Yt UU ayTraining For Professional Performance ‘This manual is one of a series for your use in learning more about equipment that you work with in the oilfield. Its purpose is to assist in developing your knowledge end skills to the point that” you ean perform your work in @ more professional menner, The manuel was prepared so that you can leer ite contents on your own time, without the assistance of an instructor ot classroom discussion. Edueetors refer to Jesrning by self-study as Programmed Learning. It is a method widely used in all industries as a means of training employees to do theit job properly and teseh them how to perform higher rated jobs. You can demonstrate vour desire to be @ professional by taking & positive ftitude toward leaming the contents of ‘his manual and others thet are appliceble to your job. ‘he author of this menus] has years of experience in operating petroleum eouipment. He slso has the technical Knowledge of how end. w! funetions. ‘The text was writt personnel with little ot no Previous experience with petroleum equip- ment. Consequently, some of the material may be femiliar io you if you have experienge with oilfield equipment. From such experience, you have observed the effect of making opereting chenges. The ‘manuel will help expiein why the chenges oeeurred that you observed. It will also teech you tow end why equipment functions. In order for you to learn the contents of the manuel, you must dig out the perti- nent facts and relate them to the subject. Simply reading the material and answering the questions is not enough. The more effort you make to learn the material the more you will learn from the manual. Teaching yourself requires self- discipline and hard work. In order to pre~ pare yourself for the sacrifice you will have to make, you should set gosls for yourself. Your ultimate goa) is to perform your work in @ more professional manner, Training is ‘one step in resching thet gol. Appliestion ‘of what you learn is another. Seeking answers to questions is @ third. Onee you have established your final gosl, you must determine the means for Feeching that yuel. You may decide, for exemple, that you must complete & series of 10 or 18 manuals to get the basic knowledge ang skills you need. “After you decide which training meterial is required, you should set 2 time table for completing each section of materiel. Achieving your final goel mey take more than & yeer, anc will require hours of hard work on your part. You will know you have achieved vour goal when you under- stand how end why to operate oilfleld equip- ment in order to obtain the maximum pro= Guet et the lowest cost, Your secrifice will have been worth-while from the setisfaetion of knowing that you ean perfarm your jod in 4 methodical professional manner, instead of «& tial-end-error-approach.Instructions For Using This Manual This is your manual. You should write your name on the cover. Upon completion you Will find it helpful to keep it in an accessible place for future reference, Problems may be included throughout the text. The solutions to the problems are sliven at the end of the book. ‘The manual is used in training progeams all over the world. In some countries, English units of monsurement such as feet, gallons, Benes ley are usec In otter counties ystems Internationale (Si) or Metrie units, Such as meters, liters, kilograms, ete, are wed. In. order_ forthe manual to be of maximum use, both SI and English units ere shown, ‘The SI unit always appears first, and the English unit follows in brackets { J. Example: the temperature is 25°C [77°F]. The English equivalent of the SI Unit will be rounded off to the nearest whole number to implify the text and examples. A distance of ® May be shown as 3.1 when te exact uivalent is 52.81 ft. If you are working in English unis, you may find it helpful to mark out the parts that ae in Suits, and view versa. Some of the Figures have units of Pssivneat. i sued eases, two Figures ere ‘neludee. The first one has SI units, and the Figure number is followed by the letter A (Example: Figure 1A). The seeond Figure will be on the next page and will have English nits. It will be the same number as the first one, bit it will be followed by the letter B (igure 18), If you use SI units, be sure to refer to Figures followed by the letter 4; if ‘The following general procedure is ree- ‘ommended for using this manual: 1 = Tum to Page 1, Read the material Until you come to the first problem or question. Work the first problem or answer the question and enter the answer in the Proper spaee in ink, If the problem ‘or question is shown in both SI and English units of measurement, answer cnly the part in units of measurement ‘that you use. Compare your answer with that shown at the end of the book; be sure to use solutions to the problems in the units you are working in, I your answer is correct, continue reading until you come to the next problem and work it. If not, restuly the manual until you understand. the reason for your error. Rework the problem if necessary. Leave your wrong answer and note the correct one. This will keep you from making the same mistake later on, Proceed stepwise #8 shown until you have completed the text, ‘The above approseh will above require thought, making mistekes, and rethinking. the situation. Coneentrate on two things ~ the how and the why, Do not cheat yourself by taking short-cuts or advance. ‘duces no real understanding. looking up the answers. in It saves time and errors but pro- Your future depends on how efficiently you perform your job and not on how rapidly you proceed ‘through this manual, Sine this is your : om FRE ee ee 1 PRS sual iy extena yal mabe srmpeiale. followed by the letter BAbbreviations Used In This Manual SI UNIT ABBREVIATIONS sy min second, minute time hyd hour, day time mm millimeter length em centimeter Tength m meter length km kilometer length m? square meter area m2 aubie meter volume m'/é cable meters per day volume rate L liter volume ‘ gram weight Fg kilogram weight kPa kilopaseal pressure MPa megapaseal pressure kPa(a) kilopaseal absolute pressure bar bar (I bar = 100 kPa) kJ kilojoule M3 megajoule WAW wait, kilowatt Mw met ENGLISH UNIT ABBREVIATIONS s, min second, minute time hyd hour, day time in, ft inch, foot length sq in square inch area sq ft square foot area cu ft eubie foot volume gal gallon volume bbl barrel (42 US gal) volume BPD barrels per day volume rate ry pound weight Psi Ibs per square inch pressure Psia Ibs per sq in absolute pressure Btu British thermal unit heat MBtu thousands of Btu heat MMBtu millions of Btu heat W, KW watt, kilowatt power bp horsepower ower ef/a eubie feet per day _gas flow rate Mef/d thousands of cf/d _gas flow rate MMef/d millions of ef/d gas flow rate M thousand MM million Units Of Measurement / SI UNITS OF MEASUREMENT Most of the SI units of measurement used in the oilfield are traditional metric units. The ‘exedptions we are concerned wit are pressure ‘and heat units, which differ as follows: IMETRIC) SIUNIT | CONVERSION UNIT kitopascet, kPa| Kiloeal |kiiojoule, ka STANDARD CONDITIONS FOR GAS VOLUME Measurement units for gas volume are cubic meters (m) or cubic feet (ef). The letters st ors are sometimes used with the units to ‘designate volume at standard temperature and pressure: m? (st) or sef. In this manual, stan= dard volumes are corrected to a temperature of 15°C and a pressure of 101.325 kPala), or 60°F and 14.7 psia. To simplify the toxt, the letters st and s are omitted. However, all gas volumes shown are at standard conditions unless speeificelly stated othernise. HEAT CAPACITY AND RELATIVE DENSITY Specific heat and specific gravity are tradi- tional terms that ave been used in both Metric and English units for mary years. These names are being replaced with the words: heat capacity and relative density. ‘The new names are used in this manual. when you see the term heat capacity (Hit Cap), it will have the seme meaning 0s. specific heat; and relative density (Rel Dens ) means specific gravity.INTRODUCTION . 1 Mi. Ww. x ‘SEPARATORS TABLE OF CONTENTS DESCRIPTION OF SEPARATORS ........0.ccceeeeeeeeeees A. Classifieation . B, Flow Patterns, C. Separator Internal Devices .....seeeeeeeere D. Construetion DESIGN OF SEPARATORS A. Principles of Separation B. Design of Separators 1. Vertical Separator Design ....seseeeeee0+ 2. Horizontal Separator Design .. C. Selection of Separator Internals APPLICATION sit Rete OPRRATION .... 35 B, Shutdown . ee . Routine Operation . Ds Control acs 7e 1. Pressure Control 2 Level Control. ‘TROUBLESHOOTING Be ances A, Troubleshooting Procedure for Liquid Carryover in Outlot Gas Stream Ee pecs 48 B. ‘Troubleshooing Procedure for Inability to Hold Constant Liquid Level . ‘ Pcs nace cena 49 VALIDATION, SI UNITS... fe eras eee SOLUTIONS TO PROBLEMS -SI UNITS ........ By VALIDATION, ENGLISH UNITS... ...0020+0ee0 5s 55 SOLUTION TO PROBLEMS - ENGLISH UNITS... +56LIST OF DRAWINGS, GRAPHS, ILLUSTRATIONS, AND TABLES 2-Phase Horizontal Separators . Horizontal Separators .. 2-Phase Vertical Separators Oil-Water Separator . Centrifugal Separator ....- +++ Flow in 3-Phase Separators . Sand Removal Facilities . é - 2 Separation Process... i Separator Sizing Procedure ++ 8 Gas and Liguid Flow in Separators .....ssesseeseeese : a2 Vertical Separator Diameter - SI Units ..... eat Vertical Separator Diameter - English Units .... ce . 20 Table 1 - Volume of Liguid in Vertical Separators oR Horizontal Separator Sizing . Sees soot ee 2% Vapor Disengeging Area in Horizontal Separator, English Units yy, Horizontal Separator Diameter, SI Units .........++ 28 Horizontal Separator Diameter, English Units ...... 29 Start-Up Procedure .......045 Shutdown Procedure ...++2++44+ Routine Operating Checks .....s.ssestsee + 38 Separator Controls .. 4... .seesersseserece es Level Control in 3-Phase Separator . eee 43 ‘Table 2 ~ Change in Interface Level with ance in Water Level. 45 Gauge Glass, : Saas eam cee AL‘SEPARATORS INTRODUCTION A separator is @ vessel in which @ mixture of fluids that are not soluble in each other are segregated from one another. In the oilfield, separators are used to segregate {gas from liquid; or one liquid such as condensate from another liquid, such as water. ‘There are more separators in oil and gas process facilities than any other type of process equipment. Sometimes they are called serubbers, accumulators, flash tanks, or other names. Regardless of what the vessel is called its function is to segregate 2 or more fluids . . . usually gas and liquid; and the operating procedures are the same. NOTE: This manual includes both SI and English units of measurements. If you use English units, disregard the SI units, and vice versa. Refer to the instruction page at the front of the manual. PRODUCTION SEPARATORS ON OFFSHORE PLATFORM2 CLASSIFICATION OF SEPARATORS L DESCRIPTION OF SEPARATORS ‘A. Classification Separators are classified in two ways: The position or shape of the vessel, and the umber of fluids to be segregated. Two vessel shapes are commonly used: 1, Horizontal, shown on pages 1, 2,3 and 4, 2, Vertical shown on pages 5 and 7. ‘The number of fluids to be segregated is usually either two or three. If there are ‘two fluids, such as gas and liquid, the separator is referred to as @ 2-phase type; if three fluids are segregated, such as gas, oil and water, the vessel is a 3-phase type. The number of phases refers to the number of streams that leave the vessel, and not the number of phases that are in the inlet stream, For example, wellstream separators frequently have gas, oil, and water in the inlet stream, but only the gas and liquid are segregated in the vessel. The liquid flows to another separator, where oil and water are segregated. Consequently, a 2-phase separator is one in which the inlet stream is divided into two fluids, and @ 3-phase will have three products. Each of the vessel shapes can be either 2-phase or S-phase. In other words, we can have a horizontal 2-phase, a horizontal 3-phase, a vertieal 2-phase, and so on. Some wellstreams contain sand or other solid particles which are removed in @ separator. Special internal devices are provided to collect and dispose of solid materials. ‘They are not considered another fluid phase in the classification of the vessel. HORIZONTAL WELLHEAD SEPARATOR2-PHASE HORIZONTAL SEPARATORS Deflector straightenis Gas si Stralgtening bts Inlet Coalesacin Mis Plates . Pad cas Outlet Centrifugal Element. Horizontal Liquia Battle Outlot igure 1 2-PHASE HORIZONTAL SEPARATORS4 HORIZONTAL SEPARATORS d 3+ PHASE HORIZONTAL SEPARATOR Inlet Gas Filter Elements Liquid Outlet 2.- PHASE HORIZONTAL FILTER-SEPARATOR Figure 2 4 HORIZONTAL SEPARATORS2-PHASE VERTICAL SEPARATORS 5 Inlet Gas Outlet Element Figure 3 ‘ 2-PHASE VERTICAL SEPARATORSOIL-WAT! PARATOR Oil-Water mixture - Section packed with hay oF ‘excelsior Controller Water Figure 4 OIL WATER SEPARATORCENTRIFUGAL SEPARATOR Reeyeling Line Vortex Chamber Figure 5 CENTRIFUGAL SEPARATOR8 FLOW PATTERNS B, Flow Patterns ‘The flow in horizontal or vertical separators is similiar for 2-phase separato ‘The mixture enters the side or end, the lighter fluid (usually gas) passes out the top, and the heavier fluid is withdrawn at the bottom. Flow in a centrifugal separator, such as that shown on Page 7 is somewhat different than that in conventional types. ‘The vessels are usually vertieal and depend on centrifugal action to segregate the fluids. ‘The inlet stream is directed to flow around the wall of the vessel in a swirling motion. ‘The heavier liquid moves to the outside, and drops collect on the wall and fall to the bottom. The lighter fluid collects in the middle of the vessel and flows up the outlet pipe. Flow in a 3-phase vessel can be in one of several manners as shown in Figure 6. The simplest method is shown in the upper left hand drawing. The $-phase inlet stream enters the side; gas flows out the top and liquid settles to the bottom. Oil floats on the water, ‘and Is withdrawn out the side of the vessel. Water is withdrawn at the bottom. ‘This type of liguid collection would be used with water and distillate, where a clean separation oceurs. ‘The disadvantage of the eystem is that the water level is controlled at the interface with oil, and if any foam or emulsion is present at that point, it will interfere with the action of the level control float. A preferable method of control in a 3-phase vertical separator is shown in the upper right hand drawing of Figure 6. In this vessel, the water falls to the bottom of the vessel ‘on the left side, and flows into the water chamber of the right side, where it is withdrawn with a level controller. Oil is withdrawn on the left side of the vessel with @ level controller. An emulsion at the oil-water interface will not interfere with the operation of the level controllers on the water or oil streams. Liquid flow in @ horizontal separator is usually a variation of one of the two schemes shown in Figure 6. In the middle drawing, the oil and water settle to the bottom in the left hand portion of the vessel. The oll layer floats on the water and spills over the weir and is withdrawn with a level controller. The water remains on the left side of the weir and is withdrawn with @ level controller. The level control float is subject to problems with emulsion at the water-oil interface. ‘The lower drawing in Figure 6 indicates the flow pattern with no interface control. il spills into the bucket and is withdrawn with a level controller. The water flows along the bottom of the vessel into the chamber on the right, where it is withdrawn.FLOW IN 3-PHASE SEPARATORS 9 iS Gas ae Water les ‘Drew-Off Inet Chamber anol Water Oil-Water kee terface VERTICAL 3-PHASE SEPARATORS Oll-Watée Interface Water | Figure 6 S-PHASE SEPARATORS10 INTERNAL DEVICES Centrifugal separators are normally used for gas-liquid separation. They are smaller than conventional units. ©, Separator Internal Devices A wide variety of meehanieal devices are used inside a separator to Improve efficiency and simplify its operation. The most commonly used device: 1, Deflector plate (Figure 1). A deflector plate is used in gas-liquid separators in front of the inlet nozzle on t vessel. ‘The plate can be flat or dished. As the inlet stream strikes it, the liquid falls to the bottom and the gas flows around the plate. I vertical vessel, the deflector may divert the inlet stream around the walll of the vessel to create a centrifugal action. 2. Mist pad (Figures 1 and 3). Mist pads are most frequently used in gas-liquid Separators to remove the mist from gas. The pad is made of closely woven wire that is 10 to 20 em (4 to 8 in.) thick. It is held in place by @ stuedy grid which prevents it from being swept ‘out or torn by a sudden surge of gas. Mist pads ure also used in oil-water separators to aid in segregating the two liquids. They are of particular value in breaking an emulsion of oil and water. MEL PAD 3. Coslesei plates (Figures 1, 2, and 3). Several configurations are available from different vendors. They are used in gas-liquid vessels to remove liquid from the gas. 4. Straightening vanes (Figure 1). These are also used in gas-liquid vessels. ‘They ‘are used when hydrate or paraffin prevents the use of mist pads. 5. Filter elements (Figures 2 and 4). Filters are used to remove solid mist from gas and oil-water vessels. The separator usually contains a quick-opening closure for access to allow replacement of the elements. 8. Coaleseing material (Figure 4). Excelsior and hay are the most commonly used materials. In special applications, pellets with coalescing properties are used. The material must be held in place with a grid or perforated plate. A manhole {ineluded on the vessel to allow replacement of the materiel. Conleseing material is use in oll-water separating vessels.INTERNAL DEVICES i 7. Weir (Figure 2). Its function has been described. 8, Centrifugal devices (Figures 1 and 3). ‘These are used in gas-liquid separators. ‘They impart a swirling action to the inlet stream that concentrates the liguid phase on the cuter wall of the device. 9. Horizontal baffles (Figure 1). ‘These are used in gas-liquid separators to prevent waves in the liquid phase. They are usually loeated near the liquid level in the vessel. 410, Vortex breakers (Figure 1). ‘These are used on all separators on the liquid éraw- off nozzles to prevent a vortex from forming, which would allow some gus to flow out the liquid tine. 11, Float shield (Figure 3). This deviee is used when an internal float is used to ‘control the liquid level. It prevents the float from flopping around from wave action in the liq 12, Water jets (Figure 7). Water jets are sometimes ealled sand jets. Their purpose is to spray the sides and bottom of the vessel with @ high pressure stream of water or ‘other liguid to fluidize sand or other solid particles so they can be drained from the bottom. 13. Sand cones (Figure 7). ‘These are used in vessels that have a continual flow of sand or other solid particles. The solids collect in the cone, and are periodically flushed ‘out. Water jets are usually included with the cones. Problem 1 Mateh each item in the column on the left with the item on the right that most closely describes it. 1. 2phase a. Prevent waves __2 Weir b. Remove liquid from gas _3. Mist pad fe. Liquid outlet nozzle 4, Horizontal baffle 4. Gas-liquid 5. Vortex breaker fe. Oil-water separator2 CONSTRUCTION D. Construction Most separators operate under pressure. They are usually constructed of steel and built accordance with rigid pressure vessel specifications. ‘The heads and shell are usually made of Intet| steel, and all seams are welded. If severe corrosion is anticipated, ‘the separator may be lined with a corrosion resistant material such Seer fas monel or stainless steel. If salt Jet water is the corrosive agent, pro- Nozzle tection can be provided with a coating oF special paints or tar. Most internals are also made of steel and welded to the wall or heads of the vessel. If manways Figure 7 e 9 VERTICAL SEPARATOR are provided, the internals may be WITH SAND REMOVAL FACILITIES bolted in a place so that they ean be removed for cleaning or repair. Il. DESIGN OF SEPARATORS A. Principles of Separation ‘Two factors are necessary for separators to funetion: ‘The fluids be be segregated must be insoluble to each other. 2, One fluid must be lighter than the other. Separators depend upon the effect of gravity to segregate the fluids. If the fluids fare soluble in each other, no separation is possible by gravity alone. For example, a ‘mixuture of distillate and crude oil will not separate in a vessel because they dissolve in each other. They must be segregated in a distillation process. Since a separator depends upon gravity to segregate the fluids, the ease with whiehPRINCIPLES OF SEPARATION 13 two fluids ean be segregated depends upon the difference in the weight of the fluids. Gas usually weighs about 5% as much as oil, and the two will separate in a few seconds. On the ‘other hand, oil may weigh only three-fourths as much as water, and separation may take several minutes. The primary factor that offeets separation is that of the the weights of the fluids. You recall the density of a flui is the weight of 1 cubie meter [1 cubie foot] of the material. Water has a density of 1000 kg/m* (62.4 Ib/ef ]. Crude oil density is about 800 kg/m? (50 tb/ef J. The density of gas will depend primarily upon its pressure. ‘The density of | m? of natural gas os 5200 kPa pressure is about 36 kg/m? [density of 1 of of as at 750 psi is about 2.25 Ib/ef ]; but at 102 KPa 15 psi J, density of gas is only 1.6 kg/m? (0.1 Ib/cf}. It would appear that gas having a density of 36 kg/m? [2.25 Ib/ef] would instantly separate from erude oil which weighs 800 kg/m? {50 Ib/ef J, About 95% separation will ‘ecur almost instantly. However some liquid will remain in the gas in a fine mist, and it ‘must settle out for separation to be complete. If mist is not removed from the gas in the separator, it will eventually settle out in the gas flow line ~ possibly in a burner = and could eause sertous problems, ‘The most difficult function of a gas-liquid separator is that of removing mist from the gus. Mist consists of tiny drops of liquid that are suspended in gas just as water droplets oceur in air as fog. It will usually not fall out unless the small drops can be torced together so that a large drop will form that will fall out. Coaleseing deviees are used to combine small drops Into larger ones, A common example of coalescing occurs when water drops form on the windshield of @ car as it is driven in a fog, As the tiny water drops, which make up the fog, strike the windshield, they combine with other drops and eventually form a drop lange enough to run down the glass. ‘The first 6 internal devices listed on pages 10 and 11 are all forms of coaleseers, In ‘each device, liquid drops adhere to the surface of the device and combine with other drops luntil a large drop forms which will fall out. The effectiveness of separation will depend upon the amount of cosleseing surface area that is present. In order to understand the way separation takes place, we will concern ourselves. with segregating a mixture of gas and oil into its components. As we mentioned, the ease with which the two fluids will separate depends upon the difference in weight of the two Tluids. The greater the difference in weight, the easier the separation,rr PRINCIPLES OF SEPARATION Droplets of liquid in gas must settle out before gas leaves the vessel, Bubbles of gas in liquid must break out before liquid leaves the vessel. Liquid SEPARATION PROCESS In the process of segregating gas from lauld, we aetually have two separation stages: 1, Separate liquid mist from the gas phase. 2. Separate gas in the form of foam from the liquid phase. Droplets of liquid mist will settle out from the gas, provided: 1, The ges remains in the separator long enough for the mist to drop out. 2 The flow of the gas through the separator is slow enough so that no turbulence occurs which will keep the gas stream stirred up and prevent Tiquid from settling out. ‘The difference in weight of the gas and liquid will determine the maximum flow rate of gas that will allow the liquid to settle out. For example, mist will drop out of gas at 5200 kPa [750 psi] pressure as long as the gas is moving in the separator less than 30 cm/s (1 ft/see]. In other words, we make the separator large enough so that the gas travels from the inlet nozzle to the outlet nozzle at a rate of 30 em/s [1 ft/sec], or less, We said that gas at 5200 kPa [750 psi ] weighed about 36 kg/m? [2.25 Ib/ef 1, whereas it weighed only 1.6 kg/m? [0.1 lb/ef ] at 102 kPa [15 psi]. Since its density is lower at 102 KPa [15 psi], the off droplets will settle out faster because there is aPRINCIPLES OF SEPARATION 6 greater difference in weight between the low-pressure gas and oil. Consequently, the gas ‘can flow faster in a low pressure separator. In fact, it can fMow at 152 em/s [5 ft see] ‘and not interfere with liquid droplets as they settle out. Gas bubbles in the liquid will break out of liquid in most oilfield applications in 30 to 60 seconds. Consequently, we design the separator so that the liquid remains in the vessel for 80 to 60 seconds. The length of time that the liquid remains in in the vessel is called its residence time. If we want a separator to have a liquid residence time of 60 seconds, and the inlet flow rate is 380 L/min [ 100 gom], we make the liquid portion of the vessel large enough to hold 380 L [100 gall. Liquid residence time is estimated by partially filling a glass container with Separator liquid, and, after violently shaking it, observing the time required for gas bubbles to break out. If the gas does not break out of the liquid in the separator, it will eventually come out in a storage tank somewhere, and will require costly reeompression to boost its pressure back up to that in the separator. Another reason that the gas and liquid streams leaving the separator must be pure that the presence of one in the other will make accurate flow measurement impossible. When liquid contains gas bubbles, the volume of the mixture is inereased by the volume of gas in it. Liquid mist in gas will also eause the flow measurement to read high. B. Design of Separators Separators are designed in two steps: 1. Determine the size of the vapor section in which liquid droplets will settle out. 2. Determine the size of the liquid section in whieh gas bubbles will break out. Vapor disengaging 1. Determine size section of gas partion Liquid settling 2. Determine size section of liquid portion SEPARATOR SIZING PROCEDURE16 DESIGN OF SEPARATORS ‘The size of the vapor seetion depends upon the difference in density of the gas and liquid, (which sets the velocity of gus in the vessel) and the gas flow rate, You recall we said that gas at 5200 kPa (750 psi} could move through the separator at 30 em/s (1 ft/sec]. If the flow of gas is 1 m?/see [25 ef/see |, the cross-sectional area of the ‘vapor seetion must be 3.3m? [25 sq ft] in order for the gas velocity to be 30 cm/s [1 ft/see ]. A 205 em [80 in] diameter vessel has a cross sectional area of 3.3 m? [85 sq ft]. Consequently, the gas flowing up a vertical separator having a diameter of 205 em { 80 in,] will travel at a speed of 30 em/s [1 ft/sec]. If the separator pressure was only 102 kPa [15 psi, the gas could flow at a rate of 152 em/s [5 ft/sec]. ‘The allowable area would be the flow rate, 1 m7/s [35 ef/see} divided by the allowable velocity, 152 em/s [5 ft/see], or 0.66 m? [7 sq ft]. A diameter of Lem (36 in} is all that is required. : Gas will separate faster from @ liquid when it is flowing in a horizontal direction than in a vertical direction. When flow is vertieal, the gas is moving up and the liquid droplets are moving down, Each fluid is moving in @ direction that interferes with the flow of the other. When both fluids are moving in a horizontal direction, the gas ean rise to the top and liquid falls to the bottom without interference. Consequently, the gas portion of a separator will be smaller in a horizontal vessel than in a vertical vessel. ‘The following table summarizes the factors that effect ga Liguid separation: FACTORS THAT EFFECT SEPARATION SEPARATION FACTOR EFFECT OF FACTOR 1. Difference in weight of fluids. Separation is easier when weight difference is greater. Residence time in separator. Separation is better with more time. . Coalescing surface area. Separation is better with more area. As we said previously, we determine the size of # separator by adding the volumes required for the gas portion to that of the liquid portion. The gas portion of separator is called the vapor disengaging space. We normally determine the size of the vapor disengaging space first, then determine the liquid portion.DESIGN OF SEPARATORS Ww GAS AND LIQUID FLOW IN SEPARATORS Problem 2 Match items in the two eolums Coaleseer a. Few seconds for gas Residence time b. Gravity Fluid separation Gas flow interferes with liquid drop-out __4 Vertical separator 4. Surface area 1. Vertical Separator Design Sizing a vertical separator is relatively easy. It is done in these steps: 1. Compare the density of the gas to that of the liquid to get the allowable velocity of gas up the vessel, 2. Determine the flow rate of the gas at the operating temperature and pressure, Divide the flow rate by the velocity to get the eross sectional area, Determine the diameter required to give the eross-sectionel area.18 VERTICAL SEPARATOR DESIGN We now have the diameter of the vessel. The caleulations involved in determining ‘the diameter are shown in graphie form in Figures 8A and 8B. Example 1: A vertical gas-oil separator ts designed to handle 1.5 million m*/d (50 MMcf/dl_ of gas at 5500 kPa [ 800 pst] pressure. The density of the oll is 850 kg/m? API gravity is 40°]. What is the diameter of the vessel? SIUNITS NGLISH UNITS Separator pressure 5500 kPa 800 pst Liquid density 850 kg/m? 40° API Gas flow rate 41.5 miltion m?/ 50 MMef/a Separator diameter (Fig 8A & B) 100 em 39 in. Example 2: What diameter is required for a vertical separator operating at 2800 kPa [400 psi} and a gas flow rate of 3 million md { 100 MMef/d] with tiquid having @ density of 700 kg/m? [70° Apri? SIUNITS ENGLISH UNITS Separator pressure 2800 kPa 400 psi Liquid density weight 700 kg/m? 70° API Gas flow rate 3 milion m?/a 100 MMef/a From Fig 8A & B, diameter = 185 em 72in Problem 3 What diameter is required in a vertical separator operating at 7600 kPa [1100 psi) with 850 kg/m? (40° APLJ oil and a gas volume of 1 500 000 m?/d [50 MMet/d]? Diameter = Once we have determined the diameter, all we need to complete the design is to find the height. It will be the sum of the height of vapor section plus the liquid portion. ‘The vapor disengaging section will usually be about 2 diameters high. If the vessel diameter is 91 em [96 in], the height of the vapor disengaging section will be 91 x 2 182 om (36x 2= 72in}.GEPARATOR INSIDE DIAMETER, OM. YERTICAL SEPARATOR DIAMETER -SI UNITS 13 EEE) emer tat tr Example: At on operating pressure | poh of 4000 kPa, 0 tiquid density of 700 ~ fg’, ard a gas flow rate of 2} = milion m fd, the inside diameter | ‘fa vertical teparator is 130 em. 19 111 600 jo oa Figure 84, VERTICAL SEPARATOR SIZING CHART - SI UNITS SFPARATOR OPERATING PRESSURE, KPA20 VERTICAL SEPARATOR DIAMETER - ENGLISH UNITS Example: At an operating pressure of 600 pst, a liquid gravity of 40° || 1400 API, and a gas flow rate of 50 7 = MMcf/d, the inside diameter of a ~_ vertical ‘separator is 42 inches, 200 =f eee SEPARATOR OPERATING PRESSURE, PSI 8 8 S Figure 88 VERTICAL SEPARATOR SIZING CHARTSeparator Diameter, em VOLUME OF LIQUIDS CONTAINED IN VERTICAL SEPARATORS SI_UNITS 10 0.01 20 0.03 30 0.07 40 0.13 30 0.20 60 0.28 0 0.38 80 0.50 90 0.64 100 0.79 10 0.95 120 1s 130 1.33 140 154 150 LIT 160 2.01 170 227 180 254 190 2.83 200 3.4 20 3.46 220 3.80 230 415. 240 452 Example: 0.10 0.30 0.70 1.30 2.00 2.80 3.80 5.00 6.40 7.90 9.50 tas 13.30 15.40 17.70 20.10 22.70 25.40 28.30 31.40 34.60 38.00 41.50 45.20 TABLE 1 Liquid Capacity m? perm Lper em ENGLISH UNITS Liquid Capacity Separator Diameter, in 2 uu 16 18 20 2 um 26 2B 30 33 36 39 42 45 48 54 60 66 R 8 at 90 96 Bbl per ft 045 0.20 0.25, 0.30 0.40 0.50 0.60 0.70 0.80 0.90 110 a Gal per in 0.5 on 09 LL Lg Ww 20 as 25 3a 3.8 a4 5.0 58 6.7 18 10.0 12.5 15.0 115 20.8 24 215 aL SI Units ~ The diameter of a vertical separator is 100 em. Each meter of height will contain 0.79 m? of Liquid, Each em of height witl contain 7.9 liters. English Units ~ Diameter is 39 in, Each foot of height will contain 1.5 barrels, Each inch of height-will contain 5 gattons.2 VERTICAL SEPARATOR DESIGN ‘The liquid section must be high enough to provide the volume required for the desired liquid residenee time, which is usually 30 to 60 seconds. The table on Page 21 is used to determine the height of the liq Example: section. In example 1 on page 18 the diameter was 100 m ($9 in.], If the oil flow rate is 450 L/min [ 120 gpm], and 1 minute of residence time ts required, what is the total vessel height? Separator diameter Height of Vapor Section Liquid flow rate Liquid residence time Volume of tiquid section From Page 21, volume of tiquid at separator diameter Height of liquid section Height of vapor section Total Height ENGLISH UNITS. 39 in 2xaia 120 gpm Lin I min ‘quid flow rate x Residence time 150 x 1= 450L 120 x 1= 120 gal Ballin 120 5 Brom 1800 000 m?/a (50 MMtefai Vapor disengaging section Height = Diameter x 2 = 100 x 2= 200m 39x 2=78 in) Liquid section, Residence time = | minute Volume = 450 L/min x 1 min = 450 Utr = (120 gpm x J min = 120 gat] Height = 57 em { 24 in] 450 L/min, 700 kg/m? [120 gpm, 70° API)VERTICAL SEPARATOR DESIGN 2 Example: In example 2 on page 18, the diameter was 180 cm (72 in] What is the height of the separator if the oil flow rate is 0.8m7/min [5 bbi/min] and the Liquid resicience time is 1/2 minute? Separator diameter Vapor disengaging height Liquid flow rate Liquid residence time Volume of liquid section = From page 21 volume of Liquid at separator diameter Height of tquid section height of Vapor section Total height SU ENGLISH UNITS 180 cm 72in Dlameter x 2 Diameter x 2 = 180 x2=360cm = 72x2=144in or 3.6m or 12 ft 0.8m 3/min 5 bbI/min 0.5 min 0.5 min Liquid flow rate x residence time 0.8 m3 x05 = 5 bbl x 0.5 0.4m? 2.5 bbl 2.54 m3/m sbbL/ft py = 0.16 m 25. os tt 3.60 m 120 ft 3.76 m 125 ft 3 000 000 mia [100 MMef/a) Vapor disengaging section Height = Dia x 2 = 180 x 2= 360 em or 3.6m =[12x2= 144 in, or 12 ft) Liquid section. Residence time = 0.5 min Volume = 0.8m*/m x 0.5 min = 0.4m? = [ 5 bbl/m x 0.5 min = 2,5 dbI] Height = 0.16 m 0.5/4 800 L/min [5 bbi/m]24 HORIZONTAL SEPARATOR DESIGN Problem 4 What height of separator will be required in Problem 3 when the oil flow rate is 500 1L/m (132 gpm) and the residence time is 60 sec? Height 2, Horizontal Separator Design Horizontal separators are sized in four steps: 1. Determine the eross-seetional area required in the vapor disengaging section. 2. Determine the eross-seetional area required for liquid residence. 3. Add the two together to get the total cross-sectional area, and determine the diameter. 4. Multiply the diameter by 4 to get the length. ‘The graphs shown in Figures 9A and 9B are used to determine the area required for vapor disengaging. 1. Determine cross- sectional area of ip vapar disengaging FO ie HORIZONTAL SEPARATOR SIZING Example: A horizontal separator has a gas flow rate of 1.5 million m*/d [50 MMcf/d} at 5500 kPa [800 psil, and the density of liquid is 700 kg/m? [70° API How much cross sectional area is required in the vapor disengaging section. SLUNITS_ ENGLISH UNITS Separator presssure 5800 KPa 800 psi Liquid density 700 kg/m * 70° API Gas flow rate 4,5 million m?/a 50 MMeta Vapor disengaging area 0.48 m* Seq ft.HORIZONTAL SEPARATOR SIZING % After the area of vapor section is determined, the diameter of the vessel is obtained using Figure 10 and 108, The oll flow rate to the separator in the previous example is 0.5 m/min [3 bbl/min]. The residence time is I minute. What (s the vessel diameter? SLONITS _ ENGLISH UNITS Liquid flow to separator 0.5 m/min 3 bbl/min a oe Tin min Tiguld volume in separator (Wotume/min) x (Residence Time) E0541 9x1 = 0.5m? = 3 bbl Vapor disengaging area (Page 25) 0.48 me S sqft Separator diameter (Fig 10 A&B) 88 em Bin Lengthof separator (#rdle) 42 88 4x34 52 om = 136 in The size separator required is 68 em diameter and 352 em long [ 36 tn diameter ‘and 136 tn tong). Problem 5 What size of horizontal separator will be required for the conditions in Problems 3 ‘and 4? (4 barrel of oil is equal to 42 gal.) The diameter is ‘The length is ‘The procedures presented for sizing separators are for estimating purposes only. An ‘actual design would take into aeeount the temperature, gas density, and other factors. However, they can be used in eheesing the size of separators in your plant. If you cheek ‘the vessels in your plant and find one or more that appear too small, you should bring it to ‘the attention of your supervisor so that the size can be accurately determined. In the examples used for sizing separators, we assumed that only gas and oil were present in the vessels. If water hiad been present, we would have taken it into consideration in sizing the Wauid section of the vessel. ‘The liquid section would have to be large enough to provide the residence time for both the oil and water.VAPOR DISENGAGING AREA, SQUARE FEET 3 Tae DS At an operating pre sure of 4000 KPa, a liquid den-——-| fity of 700 g/m ae ops 000 flew rate of 2.5 mittion m*/d, the cross sectional area re~ | Iquired for vapor disengaging 1s--~19000 H0 squre meter, 2 ey son z 8 SEPARATOR OPERATING PRESSURE, PSI Figure 98 VAPOR DISENGAGING AREA IN HORIZONTAL SEPAP ATOR - SI UNITSVAPOR DISENGAGING AREA, SQUARE FEET HORIZONTAL SEPARATOR SIZING - ENGLISH UNITS. a eee Example: at an operating pres~ -— sure of 600 ps, aliquid gravity 4 of 40° API, and a gas fiow rate | 1400 of 50 MMof/d, the cross-see- |_| tional area required for vapor | aisenaaging = 200 = hooo \s00 00 le00 SEPARATOR OPERATING PRESSURE, PSI Figure 98 VAPOR DISENGAGING AREA IN HORIZONTAL SEPARATOR - ENGLISH UNITSVAPOR DISENGAGING AREA, SQUARE METERS, 28 2.25) ote Poorer Spee eee ere iy f ] = aes UE Tigud residence volume is 7.5 culo HORIZONTAL SEPARATOR SIZING - SLUNITS ‘area is 1 square meter, and the meters, the separator inside di- ‘ameter is 165 cm. ieee f jf FLEES 125 150, SEPARATOR INSIDE DIAMETER, CM Figure 10ASEPARATOR INSIDE DIAMETER, INCHES HORIZONTAL SEPARATOR SIZING - ENGLISH UNITS HT Example: Wher vapor dlsengaghng ||" area is §.8 sq ft, and the liquid F volume 1s 50 Dbl, the separator + VAPOR DISENGAGING AREA, SQUARE FEET Figure 108 HORIZONTAL SEPARATOR DIAMETER - ENGLISH UNITS 2030 SELECTION OF INTERNAL DEVICES One other point: Even though water is present, the vapor disengaging area is based ‘on the difference in gravity of the gas and oil, and not the gas and water. Water is heavier than oil, and consequently, it will separate faster from gas than oil will. Sinee it is more difficult to separate gas from oil, we design the vessel on this basis, and the water will drop out before the oil does. HORIZONTAL SEPARATOR IN LOW TEMPERATURE HYDROCARBON RECOVERY PLANT +. Selection of Separator Internals. Internal devices are used in separators to speed up the separation process to reduce the size and cost of the separator. of internals ean reduee the cost of a Proper selection separator as much as 50% However, Improper selection of internals can reduce the capacity f the separator as much as Most of the internal devices are installed in the vapor section to remove liquid droplets from the gas. The separator sizing procedures will inerease approximately 20% if reviously discussed were based on separators containing mist pad only. The dia there is no mist pad ot other coalescing deviees in the vapor section. The diameter can be reduced approximately 10% by installing coaleseing plates or other deviees in addition to a mist pad. Selection of internal devices will depend upon the composition and quality of the ‘stream entering the separator. Coaleseing devices should not be installed if there isSELECTION OF INTERNAL DEVICES 3 4 likelihood that they will become plugged with wax; sand, hyérate, or corrosion produets. A stainless steel mist pad ean be installed in e corrosive gas stream without danger of becoming plugged with corrosion products. However, coalescing plates, straightening vanes, and centrifugal deviees should not be used when there isa liklihood of fouling from dirt, wx, oF hydrate. Centrifugal devices are highly effective in removing mist from gas so long as the flow of gas is high enough to maintain the proper velocity in the centrifugal element. Liquid entering the separator in slugs can adversely affect the benefits of a centrifugal device. These deviees are most effective when the inlet stream is mostly gas flowing at @ fairly constant rate, ‘Vortex breakers should always be installed in each liquid outlet line. Without these devices, a funneling effect may occur when liquid is withdrawn, and gas will flow out the funnel with liquid. ‘An inlet deflector plate is another internal device that can be used in all separators. ‘This device stops the liquid entering the separator and prevents it from flowing out to the middle of the vessel and thereby reducing the effectiveness of the vapor disengaging space. A float shield should be installed on all separators containing an internal float used to control level in the vessel. If the float is in an external cage, no protection is required Inside the vessel. Water jets should be installed if there is a likelihood of an accumulation of sand or dirt in the bottom of the vessel. These are most frequently used on wellhead separators to remove sand produced in the wellstream, ‘The following table shows the application and limitations of various internal devices: APPLICATION OF INTERNAL DEVICES USED IN SEPARATORS INTERNAL. PURPOSE OF DEVICE OR SITUATION DEVICE WHERE DEVICE SHOULD NOT BE USED Mist Pad a. Remove liquid mist from gas. b. Break oil-water emulsion ec. Not used where hydrate, wax, or dirt may be present.32 Deflector Plate Coaleseing Plate Straightening Vanes Filter Elements Coaleseing Materials Centrifugal Deviees Horizontal Baffles Vortex Breakers Float Shield Water Jets and Sand Cones b. SELECTION OF INTERNAL DEVICES ‘Separate liquid from gas. Used in all services. Remove liquid mist from gas. Separate oil from water. Not used where hydrate, corrosion, wax or dirt may be present. Remove liquid mist from gas. Separate oil from water. Not used where hydrate, corrosion, wax or dirt may be present. Remove solid particles from gas or liquid. Separate oil from water. Remove mist from gas. Not used where wax or hydrate may be present. Separate oil from water, ‘Not used when wax is present. Separate gus from Tiguid. Not used when wax or dirt is present, Not used with intermittent gas flow. ‘Usually used in larger gas-liquid vessels where waves oeeus. Should be used on all tiguid outlet nozzles in gas-liquid separators. Are not needed if vessel is full of liquid. Should be used when internal level control float is used. Used only when solids may be present. MI. APPLICATION Separators are a vital part of almost every process operation. Their most common ‘application in the oilfield is to segregate gas, oil, and water from each other. Each of the three fluids must have virtually 100% of the other fluids removed from them in order for them to have the highest commercial value.APPLICATION 33 GAS-LIQUID SEPARATOR AND SUCTION SCRUBBERS ON COMPRESSOR INLET GAS STREAMS ie aba ib WELLHEAD. SEPARATORS AT GAS PRODUCTION LEASE34 APPLICATION Liquid must be removed from a gas stream to prevent it from eecumulating in low arts of a pipeline and restricting the flow of gas. If the gas requites processing in a ehydration or sweetening plant, liquids must be removed to prevent serious operational problems in the processing plant. Crude oil must be free of gas so that storage tanks will not be 2 hazard from escaping gas. ‘The water content of oil must be Jow to prevent a penalty in its value. For environmental reasons as well as energy conservation, it is usually necessary to remove ofl from water that is discharged from any process operation. A list of separator applications would be endless, and would séeve no useful punpose to attempt to com; of horizontal and vertieal separators, ile it. Instead, the following table shows the most common appliestion COMMON APPLICATION OF HORIZONTAL AND VERTICAL SEPARATORS APPLICATION Horizontal |.__‘High gas-oil ratio streams. 2. Oil-water segregation where long residence time is required, Vertical 1, Low gas-oil ratio streams 3. Where @ high level of liguid must be held to prevent a pump from vapor locking, or maintain a liquid seal. ‘The designation of high or low gasoil ratio is rather erbitrary. Following are specific instances in which high or low GOR's usually aceur: LOW GAS-o, RATIO HIGH GAS-O1L RATIO il wellstresms 1. Gas melistreams 2. Flash tenks in dehydration 2. Gas pipeline serubbers ‘and sweetening plants 3. Compressor suetion serubbers Freetionator reflux accumulators 4. Fuel gus serubbors ‘The terms flash tank, aectimulator and serubber are commonly used for speeitie appliestions of separators. The vessels are gas-liquid separators.START-UP PROCEDURE % IV, OPERATION Start-Up 1, If the vessel is empty, elose a block valve in each liquid outlet line from the vessel to prevent possible leakage through # control valve in the liquid line. 2 If the vessel has a pressure controller, it should be set at about 75% of the normal control pressure, and slowly bring it up toa normal pressure after the vessel is in service. This will prevent pressure relief devices from opening in the event the pressure controller is out of adjustment and allows the pressure to build up above operating pressure, 3. If the vessel has low level shutdown devices, they must be deactivated or liquid ‘must be added to the vessel to # point above the low level devices. 4, Check the flow lines out of the vessel to see that each stream leeving the vessel flows in the proper direction, 5. , Slowly open the inlet stream to the vessel. 6. When the liguid level reaches the renge of level controllers, place level controllers in service and open the block valves that were closed in step 1. 7. Adjust level and pressure controllers to stabilize their operation. ee eae SEPARATOR START-UP PROCEDURE36 SHUTDOWN PROCEDURE 1B. Shut-down 1. Close a valve in the inlet stream. 28. Close valves in liquid outlet line to prevent liquid from leaking out. 2b, If the vessel must be drained, open the by-pass line on the level control valves, cr adjust the level controllers so the level control valves stay open until the vessel has rained. Close block valves in the liquid outlet lines after draining. 3. If the vessel must be depressured, close a block valve in the gas outlet line, 4. Depressure the vessel by opening @ valve in the line from the vessel to the vent cr blowdown system. 5. If possible, leave a small posit pressure on the vessel while it is shutdown to prevent air from entering so that it will not have to be purged prior to start-up. eas SEPARATOR SHUTDOWN PROCEDUREROUTINE OPERATION 37 Routine Operation 1. Routine operating checks are observing the v us level, pressure, temperature and flow control instcuments to see that they are controlling within the proper range. 2 Diaphragm-operated control valves should be stroked oceasionally to see that ‘they will fully open and close without restriction. 3. Gauge glassses should be drained periodically to prevent seale or debris from ‘aecumulating in the lines or gauge valves and eausing them to show false levels. If the vessel has filters or coalescing chambers, the pressure drop aeross them should be observed for an inerease which indieated a build-up of solid particles, and the need to replace or clean them. ROUTINE OPERATING CHECKS Problem 6 Match each item in the column on the right with the item on the left that most elosely describes it. 1. Start up a, Close valve in inlet stream 2% Gauge glass b. Cheek pressure drop 3. Level control valve. ¢ Close valve in liquid lines 4 Shut-down . Drain periodically _5. Filters fe. Stroke periodically38 CONTROL D. Control Separators have two major control points: 1, Pressure control. 2, Level control. Bach will be discussed separately. 1. Pressure control ‘The gas capacity of a separator inereases as its operating pressure rises. Con sequently, the pressure on a separator should be held as high as possible in order to get the best separation. Increasing the pressure reduees the actual volume of gas, and thereby Towers the velocity of gas in the vessel. Pressure is regulated with a pressure controller which regulates the flow of gas leaving the vessel. TYPICAL SEPARATOR CONTROLS 2. Level control a. 2-phase Separators ‘The point at which you hold the level of liquid in the separator can have @ significant effect on the operation of the vessel, particularly in a horizontal separator. ‘The level of liquid needs to be high enough so that the volume of liquid in the vessel will provide the desired residenee time for gas bubbles to break out. If the liquid level is too high, the liquid residence time will be more than is required. This will not affeet the quality of the liquid that is withdrawn from the vessel, but it will reduce the vapor disengaging space, and can result in some liquid carryover in the outlet gas stream.LEVEL CONTROL, 39 ‘The liquid Tevel control point in a vertical separator usually will not have much effect on the quality of the gas out of the vessel, because the vapor space is usually more than 100 en £98 in. high, end @ change of a few centimeters'finches] will have little effect. However, on a horizontal separator, » small change i the liquid level can have a signifieant effect on the vapor disengaging spnee, particularly on a small diameter vessel. Vapor Disenganing Space = 100 Volumes Lguid Settling Space = 120 Volumes Liquid Settling Space = 80 Volumes Vapor Disengaging Space = 120 Volumes Vaphr Daadseniag, Space = 120 Valumes Liquid Settling LEVEL 8CM[3 IN.) BELOW MIDPOINT Space = 60 Volumes EFFECT OF 8 CMI 5 IN.] CHANGE IN LEVEL IN 96 CM [38 IN.1 DIAMETER HORIZONTAL SEPARATOR ON VOLUMES OF LIQUID AND GAS IN VESSEL From the above you can see that changing the jevel 8 om {3 in.] ehanges the volume of vapor 20% The hange would be less in a larger dlameter vessel. ‘The point at which the lever controller should be set will depend upon the flow rates of liquid and gas entering the vessel. If the gas rate is above design, and the liquid rate is less, you should run with a lower level to allow more room in the vesel for vapor disengaging, On the other hand, if the liquid rate is up, and the gas rate is down, you should raise the level in order to provide more liquid residence time, It iS often difficult to determine whether the liquid residenee time is sufficient to allow gas bubbles to break out. If it is cumping into an atmospherie tank, you might get some idea of its gus eontent by observing the amount of gas that is being vented from the tank.40 ‘S-PHASE SEPARATOR LEVEL CONTROL If the gas leaving a separator flows to another process vessel, then liquid carryover will usually fall out in it. If liquid carryover is noticed, it often ean be stopped by lowering the liquid level. Generally, liquid earryover in the gas stream will eause more ‘operating problems than gas bubbles in the liquid stream. Consequently, it is usually better fo hold the liquid level on the low side rather than the high side in horizontal separators. ‘This is a good place to pause for u minute and discuss level eontrollers. Most level ‘controllers have a float whieh Is partially Immersed in liquid in the separator. When the level in the separator rises, the level controller senses the rise and signals the control valve in the liquid outiet line to open to allow more liquid to flow out. Conversely, when the level drops, the level controller signals the control valve to close. Most level controllers will hold @ constant level inside the separator so long as the flow of liquid is fairly constant. tiowever, if the flow of liquid inereases, the level of the separator will rise and remain at the higher point until the flow rate drops, ot until the level set point in the controller is lowered. For a detailed discussion of level controllers, refer to Manuel E-1, PNEUMATIC CONTROL SYSTEMS, If a level controller is equipped with @ reset device, the controller will hold a ‘constant level inside the soparator when there is a change in the liguid flow rate leaving the vessel. However, most ollfield level controllers do not have a reset device, and the level will change each time there is @ change in flow rate, As we said, when the liquid flow rate increases, the level in the separator will rise, and remain above the norinal level, and when the liquid flow rate decreas below normal. the level in the separator will fall und stay b. $+Phase Separator Level Control ‘A Sephase separator is one in whieh the outlet streams are gas and two liguids. In almost every 8-phase Separator, one of the liquids is oil; the other one is usually water, but it may be glycol, brine, amine, or any other liquid that is not soluble in oil. For our discussion, we will assume they are oil end water. The operating orineiples will be the samme for any two liquids that are not soluble in exeh other. ‘The term water cut is used in the oilfield to denote the pereentage to total liquid that is water. A 202 water cut would be 20% water and 80% cil. A low water eut usuallyLEVEL CONTROL aL means less than 10% water; a high water eut is more than 30% Level control in separators making water and oil is @ little more involved because ‘control of the water level will affect the residence time of both the water and oil. Furthermore, these vessels are often in a service in which the quantities of water and oil change drastically during the operation of the separator. For example, a new oll well might make 7000 m?/¢ of gus, 40 m°/4 of oil and 1 1m?/d of water 250 Mef/d of gas, 250 bbl/dof oil and 6 bbI/d of water]. After five years the production may change to 11 000 m'/0 of gas, 30 m?/d of oll and 15 m?/d of water {400 et/a of ges, 200 bb14 of il and 100 bbI of water 1. During the early stages of production, most of the liquid section is filled with oil. ‘The water level is operated near its lowest control point. After 5 years, the water level must be raised in order to provide sufficient residence time for the higher water produetion. Control of the water evel in the above ease was accomplished with a level controller having its float partially immersed in water and the remainder in oil. The float that is used on the controller must be designed for the difference in density of the oil and Water that are in the vessel, You ean visualize the float as being heavy enough so that is sinks in the oil but floats in water. A float used to eontrol the level of oil in a gas-oll interface would not function in sn oil-water interface. 11.000 m*/d [400 Mef/a 30 me 09} {2008/1 lo} [2508/41 Jeri i Fecal ‘daigaerienens im'id ismild INITIAL FLOW {6 B/d) FLOW AFTER FIVE YEARS (100 B/d) Most of liquid section Water level is raised to provide is filled with oll, ‘more water settling volurne.2 3-PHASE SEPARATOR LEVEL CONTROL In order to get away from level control at the oll-water interface one of the methods shown on the opposite drawing is used. In the vertical separator shown opposite , the oll level is changed by resetting the ofl level controller. In the horizontal separator, the level in the oil settling chamber is fixed by the height of the weir on the oil bucket. The volume of oil within the bucket is relatively small, and no significant change in the oil settling volume will result from a cchange in level within the bucket. In most separators, the total liquid settling volume is fairly constant. The percentage of the total volume that is used for oil and water settline depends upon the location of the interface. It is determined by the level of water in the water chamber. ‘The loeation of the interface is affected by two factors: 1. Difference in density of water and oil. 2 Level of water in the water chamber. ‘The effect of changing the water level on the interface level is shown on the next page for an oil having @ relative density of 0.75 [an API gravity of 57]. You will see ‘that changing the water level 1 unit moves the interface level 4 units, and significantly affects the settling volumes of oil and water. For example, if the water level is raised from 76 em to 79 eni{ {30 to 31 in], the volume of the water settling section increases from 22% to 332, whieh is a 507 inerease in volume. The water residene time will inerease 50%, The oll settling volume changes from 78% to 67%, which is a 14% reduction. ‘The effect of water level on the interface level also applies to vertical separators shown on the opposite page. In order for you to know where to set the water level in your separator so that the interface will be at the proper level, you will have to have @ chart similiar to that shown fon the page 44. To prepare such a chart, you need to know the relative density of the oil, and the height of the oil level in the vesel. The same ealeulation is used for horizontal or vertical vessels. The height of the oil level in a horizontal separator is the height of the weir on the bucket. In a vertical separator, the height of the oil level is the middle of the float on the oil level controller.S-PHASE SEPARATOR LEVEL CONTROL 2B interface Water J-PHASE SEPARATORS HAVE LOW LEVEL IN. WATER CHAMBER WITH LOW WATER CUT Low level in water chamber results in low interface level, which provides high a1) settling volume, and low water settling volume a 3-PHASE SEPARATORS HAVE HIGH LEVEL IN WATER CHAMBER WITH HIGH WATER CUT High Jevel in water chamber results in high interface level, which provides low Dil settling volume and high water settling volume,“4 4-PHASE SEPARATOR LEVEL CONTROL Example: i HEIGHT OF HEIGHT OF RELATWE SETTLING VOLUMES FOR OIL. WATER LEVEL INTERFACE HAVING RBL DENS OF 0.75 [ 57% API] cm Inches €m~—_ inches on WareR or 2 0 0 100% o 1 28 10 4 96% # 74 20 20 a 88 Ite 76 0 30 2 18 20h 79 a 4a 16 ere am al 2 31 20 55% a5 a4 a a 2 Er et 86 a4 a B 28% th 89 35 st 32 Me 20% 91 36 91 36 om 1002 When the water level is 78 em [30 in], the tnterface is 30 om [12 in] above the bottom. The oil settling volume is 78% of the total liquid volume, and the water settling ‘volume ts 22%. ‘The chart is prepared in two steps: You first detemine what the water level would be if the settling seetion was full of oil. in this ease, the interface would be at the bottom of the vessel. It is the lowest water level that can be held without the oil entering the water éraw-off chamber. It is equal to: Minimum Water Level = (Oil Height) x (Oil Relative Density). In the above separator, the oil level fs the height of the weir above the bottom Once you know the minimum water level, you use Table 2 to make yout chart.5-PHASE SEPARATOR LEVEL CONTROL 45 TABLE 2 CHANGE OF INTERFACE LEVEL WITH CHANGE IN WATER LEVEL FOR VARIOUS OIL, DENSITIES on om CM [INCHES] CHANGE IN RELATIVE apr INTERFACE LEVELWITH 1 CM DENSITY GRAVITY (1 INCH] CHANGE IN WATER LEVEL 0.50 = 20 0.55 - 22 0.80 - 25 0.85 86 29 0.10 70 33 0.15 7 40 0.80 46 5.0 0.85 35 er 0.90 % 10.0 Example: A 3-phase separator with the oll level 100 cm [ 40 in], above the bottom handles 0.8 relative density [ 45° API} ail. Determine the interface tevel at various water levels, — eon, First we determine the minimum water tevel. Minimum water level = (Weir height) x (Olt relative density) ‘Minimum water tevel = 100 em x 0.8 = 80 cm [ 40 in x 0,8 = 32 in] The level in the water chamber must always be above 80 cm [ 32 in]. Refer to Table 2; With 0.8 rel dens { 45° API] oil, the interface will change 5 em (5 in] for each em [in] change in the water level. We start with a water level of 80 em [82 in}, at which point the interface level is 0. Bach unit we45 3-PHASE SEPARATOR LEVEL CONTROL ‘add to the water level raises the interface § units. The chart looks like this: SIUNITS ENGLISH UNITS WATER LEVEL INTERFACE LEVEL WATER LEVEL INTERFACE LEVEL cM co INCHES INCHES 80 o 2 o 2 10 a 5 4 20 4 10 86 30 35 5 8 40 6 2 90 50 7 Fs 92 60 38 40 oy 70 39 35 96 80 40 40 98 90 100 100 When the water level is above 100 em’{ 40 in], the entire settling volume is full of water. Water will spill into the bucket and flow with oil. Problem 7 ‘A S-phase separator has an internal diameter of 250 em (100 in], The weir is at the mid-point of the vessel. Oil relative density is 0.8. What height of water must be held in ‘order for the interface height to be 60 em {25 in]? ‘The oil-water interface is often difficult to detect. Wood, rags, seale and dirt that sinks in ol but floats on water will accumulate at the interface. ‘This material tends to promote foam or an emulsion of water and oil. Consequently, there may be no clear cut interface, but instead, a layer of trash and oil-water emulsion will form betwen the oil and water. The mixutre will eause erratie action of the level controller. It is not unusual for a gauge glass to show a distinet interface when this layer is in the separator. The following drawing illustrates this.3-PHASE SEPARATOR LEVEL CONTROL a7 ou Liquid in gauge glass is clean oil and water. Trash ESSE Trash layer in separator Myo does not show in gauge Water glass. If one of the gauge glass connections to the vessel is in the trash layer, the glass may fill with the material, and an interface cannot be seen, When this occurs, the trash layer should be drained from the vessel. on ‘When one gauge lass connecting isin trash layer, the entire gauge Trash glass may fill with trash ne and no oll-water inter- Water face is visible. If the float on the water level controller is immersed in a layer of trash and emulsion, it may not be able to distinguish a difference in density between oll and watery ‘and will not operate properly. V. TROUBLESHOOTING ‘The cause of an operating problem is found by a process of elimination, Each event which ean cause the problem is checked until the culprit is found. The proper sequence for checking the various causes is to elminate the easy ones first. ‘These are the instruments: pressure gauges, control valve positions, controller output pressures, gauge glasses, flow meters, ete, In making these checks, be sure that the instruments are working properly, and not giving a false reading- Once the easy causes are checked and eliminated, the more difficult causes are checked.48 A. TROUBLESHOOTING PROCEDURE FOR LIQUID CARRYOVER IN OUTLET GAS STREAM Another important part of troubleshooting is that of maintaining an overall Perspective of the total process, and not just the troublesome equipment. Upsets at Tront end of a plant often show up at the back end. Find the souree of the problem before attempting to locate the cause, ‘TROUBLESHOOTING PROCEDURE FOR LIQUID CARRYOVER IN OUTLET GAS STREAM CAUSE OF CARRYOVER 1, High inlet gas flow rate High liquid level whieh cuts down vapor disengaging space 3. Coalescing plates, mist pad, or ‘centrifugal deviee is plugged. 4. Excessive wave action in liquie 5. Operating pressure is below design 6. Liquid density is less than de- sign __TROUBLESHOOTING _ PROCEDURE. Cheek gas flow rate and cut back to design rate, Check liquid level. Blow down gauge glass. Lower level to design point. fa, Check temperature and pressure to de~ termine if hydrate has formed. Lower pressure to melt nyarate. Measure pressure drop across device. It should be less than 10 kPa [2 psi. If pressure drop across mist pad Is 0, pad may have tom or come loose from its mounting. Pressure drop measurement should be made at design gas flow rate. High pressure drop indicates plugging. Internally inspect and elean if necessary. Install horizontal baffles, Cheek pressure and raise to design or lower gas rate in proportion to reduction in pres- Check liquid density. If it Is less than design, gas rate will have to be cut in proportion to eduetion in density.B. TROUBLESHOOTING PROCEDURE FOR INABILITY 9 ‘TO HOLD CONSTANT LIQUID LEVEL (CAUSE OF CHANGING LEVEL ‘TROUBLESHOOTING PROCEDURE. 1, Float is totally covered with Clean gauge class to get accurate level liquid ending b. If float cage is external, drain it to be sure pipes between eage and vessel are not plugged. fc. When gauge glass and float cage are lean, check {0 seo if float is covered with liquié. 4. Manually drain enough liguié from vessel so that 1/2 of float is immersed, ©. Put level controller in service 2, Liquid level is below float 8, Perform steps a and b above Noneeherenicia sia If level is below float, elose valve in funetion if the liquid level is abowe for below float. The float must be liquid outlet line to allow Jevel to rise until float is 1/2 covered. carbs ipihieosst ian @. Put level controller in service ‘order for controller to work. 3. Liquid flow rate has changed. If level controller does not have reset, the level controller will have to be hanged each time the liquid flow rate makes a signifieant change. If the controller has reset, it can be adjusted to take eare of changes in liquid flow rate. Liquid enters vessel in slugs. Lower set point in level controller. Level controller does not b, Lower proportional band setting. react fast enough to drain In some cases it may be helpful to install liguia 2 valve positioner on the level eontrol valve in order for it to open rapidly. 5. Wave action is causing internal float to move. Install float shield.50 ‘TROUBLESHOOTING PROCEDURE FOR INABILITY TO HOLD CONSTANT LIQUID LEVEL Level control valve is not ‘Cheek valve action to see that it is not operating properly. closing when it is supposed to open. b. Stroke valve to full open and closed positions to se that the spring tension is hot too tight or too loose, and that nothing is under the valve seat to pre~ vent it from closing. ©. Cheek liquid flow rate with valve fully ‘open to see that there is no restrietion in ‘the line, T. Level controller shows no re- Manually twist torque tube or float arm sponse to change in level. to see that controller shows resnonse. If there is no response, repair controller. If controller shows response, float has apparently dropped off, or liquid level is ‘above or below float. b. Cheek liquid level as described in items Land 2. ¢. Manually open and close drain valve so that the liquid level travels the full length of the float. If the controller shows no response, the float has fallen off. 8. Float in oll-water interface is Check for emulsion in vessel by draining totally immersed in emulsion. f line conneeted to the vessel near the float. b. Drain emulsion from vessel if it is pre~ sent. 9. Density of oil has changed so a. Cheek density of oil. ‘that float will not respond to b. If it Is different from design, consult change in level. evel control suplier to get anew float.‘TROUBLESHOOTING 5 ‘The gauge glass that indicates the liquid level is probably the most important opera- ting device on @ separator. It is also one of the easiest devices to plug with dirt and debris, and cause it to show a false level. Gauge glasses should be eleaned with a brush or with @ chemical solution at frequent intervals; and the gauge valves should be blown down as required to prevent an accumulation of in them. Problem 8 a. Liquid earryover in outlet gas from a separator is eaused by: Saeey ___2. High gas flow rate, __8. Low liquid level in separator High liquid level in separator Low gas flow rate. Difficulty in holding proper liquid level is eaused by: Level control float is covered with liquid Level control float is 1/2 immersed in liquid Level of liquid is below float Float is immersed in emulsionNOTESSEPARATORS. VALIDATION ‘Trainee StUNITS Determine the minimum size of horizontal and vertical separator for the following conditions: ‘Operating pressure 8000 kPa Gas flow rate 1 400 000 m3/4 ll flow rate 192 m? ne Oil density. 850 kg/m? Oil residence time J minute Vertical Separator size: dia height Horizontal Separator size: dia long ‘The most important instrument on a separator ist __Level controller _ Pressure gouge Gauge glass Mist is removed from gas with Vortex breaker _Coaleseing plates _Weir Mist Pad Indicate the type of separator to use in the following services: Wellhead separator on low GOR oil well Horizontal/Vertieal Compressor suction serubber Horizontal/Vertical Fraetionator reflux accumulator Horizontal/Vertical ‘The most critiesl control point in a 8-phase separator is: __Gas-oil interface __Oil-water interface _Pressure If the flow of liquid entering a separator inereases, the liquid level will: Rise _ Stay the same __ Fall 5a In a.gas-oil separator, the gas flow rate has inereased and the oll flow has decreased. ‘The liquid level should _Raised __Kept the same _lowered ‘The liquid volume of a separator is determined by :SOLUTIONS TO PROBLEMS - SI UNITS Refer to Figure 8A. At 7600 kPa, 850 kg/m?, 1.5 million m*/, dia Liquid section must hold $00 Ite/min for 1 min. Volume Is 500 x Hn page i, S0.em diameter ena ws 8 rm Hight required for £00 ters = 300 < 18 om Yestl hit for tigui setion = z8em Vesel hich for one = 2x a= 2x50 1a em Teta eit = ‘stem Refer to Figure 9A. At 7600 kPa, 850 Kg/m’, 1.5 million m*/d Vapor disengaging area = 0.33 m ? Liguid volume = 500 Itr/m x 1 min = 900 Ite or 0.5m? Refer to Figure 10A. At 0.83 m/ vapor area and 0.5 m? residence volume, diameter = 82 em Length = 82 x 1 Weir height = 1/2 diameter = 0.5 x 290 =125 em. Minimum water level = (Weir Height) x (Rel Dens) = 125 x 0.8 = 100 em For 0.8 relative density oil, 1 em change in water level will cause 5 em change in interface level (Table 2, P-45). Water Level Interface Level 100 em dem 101 em sem 102 em 10.em 104 em 20em 112 em sdem a bd b Las58 SEPARATORS VALIDATION Trainee, ENGLISH UNITS 1. Determine the minimum size of horizontal and vertical separator for the following. ‘conditions: Operating pressure 1,200 psi Gas flow rate 50 MMef/d Oil flow rate 2 bbI/min Oil gravity 40° API Oil residence time 1 minute wrtical Separator size: dia height Horizontal Separator size: dia long. 2. ‘The most important instrument on a separator ist __Level Controller __Pressure gauge _Gauge glass 3. Mist is removed from gas with __Vortex breaker _Cowlleseing plates. —__Weir_Mist Pad 4, Indicate the type of sepsrator to use in the following services: Wellhead separator on low GOR oil well Horizontal/Vertical Compressor suction serubber Horizontal/Vertical Fractionator reflux aecumulator Horizontal/Vertical 5. The most eritieal control point in a 3-phase separator is: __Gas-oll interface __Oil-water interface _Pressure 5, If the flow of liquid entering a separator increases, the liquid level will: __ Rise __Stay the same __ Fal Ina gas-oil separator, the ges flow rate has inereased and the oil flow has decreased. ‘The liquid level should _Raised __Kept the same __Lowered 8 The liquid volume of w separator is determined by :56 SOLUTIONS TO PROBLEMS - ENGLISH UNITS lalsicioia 3. Refer to Figure 8B. At 1100 psi, 40° API, 50 MMefd, diameter = 35 in 4. Liguid seetion must hold 182 gpm for 1 min, Volume is 182 x1 = 132 gal From Page 21, 35 in diameter vessel holds 4.2 gal per inch. Height requived for 182 gal Hin Vessel height for liquid seetior ain ‘Vessel height for vapor = 2x dia 20in Total height = 101 in 5. Refer to Figure 9B. At 1100 psi, 40° API, 50 MMet/q, Vapor disengaging ares = 3.8 sa ft Liquid volume = 132 gpm x1 min = 132 gal or Refer to Figure LOB. At 3.8 sq ft vapor area and 9.1 bbl r Diameter = 32 in. Length = Dia x 2x 4 = 128 in 1. Weir height = 1/2 diameter = 0.5 x 100 = 80 in Minimum water level = (Weir Height) x (Rel Dens) = 90 x 0.8 = 40 in For 0.8 relative density oil, 1 in. change in water level will cause 5 in. ehange in interface level (Table 2, P-45). Water Level Interface Levet 40 in in Alin sin ‘in 10 in 43 in 15in 44in 20 in 45 in 25 in