 kPa) and higher oil viscosities .
Separator Design
Horizontal Separators Sizing—Half Full
The guidelines presented in this section can be used for the initial sizing of a horizontal
separator 50% full of liquid. They are meant to complement, and not replace, operating
experience. Determination of the type and size of separator must be on an individual basis.
All the functions and requirements should be considered, including the uncertainties in
design flow rates and fluid properties. For this reason, there is no substitute for good
engineering evaluations of each separator by the design engineer. The “trade-off ” between
design size and details and uncertainties in design parameters should not be left to
manufacturer recommendations or rule of thumb .

50% Full of liquid

When sizing a horizontal separator, it is necessary to choose a seam-to seam vessel
length and a diameter. This choice must satisfy the conditions for:
 gas capacity that allow the liquid droplets to fall from the gas to the liquid
volume as the gas traverses the effective length of the vessel.
provide sufficient retention time to allow the liquid to reach equilibrium.

Gas Capacity Constraint

The principles of liquid droplets settling through a gas can be used to develop an
equation to size a separator for a gas flow rate. The gas capacity constraint
equations are based on setting the gas retention time tg equal to the time required
for a droplet to settle to the liquid interface td, tg = td. a vessel 50% full of liquid,
and separation of 100-micron liquid droplets from the gas, the following equation
may be derived:
Field Units
dLeff = 420 ……..(4-8a)

Where
d = vessel internal diameter, inch
Leff = effective length of the vessel where separation occurs, ft,
T = operating temperature, R), F+460
Qg = gas flow rate, MMscfd ,
P = operating pressure, psia,
Z = gas compressibility,
CD = drag coefficient, dm = liquid droplet to be separated, micron,
g = density of gas, lb/ft3
Equations (4-8a) is derived as follows: assume horizontal vessel is half full of
liquid. Determine gas velocity, Vg. A is in ft2 D in ft, d in inches ,Q in ft3 /s In field
units :

Qg in MMscfd:
Set the residence time of the gas equal to the time required for the droplet to fall to
the gas-liquid interface:
Field Units

Setting tg = td,
Liquid Capacity Constraint
Two-phase separators must be sized to provide some liquid retention time so the
liquid can reach phase equilibrium with the gas. For a vessel 50% full of liquid, with
a specified liquid flow rate and retention time, the following may be used to
determine vessel size.

Field Units
…………………..(4-9a)

where tr = desired retention time for the liquid, min,

Ql = liquid flow rate, bpd

Field Units
t=
Seam-to-Seam Length
The effective length may be calculated from Eqs. (4-8a). From this, a vessel
seam-to-seam length may be determined. The actual required seam-to-seam
length is dependent on the physical design of the internals of the vessel.

Lss = Leff + for Gas capacity (4-10a)

For vessels sized on a liquid capacity basis, some portion of the vessel length is
required for inlet diverter flow distribution and liquid outlet. The seam-to-seam length
should not exceed the following:
Lss = (4/3) Leff ……………………….(4-11)
Slenderness Ratio
Equations (4-8a) and (4-9a) allow for various choices of diameter and length. For
each vessel design, a combination of Leff and d exists that will minimize the cost
of the vessel. It can be shown that the smaller the diameter, the less the vessel
will weigh and thus the lower its cost. There is a point, however, where
decreasing the diameter increases the possibility that high velocity in the gas flow
will create waves and re-entrain liquids at the gas-liquid interface. Experience has
shown that if the gas capacity governs and the length divided by the diameter,
referred to as the “slenderness ratio,” is greater than 4 or 5, re-entrainment could
become a problem. Equation (4-11) indicates that slenderness ratios must be at
least 1 or more. Most two-phase separators are designed for slenderness ratios
between 3 and 4. Slenderness ratios outside the 3 to 4 range may be used, but the
design should be checked to assure that re-entrainment will not occur.

dLeff = 420 ……..(4-8a)

…………………..(4-9a)
Procedure for Sizing Horizontal Separators—Half Full
1. The first step in sizing a horizontal separator is to establish the design
basis. This includes specifying the maximum and minimum flow
rates, operating pressure and temperature, droplet size to be removed,
etc.
2. Prepare a table with calculated values of Leff for selected values of d
that satisfy Eqs. (4-8a, and the gas capacity constraint. Calculate Lss
using Eqs. (4-10a) .
dLeff = 420 ……..(4-8a)
3. For the same values of d, calculate values of Leff using Eqs. (4-9a) and)
for liquid capacity and list these values in the same table. Calculate Lss
using Eq. (4-11).
d2 Leff =
4. For each d, the larger Leff should be used.
5. Calculate the slenderness ratio, 12Leff/do and list for each d. Select a
combination of d and Lss that has a slenderness ratio between 3 and 4. Lower ratios
can be chosen if dictated by available space, but they will probably be more
expensive. Higher ratios can be chosen if the vessel is checked for re-entrainment.
6. When making a final selection, it is always more economical to select a standard
vessel size. Vessels with outside diameters up through 24 inches (600 mm) have
nominal pipe dimensions. Vessels with outside diameters larger than 24 inches (600
mm) are typically rolled from plate with diameter increments of 6 inches (150 mm).
The shell seam-to-seam length is expanded in 2.5-ft (750-mm) segments and is
usually from 5 ft to 10 ft (1500 mm to 3000 mm). Standard separator vessel sizes
may be obtained from API 12J.
Horizontal Separators Sizing Other Than Half Full
The majority of oil field two-phase separators are designed with the liquid level at the
vessel centerline, that is, 50% full of liquid. For a vessel other than 50% full of
liquid, Eqs. (4-12a)and (4-13a) apply. These equations were derived using the actual
gas and liquid areas to calculate gas velocity and liquid volume (refer to Figure 4-44).
Gas Capacity Constraint
dLeff = () 420 (4-12a)
Where () = Design Constant
= Figure 4-45

Figure 4-44. Definition of parallel areas.

Figure 4-45. Gas capacity constraint design constant [1−/1−] vs. liquid height of a cylinder for a horizontal separator other
than 50% full of liquid (field units)
Liquid Capacity Constraint
Field Units : …………(4-13a)
where α = design constant If

ᵦ
If known, α can be determined from Figure known, can be determined from
Figure (4-47):
 ᵦ
Figure 4-47. Liquid capacity constraint design constant—ratio of areas (α) vs. ratio of heights ( ) for a horizontal separator other
than 50% full of liquid (field units)
Example : Sizing a Horizontal Separator (Field Units) Given:
Gas flow rate: 10 MMscfd at 0.6 specific gravity
Oil flow rate: 2,000 BOPD at 40 API
Operating pressure: 1,000 psia
Operating temperature: 60F
Droplet size removal: 140 microns Retention time: 3 minutes.
Solution :
Given: Ql,Qg,API=40,Sg,P,Z=0.84,dm=140micron,tr, µ =
0.013@1000psi&60F,Z=0.84
Sizing a separator means finding Lss,d .In order to find these,there are two
equations for sizing a horizontal separator as shown below :
Gas capacity constraint
dLeff = 420 ……..(4-8a)
Here all are given, but CD is unknown .
Liquid Capacity Constraint
…………………..(4-9a)
ρl = 62.4 x Sl
ρg = 62.4 x Sg
To find Sl from API :
then ρl = 62.4 x Sl
= 51.5 lb/ft3

1.Star with CD=0.34

To find ρg From Sg ρg = 2.7x = 2.7x =3.71 lb/ft3

Vt = 0.0119[( , assume CD = 0.34 then Vt will be

Vt=0.867
Vt = 0.0119[(
CD = + + 0.34 CD = + + 0.34 =0.712
Repeat using CD = 0.712
CD = 0.712. Vt = 0.599 ft/s, Re = 117 CD = 0.822

Repeat by assuming CD=0.822

Vt=0.556 ft/s , Re=110, CD=0.844

Repeat by assuming CD=0.844

Vt = 0548ft/s Re = 108, CD = 0.851

Repeat by assuming CD=0.851

Repeat: Vt = 0.545 ft/s Re = 108 ,CD = 0.854 it is ok as the assumed CD=Calculated
Now, we can find the sizing by using gas and liquid constraint :
2.Gas capacity constraint
dLeff = 420 ……..(4-8a)
dLeff = 420
=55.4
3.Liquid Capacity Constraint
…………………..(4-9a)
=
= 8571.43
. Compute combinations of d and Lss for gas and liquid capacity.
5. Compute seam-to-seam length for various d:
Lss = Leff + for Gas capacity (4-10a)
6. Compute slenderness ratios, 12Lss/d. Choices in the range of 3 to 4 are common.
7. Choose a reasonable size with a diameter and length combination above both
the gas capacity and the liquid capacity constraint lines.
d ft Leff ft (Gas) Leff ft(liquid) Lss ft 12Lss/d
16 2.5 33.5 44.7 33.5
20 2.0 21.4 28.5 17.1
24 1.7 14.9 19.9 9.9
30 1.3 9.5 12.7 5.5
36 1.1 6.6 9.1 3
42 0.9 4.9 7.4 2.1
Vertical Separators’ Sizing:
This section can be used for initial sizing of a vertical two-phase separator.
They are meant to complement, and not replace, operating experience.
Determination of the type and size of separator must be on an individual basis.
All the functions and requirements should be considered, including the
uncertainties in design flow rates and properties. For this reason, there is no
substitute for good engineering evaluations of each separator by the design
engineer. The “trade-off ” between design size and details and uncertainties
should not be left to manufacturer recommendations or rules of thumb. In
vertical separators, a minimum diameter must be maintained to allow liquid
droplets to separate from the vertically moving gas. The liquid retention time
requirement specifies a combination of diameter and liquid volume height.
Any diameter greater than the minimum required for gas capacity can be
chosen. Figure 4-49 shows the model used for a vertical separator
Gas Capacity Constraint
The principles of liquid droplets settling through a gas can be used to
develop an equation to size a separator for a gas flow rate. By setting the
gas retention time equal to the time required for a droplet to settle to the
liquid interface, the following equation may be derived.
Field Units
= 5040 ……..(4-14a)
Equations (4-14a) may be derived as follows: for the droplets to fall, the
gas velocity must be less than the terminal velocity of the droplet. Recall
that:
Vt = 0.0119[(
Determine gas velocity, Vg A is in ft2 m2, D in ft
(m), d in inches (mm), Q in , ,
Field Units :
Vg =
Ag =
=
=

Model of a vertical separator.

Liquid Capacity Constraint
Two-phase separators must be sized to provide some liquid retention time so
the liquid can reach phase equilibrium with the gas. For a specified liquid flow
rate and retention time, the following may be used to determine a vessel size.
Field units :
……………..(4-15a)
where h = height of the liquid volume in (mm) .

Equations (4-15a) is derived as follows:

where t is in s, V is in ft3 , Q is in ft3 /s , and h is in inches .
t= ,
Seam-to-Seam Length
As with horizontal separators, the specific design of the vessel internals will affect
the seam-to-seam length. The seam-to-seam length of vertical vessels may be
estimated based on the diameter and liquid height. As shown in Figure 4-50,
allowance must be made for the gas separation section and mist extractor and for
any space below the water outlet. For screening purposes, the following may be
used to estimate Lss.
Field Units
Lss= for diameters ≤ 36 in ……….(4-16a)

Lss= for diameters ≥ 36 in ……….(4-17a)

where h = height of liquid level, in. (mm),
d = vessel ID, in. (mm).
The larger of the Lss values from Eqs. (4-16a and
(4-17a) should be used.

where h = height of liquid level, in. (mm), d = vessel

ID, in. (mm). The larger of the Lss values from Eqs.
(4-16a) and (4-17a) should be used.

Figure 4-50. Approximate seam-to-seam shell length for a

vertical separator.
Slenderness Ratio
As with horizontal separators, the larger the slenderness ratio, the less
expensive the vessel will be. In vertical separators whose sizing is liquid
dominated, it is common to choose slenderness ratios no greater than 4
to keep the height of the liquid collection section to a reasonable level.
Choices of between 3 and 4 are common, although height restrictions
may force the choice of a lower slenderness ratio.
Field Units

= 5040 ……..(4-14a)
Procedure for Sizing Vertical Separators
1. The first step in sizing a vertical separator is to establish the design basis. This
includes specifying the maximum and minimum flow rates, operating pressure and
temperature, droplet size to be removed, etc.
2. Equations (4-14a) may be used to determine the minimum required d. Any
diameter larger than this value may be used.
3. For a selected d, Eqs. (4-15a) may be used to determine h.
4. From d and h, the seam-to-seam length may be estimated using Eqs. (4-16a )and (4-
17a). The larger value of Lss should be used.
5. Check the slenderness ratio to determine if it is less than 4.
6. When making a final selection, it is always more economical to select a standard
vessel size. Vessels with outside diameters up through 24 inches (600 mm) have
nominal pipe dimensions. Vessels with outside diameters larger than 24 inches (600
mm) are rolled from plate with diameter increments of 6 inches (150 mm). The shell
seam-to-seam length is expanded in 2.5-ft (750-mm) segments and is usually from 5 ft
to 10 ft (1500 mm to 3000 mm). Standard separator vessel sizes may be obtained from
Hint: In most calculations the specific gravity of the gas is always referred to in
terms of standard conditions of temperature and pressure and therefore is always
given, Eq. below , once the molecular weight of the gas is known. The density of a
gas at any condition of temperature and pressure can be determined by
remembering that the density of air at standard conditions of temperature and
pressure (60F and 14.7 psia) is 0.00764 lb/ft3 . Then density of gas is thus given
ρg= 2.70
ρg= 2.70
where ρg = density of gas, lb/ft3 , S = specific gravity of gas (air = 1), P = pressure,
psia, T = temperature, R, Z = gas compressibility factor, MW = gas molecular
weight.
141.5 /S -131.5 = API

ρl = 62.4 x Sl
ρg = 62.4 x Sg
Examples :
Example 2: Sizing a Vertical Separator (Field Units) Given:
Gas flow rate: 10 MMSCFD at 0.6 specific gravity
Oil flow rate: 2,000 BOPD at 40 API
Operating pressure: 1,000 psia Operating temperature: 60 F
Droplet size removal: 140 microns
Retention time: 3 .
Solution : Given, Ql,Qg,API=40,Sg,P,Z=0.84,dm=140micron,tr, µ = 0.013@1000psi&60F
Sizing a separator means finding Lss,d and h .In order to find these,there are two equations for
sizing a vertical separator as shown below :
Gas Capacity Constraint
= 5040 ……..(4-14a) . !You must start with CD = 0.34 then iterate.
Liquid Capacity Constraint
……………..(4-15a)
where h = height of the liquid volume in (inch) .
ρl = 62.4 x Sl
ρg = 62.4 x Sg
To find Sl from API :
then ρl = 62.4 x Sl
= 51.5 lb/ft3

CD=0.34
To find ρg From Sg ρg = 2.7x = 2.7x =3.71 lb/ft3

Vt = 0.0119[( , assume CD = 0.34 then Vt will be

Vt=0.867
Vt = 0.0119[(

Re = 0.0049 Re= 0.0049 = 169.73

CD = + + 0.34 CD = + + 0.34 =0.712
Repeat using CD = 0.712

Repeat by assuming CD=0.822

CD = 0712. Vt = 0.599 ft/s Re = 117 CD = 0.822

Vt=0.556 ft/s , Re=110,CD=0.844

Repeat by assuming CD=0.844

Repeat by assuming CD=0.851

Vt = 0548ft/s Re = 108, CD = 0.851

Repeat: Vt = 0.545 ft/s Re = 108 ,CD = 0.854 it is ok as the assumed CD=Calculated

= 5040 ……..(4-14a) .
= 5040x = 21.9 inch
3.Liquid Capacity Constraint
……………..(4-15a)
4. Compute combinations of d and h for various tr.
5. Compute seam-to-seam length :
Lss= for diameters ≤ 36 in ……….(4-16a)

Lss= for diameters ≥ 36 in ……….(4-17a)

where d is the minimum diameter for gas capacity
6. Compute slenderness ratio: 12Lss/d. Choices in the range of 3 to 4 are most
common .
7. Choose a reasonable size with a diameter greater than that determined by the
gas capacity. A 36-in diameter by 10-ft. seam-to-seam separator provides slightly
more than 3 minutes’ retention tim
a diameter greater than 21.8 in. and a slenderness ratio of 3.2 .

tr(min) d(inch) h(inch) Lss (ft) SR(12Ls/d)

3 24 86.8 13.6 6.8
30 55.6 11 4.4
36 38.6 9.6 3.2
42
1 24
30
36
42
• Q1: Design Problem, Vertical Separator Determine the diameter and height
(seam-to-seam length) of a vertical separator for the following operating
conditions:
• Gas rate: 15 MMSCFD, Gas specific gravity: 0.6, Oil rate: 3000 bbl/day
• Oil gravity: 35 API ,Operating pressure: 985 psi,Operating temperature: 60F
• Retention time: 3 min, Z = 0:84 ,µg= 0:013 CP, dm=100 micron
• = 5040
• ……………..
Lss= for diameters ≤ 36 in ……….(4-16a)
Lss= for diameters ≥ 36 in ……….(4-17a)
SR= 12Lss/d
Answer:
Dmin =31.357 in:
Select values for d greater than 31.357 in. and calculate the corresponding values
of H from equation :
‫في العازله العموديه نختار اقطار اكبر من القطر المحسوب (اصغر قطر هنا‬
‫) فنبدأ بفرض (اقطار ونجد ارتفاع السائل في العازله‬31.357= (

d inch h inch Lss ft SR

36 60.03 11.34 3.78
42 44.10 10.51 3
48 33.77 10.15 2.54
• Q 2: Performance Problem, Vertical Separator Determine the actual gas and oil
capacity of a 36-in. -diameter by 12-ft seam-to-seam length vertical separator
operating under the following conditions:
• Gas specific gravity: 0.6 , Oil gravity: 35 API, Operating pressure: 985 psi
• Operating temperature: 60 F, Retention time: 3 min., Z = 0:84 ,µg= 0:013 CP
• Cd: 1.1709
• = 5040
• ……………..
Lss= for diameters ≤ 36 in ……….(4-16a)
Lss= for diameters ≥ 36 in ……….(4-17a)
SR= 12Lss/d
Solution :
= 5040
• Q3: Determine the diameter and seam-to-seam length of a horizontal separator
for the following operating conditions. Determine the actual gas and oil capacity
of the designed separator.
• Gas rate: 15 MMSCFD ,Gas specific gravity: 0.6, Oil rate: 3,000 bbl/day
• Oil gravity: 35 API ,Operating pressure: 985 psi, Operating temperature: 60 F
• Retention time: 3 min, Z = 0.84,µg= 0:013 CP
Gas capacity constraint
dLeff = 420 ……..(4-8a)
Liquid Capacity Constraint
…………………..(4-9a)
Gas capacity constraint
dLeff = 420 ……..(4-8a)
dLeff gas= 82.04

…………………..(4-9a)
L =12852

D inch leffgas Lssgas = Leff + leffliq Lssliq= 4/3Leffliq SR= 12Lss/d

30 2.73 5.23 14.28 19.04 7.62
36 2.28 5.28 9.92 13.22 4.41
42 1.95 5.45 7.29 9.71 2.78
48
Q1.Ali is an engineer at an oil field. He was asked to design a vertical separator
according to the following operating conditions:
Oil rate: 8000 BBL/day ,Gas rate :9.6 MMScf , pressure: 500 psia
temperature: 80 F ,Oil gravity: 35 API, Gas specific gravity: 0.6,Oil viscosity:
10cP , retention time: 3Min, ,dm=100 Micron z: 0.84,CD:1.1709.
Eng.Ali separator’s design dimension was D =50 inch Ls=14.2 Ft. What was the
range(interval) of diameters that he could use? Did he choose the right diameter or
not ,prove that ?
= 5040
Lss= for diameters ≤ 36 in ……….(4-16a)
Lss= for diameters › 36 in ……….(4-17a)
SR= 12Lss/d
Q2.Which type of separator is the most commercial one ? Explain why ? Also,
explain the problem of it ?
Q1.Ali is an engineer at an oil field. He was asked to design a horizontal separator
according to the following operating conditions:
Oil rate: 8000 BBL/day ,Gas rate :9.6 MMScf , pressure: 500 psia,temperature:
80F ,Oil gravity: 35 API, Gas specific gravity: 0.6 ,Oil viscosity: 10cP ,
retention time: 3Min, z: 0.84,CD:1.1709, dm=100m
Help him in writing the two design equation for the separator? Ali design
dimension was D =50 inch Ls=16.93 Ft. Did he choose the right dimension, or
not ,prove that ?
dLeff= 420 ,
Lss= 4/3 Leffliq
SR= 12Lss/d

Q2.Mention Four major sections of gas liquid separator (two phase separator)?
Q1.Ali is an engineer at an oil field. He was asked to design a vertical separator
according to the following operating conditions:
Oil rate: 8000 BBL/day ,Gas rate :9.6 MMScf , pressure: 500 psia
temperature: 80 F ,Oil gravity: 35 API, Gas specific gravity: 0.6,Oil viscosity:
10cP , retention time: 3Min, ,dm=100 Micron z: 0.84,CD:1.1709.
Eng.Ali separator’s design dimension was D =50 inch Ls=14.2 Ft. What was the
range(interval) of diameters that he could use? Did he choose the right diameter or
not ,prove that ?
= 5040
Lss= for diameters ≤ 36 in ……….(4-16a)
Lss= for diameters › 36 in ……….(4-17a)
SR= 12Lss/d
Q2.Which type of separator is the most commercial one ? Explain why ? Also,
explain the problem of it ?
Name the four main function of two phase separator on the
diagram ?
QUESTIONS :
Mention two factors affect separation ? .
Mention Four major sections of gas liquid separator ? .
Draw a diagram illustrating the main and secondary processes .
What is the main target of gas – oil separation ?
Compare between differential and flash and flash separation ? .
Name the functional components of a gas oil separator on the
diagram ? .
Mention the advantage and disadvantage of a vertical separator .
Which type of separator is the most commercial one ? Explain why ?
Also, explain the problem of it .
Define ‘ retention time’ ? And what is the range of it in minutes ?