Gravity Separation Oil and Water

Upstream Engineering Centre
Gravity Separator Design:

Theory vs. Practice
Mike Power,
Separation Subject Matter Expert,
BP UEC Sunbury
TEKNA Separation Conference 2013
Agenda
Separation Design Methods
Theory vs. Practice
Upstream vs. Downstream
BP Approach to 3 Phase Separator Sizing
Separator Internals
Inhibitors to Gravity Separation
Separation Design Approaches

Residence Time
e.g. API, GPA
Oil Relative Density Retention Time (min.)

< 0.85
35
> 0.85 > 100 oF
80 100 oF
60 80 oF
Stokes Law Cut Point

Typical Guidelines:
Good Separation 150 mm
Bulk Separation 500 mm
5 10
10 20
20 30
In 1851, George Gabriel

Stokes derived an expression
for drag force in laminar flow
& so solving the generally
unsolvable Navier-Stokes
equations.
Separability
e.g. Bottle Tests
3
Stokes and Residence Time

Settling velocity according to
Stokes Law:
vsettle
1000.d 2 w o
g
18
Example:
How long does it take for a
500mm droplet to settle through
a distance of 1 meter ?
Water Density: 1000 kg/m3
Oil Density: 760 kg/m3
Oil Viscosity: 4 cP
Settling time = 2 minutes
However:
If the oil had a higher density and viscosity,
e.g:
Oil Density: 900 kg/m3
Oil Viscosity: 50 cP
Settling time = 60 minutes
Residence Time Approach takes no account of viscosity

4
Typical Literature Criteria Typically the sizing is

Good Separation 150 mm
Bulk Separation 500 mm
based upon removal of

150 micron diameter
droplets.
Water in Oil
Typical Required Specifications

100
80
60
40
20
85
75
0
65
55
45
35
9 mbpd = 18% of Total Water (50mbpd)

Cut Point Required = 325 micron
120
25
<0.1 USG/mmSCF Gas
= 50 mbpd
= 50 mbpd
= 15% Vol
50
<1000ppm Oil in Water
Oil Flow rate Rate

Water Flow Rate
WiO Spec Required
15% Water = 9/(50+9)
15
<15% Water in Oil
Accumulative Volume %
Stokes Law Approach
Droplet Size, Microns
However,
sizing 3 phase separators for 150 mm can lead to >50m t/t
(without coalescing internals)
consistent representative DSD samples generally unavailable
Upstream versus Downstream

Downstream Services:
typically constant flows, operating conditions, known
compositions of liquids and gases
where liquid contain immiscible components, typically
maximum of three phases
internals kept to a minimum as conditions in
separators well defined and controlled
sizing criteria for separator readily accommodated by
well established design rules
Upstream Services:
typically wide range of flows, gas/liquid ratios, fluid
compositions, flow regimes (slug, mist, annular etc.)
flowrates and compositions highly dependent on
operation of field & production profiles of wells
flow to separators generally highly turbulent
separators typically deal with six phases: oil, water,
gas, emulsion, foam and solids
good functioning of the separator highly dependent
upon good choice of internals
FPSO movement may also need to be accounted for
6
Separator operating performance.

25
Performance compared against Stokes

Law theoretical Cut Point.
Extrapolated to provide Cut Point versus
Performance for new designs.
Internals provided in vessel to produce
flow regimes in vessel to bring about
theoreical Stokes Law type behaviour.
Water in Oil, Vol%
Current Design Approach
2.5
100
Stokes Cut Point, mm
1000
Generic Description
Challenge:
Assumed valid for Oils < 10cP
Applicability for Oils > 10cP?
7
Intent often lost on the journey
What the FEED said
What the construction

contractor installed
What the design

contractor designed
What the commissioning

team commissioned
What the fabrication

contractor built
What the Operator

wanted
8
Three Phase Separation: Theory vs. ?

What the Designer Imagined
What the operator got!
Essential Internals
Separator Arrangement
Critical Internals for Separation:
1) Inlet Distributor
2) Baffle Plate
3) Demisting Device
4) Vortex Beaker
Other internals as required:
sand removal facilities,
overflow weir for 3 phase
separation
Challenge:
Are current Design Limitations (V2, inlet/outlet velocities
etc.) applicable for HP/HT Operation
10
Structured Packing & Longitudinal Baffles

Internals greatly simplified:
Packing Removed,
Longitudinal Baffles Opened,
Perforated Baffled,
Vane Type Inlet, Cyclonic Demister
11
Vessel Inlet Devices
Many Inlet Device Designs available
Preferred Inlet Device for typical services:

Open Vane Type
Except for Foaming Services:

Cyclonic Type
Both types require baffle plate immediately

downstream to assist reducing turbulence
Experience of inappropriate selection and

installation
Open Vane Type
Cyclonic Type
12
Gas Outlet Demisting Devices

3 Common Types
Wire Mesh:
Clean Basic Services
Vane Pack:
Downcomers require
adequate hydraulic sizing,
well positioned and be
free-flowing
High Spec < 30bar
Cyclonic Device:
High Spec > 30 Bar
13
Vertical Separators
OUTLET
Souders Brown Equation (1934)
l g
U k

g
MIN
0.85 D
- 150 mm
150 mm
0.5
600 mm MIN
FEED NOZZLE
FEED NOZZLE
600 mm
HHLL
U = Maximum superficial gasvelocity (m/s)
k = 0.107 wire mesh demister

= 0.061 no wire mesh
= 0.400 vane pack
l = liquid density (kg/m3)
1 MIN
HLL
LLL
600 mm MIN
0.6 D
1200 mm MAX
DRY DRUM
1 MIN
600 mm (DRY DRUM)
1 MIN
300 mm MIN
Vortex Breaker if Continuous Flow
to Pump or Control Valve
g = gas density (kg/m3)
14
Vessel Diameter: Impact of k

l g
U k

g
Souders- Brown Equation:
0.5
Vertical G/L Separator Design

Stream Properties
Temperature: 40oC
Pressure: 160 kPa
Gas Flow: 50,000 kg/hr
Gas Density: 2.9 kg/m3
Liquid Flow: 9800 kg/hr
Liq. Density: 690 kg/m3
Demister Type: K Factor 0.06

Vessel Diam. 2.6m
Mesh
0.11
2.0m
Vane
0.4
1.1m
?
0.6
0.9m
Challenge: Are the K factors valid for HP/HT

and Viscous Oil Operation
15
CFD Modelling of Flow Distribution

For separators in critical services, (slugcatchers, HP /LP separators, Flare
KO drums) CFD analysis performed on the vessel, as well as the first two
inlet piping upstream bends, to identify possible unpredicted fluid flow
behaviour, including FPSO movement.
16
Inhibitors to Stokes Law behaviour

Turbulence
Stokes Law not applicable
Inlet to Separators typically highly turbulent
May be increased by vessel internals
Emulsions
Inhibits/prevents oil/water separation
May lead to formation of growing rag layer
Sand
Reduces separation capacity
Plugs internals
Particle stabilised emulsions
Pump & valve wear/damage/blockage
valve/pipeline/equipment erosion/corrosion
17
Emulsions: Impact of Water Cut

Gas
Emulsion inversion point:
- below 30-60% water cut oil is
the continuous phase,
-above 30-60% water cut water
is the continuous phase
BP Experience:
Continuous Water generally
better than Continuous Oil
Typically, Separators perform
better at higher watercut
regimes
Foam
Oil
Emulsion
Water
Sand
18
Emulsion Breaking Strategies

Heat
reduces viscosity & promotes coalescence
Residence Time with Sedimentation

Promotes Gravity Settling
Centrifugal Force
enhances settling velocity
Coalescence
utilise plates or vane packs
electrostatics
Chemical Injection
droplet surface forces destabilised
coalescence promoted
19
Sand Removal Systems

Sand fluidisation and removal from separators
Jetting System
Cyclonic Devices
Hybrid System
Original sand layer
1. Start of jetting
Suction point
Nozzle
Nozzle fluidisation flow
2. End of jetting
Nozzle
Cyclonic Device
Fluidised sand particles
Jetting nozzles
Challenge: Are current technologies adequate for increasingly

viscous sand prone reservoirs?
20
Foam? Homework?
Gravity Separator Design: Theory vs. Practice
Thanks for Listening

Questions?
22

Gravity Separation Oil and Water

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Upstream Engineering Centre

Gravity Separator Design:

TEKNA Separation Conference 2013

Separation Design Methods

Theory vs. Practice

Upstream vs. Downstream

BP Approach to 3 Phase Separator Sizing

Inhibitors to Gravity Separation

TEKNA Separation Conference 2013

Separation Design Approaches

Oil Relative Density Retention Time (min.)

Stokes Law Cut Point

In 1851, George Gabriel

TEKNA Separation Conference 2013

Stokes and Residence Time

Settling time = 60 minutes

Residence Time Approach takes no account of viscosity

Typical Literature Criteria Typically the sizing is

based upon removal of

Typical Required Specifications

9 mbpd = 18% of Total Water (50mbpd)

<0.1 USG/mmSCF Gas

<1000ppm Oil in Water

Oil Flow rate Rate

<15% Water in Oil

TEKNA Separation Conference 2013

Stokes Law Approach

Droplet Size, Microns

TEKNA Separation Conference 2013

Upstream versus Downstream

Separator operating performance.

Performance compared against Stokes

Water in Oil, Vol%

TEKNA Separation Conference 2013

Current Design Approach

Stokes Cut Point, mm

TEKNA Separation Conference 2013

Intent often lost on the journey

What the FEED said

What the construction

What the design

What the commissioning

What the fabrication

What the Operator

TEKNA Separation Conference 2013

Three Phase Separation: Theory vs. ?

What the operator got!

TEKNA Separation Conference 2013

TEKNA Separation Conference 2013

Structured Packing & Longitudinal Baffles

TEKNA Separation Conference 2013

Vessel Inlet Devices

Many Inlet Device Designs available

Preferred Inlet Device for typical services:

Except for Foaming Services:

Both types require baffle plate immediately

Experience of inappropriate selection and

Open Vane Type

TEKNA Separation Conference 2013

Gas Outlet Demisting Devices

High Spec < 30bar

Souders Brown Equation (1934)

U = Maximum superficial gasvelocity (m/s)