1902-01GN-00-00L-G0004 - D1 Engineering Method Separator Design - Review

GENTING OIL KASURI PTE.LTD.
AKM PRODUCTION FACILITIES

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DOC. NO: 1902-01GN-00-00L-G0004

GUIDANCE ON ENGINEERING REVISION: D1
METHOD SEPARATOR DESIGN DATE: 14 AUGUST 2019
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TABLE OF CONTENTS
TABLE OF CONTENTS ............................................................................................................. 3
LIST OF TABLES ....................................................................................................................... 4
1. INTRODUCTION ............................................................................................................... 5
2. DEFINITION ...................................................................................................................... 6
3. OBJECTIVE ...................................................................................................................... 6
4. REFERENCES .................................................................................................................. 6
4.1 International Code and Standard .............................................................................. 6
4.2 Others ....................................................................................................................... 7
5. TERMINOLOGY ................................................................................................................ 7
6. DESIGN AND SIZING ....................................................................................................... 8
6.1 Definitions ................................................................................................................. 8
6.2 Basic Design ............................................................................................................. 9
6.3 Design Margin........................................................................................................... 9
6.4 Selection Criteria .................................................................................................... 10
6.4.1 Vertical Separator......................................................................................... 10
6.4.2 Horizontal Separator .................................................................................... 10
6.5 Gas/Liquid 2-Phase Separator Design .................................................................... 11
6.5.1 With Wire Mesh Mist Extractor ..................................................................... 11
6.5.1.1 Vertical Separator with Wire Mesh Mist Extractor ............................................... 14
6.5.1.2 Horizontal Separator with Wire Mesh Mist Extractor ........................................... 14
6.5.2 Separator Without Mist Extractor .................................................................. 15
6.5.2.3 Vertical Separator without Mist Extractor ............................................................ 17
6.5.2.4 Horizontal Separator without Mist Extractor ........................................................ 17
6.5.3 Liquid Retention Time................................................................................... 18
6.5.4 Inlet and Outlet Devices ............................................................................... 19
6.6 Liquid/Liquid Separator Design ............................................................................... 20
6.7 Gas/Liquid/Liquid Separator Design........................................................................ 21
6.7.1 Vertical Three Phase Separator ................................................................... 22
6.7.2 Horizontal Three Phase Separator ............................................................... 24
6.8 Sizing Criteria of Suction and Discharge Scrubber .................................................. 25
6.9 Sizing Criteria of KO Drum ...................................................................................... 25
6.10 Sizing Criteria of Filter............................................................................................. 25
7. ABBREVIATION.............................................................................................................. 25
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LIST OF FIGURES
Figure 1-1 Kasuri Block Plan of Development .............................................................................5
Figure 6-1 Drag Coefficient of Rigid Sphere ..............................................................................15
Figure 6-2 Horizontal 3-phase Separator Weir Type .................................................................24
Figure 6-3 Horizontal 3-phase Separator Boot Type .................................................................24
LIST OF TABLES
Table 6-1 Typical Surge Factors ...............................................................................................10
Table 6-2 K-Factor ....................................................................................................................11
Table 6-3 Adjusment of K-Factor for Pressure Condition ..........................................................11
Table 6-4 L/D Ratio at High Pressure ........................................................................................14
Table 6-5 Liquid Retention Time for Two-Phase Separator .......................................................18
Table 6-6 Momentum Criteria for Inlet Nozzle ...........................................................................19
Table 6-7 Liquid Retention Time for Liquid/Liquid Separator .....................................................20
Table 6-8 Value of C* ................................................................................................................21
Table 6-9 Liquid Retention Time for Three-Phase Separator ....................................................22
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1. INTRODUCTION
COMPANY intends to develop Asap, Kido and Merah (AKM) Gas Field which is located within
the Kasuri Production Sharing Contract (PSC) Block in Kabupaten Teluk Bintuni, West Papua
Province.
The Asap Kido and Merah (AKM) Production Facilities consists of:
a) A gathering system consisting of ten (10) well pads, three (3) GGS and flowlines;
b) Liquid Processing Plant (LPP) in Nagote;

c) Gas Trunk line from GGS to petrochemical plant; liquid pipeline from GGS to LPP, and
Condensate Export pipeline
d) Tofoi Receiving Facilities;
e) Gas Receiving station plant;
f) Supporting infrastructure facilities; and
g) Future Compressors System.
Figure 1-1 Kasuri Block Plan of Development

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2. DEFINITION
Term Definition of Term

COMPANY GENTING OIL Kasuri Pte. Ltd.
Consortium Bina Rekacipta Utama – Tiga Inti Pilar – Suluh Ardi
FEED CONTRACTOR
Engineering
A CONTRACTOR who has entered into a contract and/or purchase
EPCI CONTRACTOR
order relating to the EPCI PROJECT with COMPANY
Project FEED Asap Kido and Merah (AKM) Production Facilities Project
All equipment used in operation of oil and gas facilities where it is
Equipment necessary to perform special examination to ensure the safety of
environment
3. OBJECTIVE
The basic objective of this document is to define the minimum requirement for separator
design to be implemented on AKM Field.
This guidelines specifies minimum requirement and gives recommendations for the selection
and design of separator that need to be implemented by COMPANY. Scope of this guidance
is to provide general sizing criteria for types of separator as follow:
 Gas/Liquid 2-Phase Separators

 Liquid/Liquid Separators
 Gas/Liquid/Liquid 3-Phase Separators
4. REFERENCES
4.1 International Code and Standard
The International codes and standards referred to in this document shall be taken to mean the
latest edition of that Code or Standard, including all parts, addenda, and supplements
revisions.
Code and Standard No. Code and Standard Title

API RP 14E Recommended Practice for Design and Installation of
Offshore Production Platform Piping Systems, 5th Ed 1991
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Code and Standard No. Code and Standard Title

API SPEC 12J Specification for Oil and Gas Separators, 8th Ed. 2008
4.2 Others
Document Document Title

GPSA 11th Ed Engineering Data Book, Gas Processors Suppliers Association,
FPS 1998
Ken Arnold and Maurice Stewarart, Surface Operation
Productions
McKetta Vol 31 Encyclopedia Chemical Process and Design
5. TERMINOLOGY
Throughout this document, the words ‘will’, ‘may’, ‘should’, ‘shall’ and ‘must’, when used in the
context of actions by Company or others, have specific meanings. For purposes of this
Procedure, the following terms apply:
Will : used normally in connection with an action by

COMPANY, rather than by a contractor or supplier
May : used if alternatives are equally acceptable
Should : used if a provision is preferred
Shall : used if a provision is mandatory by COMPANY
Must : used only if a provision is a statutory requirement

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6. DESIGN AND SIZING
6.1 Definitions
Separator
A vessel used to separate a mixed-phase stream into gas and liquid phases that are relatively
free of each other.
Liquid-Liquid Separator
Two immiscible liquid phases can be separated using same principles as for gas and liquid
separators.
Three Phase Separator
A vessel used to separate gas and two immiscible liquids of different densities (e.g. gas, water,
and oil).
Scrubber
Scrubber is a type of separator designed to handle flow streams with high gas-to-liquid ratios.
Knock-out
Knock-out is a type of separator which falls into two categories: free water and total liquid
knock outs.
Free water knock –out is a vessel used to separate free water from a flow stream of gas, oil,
and water. The gas and oil usually leave the vessel through the same outlet to be processed
by other equipment.
The total liquid knock-out is normally used to remove the combined liquids from a gas stream.
Slug Catcher
A particular separator design able to absorb sustained in-flow of large liquid volumes at
irregular intervals.
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6.2 Basic Design
Separator are designed for the following general purposes such as:
a. To accommodate vapor or liquid for:
 stable operation of the unit

 protect downstream equipment during emergency shutdown or mal-operation
 pigging activities
b. To separate entrained liquid/solid from vapor or heavier liquid to

 reduce loss of valuable product
 improve purity of product
 eliminate contamination
 avoid downstream erosion/corrosion
 prevent environmental pollution
Drums are often intended to have two or more functions, for example, vapor-liquid separation
and liquid-liquid separation simultaneously, drum shall be designed to satisfy each
requirement.
Separators without internal device (mist extractors) are designed for gravity settling.
In the gravity settling section the liquid drops will settle at a velocity determined by equating
the gravity force on the drop with the drag force caused by its motion relative to the gas
continues phase.
The drag coefficient has been found to be a function of the shape of the particle and the
Reynolds number of the following gas.
6.3 Design Margin
The function of separator is to provide removal for free gas from oil and water at specified
pressure and temperature. Where a separator is receiving well stream fluid and surging flow
may occur, a flow surge factor should be applied. To accommodate the surge, typical factor
are taken from API RP 14E shown in Table 5-1.
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Table 6-1 Typical Surge Factors

NO. DESCRIPTION FACTOR
1. Facility handling primary production from its own facility 10%
2. Facility handling primary production from another facility 30%
4. Facility handling gas lifted production from its own facility 40%
5. Facility handling gas lifted production from another facility 50%
Detail surge capacity need to be confirmed using flow transient analysis (dynamic simulation)
to consider large liquid volume during pigging activities.
6.4 Selection Criteria
A care shall be taken in selecting a separator in order to match the specific duty, and then it
will meet gas and liquid specification for the downstream equipment.
Droplet size recovery and separator internal determination is very important to accommodate
the specific duty.
6.4.1 Vertical Separator
 Selected when gas-liquid ratio is high

 Smaller plan area is required
 Easier solids removal
 Liquid removal efficiency does not vary with liquid level (area in vessel available for
gas flow remains constant)
 Vessel volume generally smaller
 Stable vapor-liquid separation is required even if liquid level fluctuates frequently
 Re-vaporization or re-mixing of fluids should be avoided.
6.4.2 Horizontal Separator
 Large liquid have to be accommodate

 Vapor-liquid ratio is low
 Required separation efficiency
 A low downward liquid velocity is required (for de-gassing purposes, for foam
breakdown or a difficult liquid-liquid separation)
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 A large liquid surface area is required for degassing purposes

 Head space is restricted
6.5 Gas/Liquid 2-Phase Separator Design
6.5.1 With Wire Mesh Mist Extractor
a. K-Factor
Refers to API Specification 12J, K-Factor for determining maximum allowable

superficial velocity is shown in table below.
Table 6-2 K-Factor

Type Separator Height or Length (m) K-Factor (m/s)
1,5 0,04 – 0,07
Vertical
3 0,05 – 0,11
3 0,12– 0,15
Horizontal (0,12 – 0,15) multiply by
Other length
(L/3,05)0.56
Adjusments of K-Factor for pressure condition are shows in table below.
Table 6-3 Adjusment of K-Factor for Pressure Condition

Pressure (psig) K-Factor (% of design)
Atmospheric 100
150 90
300 85
600 80
1150 75
b. Gas Capacity
Gas capacities of separators can be determined by a modification of Stoke’s Law. When

using Stoke’s Law, the capacity is based on the principle of the minimum droplet size
that will settle out of a moving gas stream at a given velocity. Liquid droplets will settle
out of a gas phase if the gravitational force acting on the droplet is greater than the drag
force of the gas flowing around the droplet.
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Following equations used to calculate terminal gas velocity.
 Most vertical separators that employ mist extractor and horizontal separator with
length less than 3 m in height are sized using equation
𝝆𝒍 −𝝆𝒈
𝑽𝒕 = 𝑲 √ Equation 6-1
𝝆𝒈
Horizontal separator with length greater than 3 m with mist extractors are sized
using equation
𝜌𝑙 −𝜌𝑔 𝐿 0.56
𝑉𝑡 = 𝐾 √ ( ) Equation 6-2
𝜌𝑔 3.05
Where
K = empirical constant for separator sizing, m/s
𝜌𝑙 = Liquid phase density, droplet or particle (kg/m3)
𝜌𝑔 = Gas phase density (kg/m3)
𝑉𝑡 = Critical or terminal gas velocity (m/s)
𝐿 = Separator length seam to seam (mm)
It shall be ensured that an actual gas velocity shall be less than a maximum terminal
gas velocity supplied by K-factor.
Other criteria shall be defined by considering a specified residence time of oil droplets
in gas phase and the droplets fall time. To determine this value we shall estimate the
settling velocity (terminal velocity). Following equation is used to calculate terminal
velocity of the gas at operating conditions with limiting conditions.
 Stoke’s Law
Applicable at low Reynold numbers (less than 2) and droplet diameter of

approximately 3-100 microns. The droplet diameter corresponding to a Reynolds
number of 2 can be found using a value of 0.0080 for KCR in equation 6-3. Thus,
equation of Stoke’s law can be expressed as:
1000 𝑔 𝐷𝑝2 (𝜌𝑙 −𝜌𝑔 )

𝑉𝑡 = 18𝜇
where KCR = 0.025 Equation 6-3
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 Intermediate’s Law
Provided to cover gap range of particles size (100-1000 microns) and Reynolds
number (2-500) between Stoke’s and Newton’s law. Equation for Intermediate’s
law can be expressed as:
𝟎.𝟕𝟏
𝟑.𝟓𝟒𝒈𝟎.𝟕𝟏 𝑫𝟏.𝟏𝟒
𝒑 (𝝆𝒍 −𝝆𝒈 )
𝑽𝒕 = where KCR = 0.334 Equation 6-4
𝝆𝟎.𝟐𝟗
𝒈 𝝁
𝟎.𝟒𝟑
 Newton’s Law
For relatively larger particles (approximately 1000 microns and larger) the gravity
settling is described by Newton’s law. The maximum droplet which can settle out
can be determined by:
𝟏/𝟑
𝝁𝟐
𝑫𝒑 = 𝑲𝑪𝑹 𝒙 ( ) where KCR = 18.13 Equation 6-5
𝒈 𝒙 𝝆𝒈 𝒙 (𝝆𝒍 −𝝆𝒈 )
The limiting drag coefficient is 0.44 at Reynolds numbers 500 – 200,000. The
Newton’s law equation expressed as:
𝒈𝑫𝒑 (𝝆𝒍 −𝝆𝒈 )

𝑽𝒕 = 𝟏. 𝟕𝟒 𝒙 √ Equation 6-6
𝝆𝒈
c. Liquid Capacity
Liquid capacity of separator is primarily dependent upon the retention time of liquid in
the vessel. The liquid capacity of a separator or settling volume required based on
retention time that can be determined from the following equation:
𝟏𝟒𝟒𝟎𝑽
𝑾= Equation 6-7
𝒕
Where
W = liquid hold-up capacity (m3/day) (m3/day = 6.2898 bpd)

V = liquid settling volume (m3) (m3 = 6.2898 barrel)
t = retention time (minutes)
Separators can be any length, but the ratio of seam-to-seam length to the diameter of
the vessel, L/D, is usually in the range of 2:1 to 4:1.
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For the higher design pressure, the larger L/D ratio is preferred considering economic
design and restriction of plot plan. Economic L/D ratio as a guide is shown in Table 6-4.
Table 6-4 L/D Ratio at High Pressure

Design Pressure (psig) L/D Ratio
≤ 256 3
256 – 505 4
≥ 505 5
6.5.1.1 Vertical Separator with Wire Mesh Mist Extractor
In the vertical separator, the fluids enter the vessel striking a diverting baffle which initiates
primary separation. Liquid removed by the inlet baffle falls to the bottom of the vessel and
the gas moves upward. If the size of the liquid droplet is too small, it will be carried up and
out with the gas/ vapor. Thus, a wire mesh mist extractor section is added to capture small
liquid droplets.
When the gas goes through the mist extractor, liquid carry-over will be removed by the mist
extractor and coalesced into larger droplets which then fall through the gas to the liquid
reservoir in the bottom.
6.5.1.2 Horizontal Separator with Wire Mesh Mist Extractor
In the horizontal separator, fluid enters the separator and hits inlet diverter, causing a
sudden change in momentum. The initial gross separation of the liquid and vapor occurs at
the inlet diameter. The force of the gravity causes the liquid droplet to fall out of the gas
stream to the bottom of vessel, where it is collected.
The liquid collection shall consider:
- The retention time required to let entrain gas out and rise to vapour space
- A surge volume to handle intermediate slug during pigging activities.
The gas and liquid carry-over, which not separated in gravity settling section, will pass
through mist extractor that removes very small droplets of liquid carry-over in one final
separation before gas leaves the vessel.
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6.5.2 Separator Without Mist Extractor
This is typically a horizontal vessel which utilizes gravity as the sole mechanism for
separating the liquid and gas phases. Gas and liquid enter through the inlet nozzle and are
slowed to a velocity such that the liquid droplets can fall out of the gas phase. The dry gas
passes into the outlet nozzle and the liquid is drained from the lower section of the vessel.
To design a separator without a mist extractor, the minimum size diameter droplet to be
removed must be set. Typically this diameter is in the range of 150 to 2,000 microns.
a. Drag Coefficient
The drag coefficient has been found to be a function of the shape of the particle and
the Reynolds number of the flowing gas. For the purpose of this equation particle shape
is considered to be a solid, rigid sphere.
Figure 6-1 Drag Coefficient of Rigid Sphere

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The abscissa of Figure 6-1 is given by
(1.31)(107 )𝜌𝑔 𝐷𝑝3 (𝜌𝑙 −𝜌𝑔 )

𝐶 ′ (𝑅𝑒)2 = Equation 6-8
𝜇2
Where
𝐷𝑝 = droplet diameter (m)

µ = viscosity of continuous phas (cP)
𝐶′ = drag coefficient of particle
b. Terminal Velocity
𝟒 𝒈 𝑫𝒑 (𝝆𝒍 −𝝆𝒈 )
𝑽𝒕 = √ Equation 6-9
𝟑𝝆𝒈 𝑪′
Where
𝑉𝑡 = terminal velocity (m/s)

𝑔 = acceleration due to gravity, at 9,81 m/s2
𝐷𝑝 = droplet diameter (m)

𝐶′ = drag coefficient of particle
c. Minimum Area
The minimum area requirement can be calculated with following equation:
𝑸𝑨
𝑨= Equation 6-10
𝑽𝒕
Where
A = minimum area requirement (m2)
QA = actual gas flowrate (m3/s) (m3/s = 2118.88 ACFM)
Vt = terminal velocity (m/s)

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d. Length of Separator
The length of vessel required can then be calculated by assuming that the time for the
gas to flow from inlet to outlet is the same as the time for the liquid droplet of size Dp to
fall from the top of the vessel to the liquid surface. Following equation to calculate length
of separator (assuming no liquid retention):
𝟒 (𝟏𝟎𝟑 𝒎𝒎/𝒎)𝟐 𝑸𝑨
𝑳= Equation 6-11
𝝅 𝑽𝒕 𝑫 𝒗
Where
L = seam to seam length of vessel, mm
Dv = vessel diameter (mm)
QA = actual gas flowrate (m3/s) (m3/s = 2118.88 ACFM)
Vt = terminal velocity (m/s)
6.5.2.3 Vertical Separator without Mist Extractor
Vertical separator is used when the wellfluid containing sand and other sediments and fitted
with false cone bottom to handle sand production. Recommended for diameter-length ratio
from 2 to 4. Large diameter will be used when vapor-liquid separation relative small
compared with liquid surge volume.
Typically use one-half of K at Table 6-2 for approximate sizing of vertical separators without
mist extractors.
6.5.2.4 Horizontal Separator without Mist Extractor
Horizontal separator used when ratio of vapor load to liquid is small and minimum droplets
size to be removed is 150 µm.
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6.5.3 Liquid Retention Time
Basic design criteria for liquid retention time in two-phase separators are generally as
follows:
Table 6-5 Liquid Retention Time for Two-Phase Separator

Oil Gravities Minutes
o
Above 35 API 1
20 – 30o API 1–2
10 – 20 API
o
2–4
The liquid levels and residence times below are recommended for two-phase separator.
Sizes may be optimized by vessel vendor.
1. Vertical Separator
h1 : minimum 150
h2 : 1 minute with minimum 150
h3 : 3 minutes + slug allowance with minimum 300
h4 : 1 minute with minimum 150 mm
2. Horizontal Separator
h1 : minimum 150
h2 : 1 minutes minimum 150
h3 : 3 minutes + slug allowance minimum 300
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Notes:
1 All indicated level is in mm unless specified otherwise.
2 NLL will be determined on a case by case basis but will generally be halfway between LLL
and HLL.
3 LLLL to BTL shall also consider closure time of liquid outlet SDV and potential for gas
blowby.
The volume required to handle liquid surges/slugs will be determined on a vessel by vessel
basis. The liquid surge/slug volume should be accommodated between NLL and HLL.
6.5.4 Inlet and Outlet Devices
a. Inlet Nozzle
Diameter of the inlet nozzle is a function of the feed flow rate and pressure. The criteria
for nozzle sizing is the momentum of feed shall not exceed prescribed levels.
Momentum criteria are given in table below:
Table 6-6 Momentum Criteria for Inlet Nozzle

Criteria as max ρ.v2
Inlet Device
(kg/m.s2)
No inlet device 1000
Half open pipe 1500
Schoepentoeter or equivalent 6000
Note: The inlet criteria use a mixture gas liquid density
b. Outlet Nozzle
 Diameter of gas outlet nozzle shall normaly be taken equal to outlet pipe, but
generally maximum ρv2 as 3750 (kg/m.s2).
 Liquid outlet nozzle velocity shall be less than 2 m/s or minimum diameter 2 inch.
 If the liquid outlet supplies a pump or other devices requiring low pressure drop,
velocity of liquid shall be reduced to 0.9 m/s.
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6.6 Liquid/Liquid Separator Design
Liquid-liquid separation may be divided into two board categories of operation:
 Gravity separation, where the two immiscible liquid phases separate within the vessel by
the differences in density of the liquids. Sufficient retention time must be provided in the
separator to allow for the gravity separation to take place.
 Coalescing separation, where small particles of one liquid phase must be separated or
removed from a large quantity of another liquid phase. Different types of internal
construction of separators must be provided for each type of liquid-liquid separation.
Retention times for liquid/liquid separation provides in table below.
Table 6-7 Liquid Retention Time for Liquid/Liquid Separator
Type Separation Minutes

Hydrocarbon/Water Separators
Above 35o API hydrocarbon 3–5
Below 35o API hydrocarbon
38 oC and above 5 – 10
27 oC 10 – 20
15 oC 20 – 30
Coalescer, Hydrocarbon/Water Separator
27 oC 10 – 20
15 oC 20 – 30
The liquid-liquid separation capacity of separators can be determined from equation below.
 Vertical Vessels
𝑆ℎ𝑙 −𝑆𝑙𝑙
𝑊𝑐𝑙 = 𝐶 ∗ ( 𝜇
) (0.785)(10−6 )𝐷𝑣2 Equation 6-12
 Horizontal Vessel
𝑺𝒉𝒍 −𝑺𝒍𝒍
𝑾𝒄𝒍 = 𝑪∗ ( ) 𝑳𝒍 𝑯𝒍 Equation 6-13
𝝁
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With value of C*
Table 6-8 Value of C*

Emulsion Droplet Diameter, Constant,
Characteristics Microns C*
Free liquid 200 1880
Loose emulsion 150 1060
Moderate emulsion 100 470
Tight emulsion 60 170
Where
Wcl = flowrate of light liquid (m3/day) (m3/day = 6.2898 bpd)

C* = empirical constant for liquid/liquid separators
Dv = inside diameter of vessel (mm)
Shl = specific graviy of heavy liquid
Sll = specific gravity of light liquid
µ = viscosity of continuous phase (cP)
Ll = length of liquid interface area (mm)
Hl = width of liquid interface area (m)
6.7 Gas/Liquid/Liquid Separator Design
All of the basic separators may be used for three-phase separation. Sizing three-phase
separator is mainly a function of retention time. There are two primary considerations in
specifying retention time:
 Oil settling time to allow adequate water removal from oil

 Water settling time to allow adequate oil removal from water
Preliminary sizing of 3 phase separators will be as follows:
Between IHLL and ILLL (water volume) 5 minutes (minimum)
Between HLL and LLL (oil volume) 5 minutes (minimum)

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The axial velocity of both liquid phases should be kept below approximately 0,04 m/s and the
slip between both phases should be minimized where practicable.
The volume required to handle oil surges/slugs will be determined on a vessel by vessel basis.
The oil surge/slug volume should be accommodated between NIL and IHLL. The water
surge/slug volume should be accommodated without activation of IHHLL or HHLL.
If the water volumetric flowrate is small and does not warrant the use of a separate baffled
settling compartment, a water boot may be used instead.
Basic design criteria for liquid retention time in three-phase separators are generally as
follows:
Table 6-9 Liquid Retention Time for Three-Phase Separator
Oil Gravities Minutes
Above 35o API 3–5

Below 35o API
27 oC 10 – 20
15 oC 20 – 30
6.7.1 Vertical Three Phase Separator
Vertical three phase separator is used when it is necessary to separate gas, oil, and water.
The selection of this type should follow Section 6.4.
Minimum requirement of three phase separator to ensure proper separation is as follows:
 For condensate/ HC and water criteria is that the vertical velocity shall be smaller than
settling velocity. If not, it is impossible to decant HC in water phase and/ or water in HC
phase.
 To avoid having water in condensate/ HC downcomer at any time, a water droplet

should have a settling velocity high enough to not reach the baffles. The vertical falling
time shall be smaller than the time to reach the baffle horizontally
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DOC. NO: 1902-01GN-00-00L-G0004

PAGE: 23 OF 26
 The criteria VL1 < 6 cm/s is used by analogy with column downcomer design. The ratio
VL1/V1 has to be higher than 1 to allow a proper circulation of liquid between the baffles.
Where: V1 is velocity of decanting HC in water
VL1 is velocity in downcomer
 The recommended level and retention time
h8 : minimum 150
h7 : 1 minutes or minimum 150
h6 : 5 minutes + slug allowance or minimum 300
h6 : minimum 150
h5 : minimum 150
h3 : 5 minutes + slug allowance or minimum 300
h1 : minimum 150
* All level in mm, unless otherwise specified.

PROJECT
DOC. NO: 1902-01GN-00-00L-G0004

PAGE: 24 OF 26
6.7.2 Horizontal Three Phase Separator
Horizontal type of three phase separator is commonly used than the vertical type. Two
types of horizontal three phase separator which are with boot and with weir.
The recommended level and retention time to ensure proper separation of horizontal three
phase separator is as follows:
Figure 6-2 Horizontal 3-phase Separator Weir Figure 6-3 Horizontal 3-phase Separator
Type Boot Type
h1 : minimum 150
h3 : 3 minutes + slug allowance minimum 300
h5 : minimum 150
* All level in mm unless otherwise specified.

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DOC. NO: 1902-01GN-00-00L-G0004

PAGE: 25 OF 26
6.8 Sizing Criteria of Suction and Discharge Scrubber
The droplet diameter of Suction Scrubber should be 50 microns if separator is not equipped
with mist extractor and if otherwise 375 microns should be used.
For compressor suction scrubbers multiply K at Table 6-2 by 0.7 - 0.8 and discharge scrubber
use no multiply factor.
6.9 Sizing Criteria of KO Drum
General design criteria for KO Drum are similar to a two-phase separator without mist
extractor. The sizing calculation method shall refers to Section 6.5.2.
Detail of KO Drum sizing can be found at Guidance on Engineering Method Relief and
Disposal System for Manned Station-Facilities (1902-01GN-00-00L -G0047).
6.10 Sizing Criteria of Filter
The design of filter is proprietary and a manufacturer should be consulted for specific size and
recommendations. It because manufacturer has own consideration and will vary for cartridge
or filter element size (different manufacturers will have different cartridge size).
However to calculate the body size of a filter, approach of 0.40 m/s K factor can be
implemented according to GPSA Handbook Vol I Section 7 Separator and Filter.
7. ABBREVIATION
AKM Asap, Kido, Merah

BOV Bottom of Vessel
BTL Bottom Tangen Line
GGS Gas Gathering Station
HHLL High High Liquid Level
HLL High Liquid Level
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DOC. NO: 1902-01GN-00-00L-G0004

PAGE: 26 OF 26

KO Knock Out
LLL Low Liquid Level
LLLL Low Low Liquid Level
LPP Liquid Processing Plant
RP Recommended Practice
SDV Shutdown Valve

1902-01GN-00-00L-G0004 - D1 Engineering Method Separator Design - Review

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GENTING OIL KASURI PTE.LTD.

AKM PRODUCTION FACILITIES

DOC. NO: 1902-01GN-00-00L-G0004

TABULATION OF REVISED PAGES

REVISION REVISION REVISION

DOC. NO: 1902-01GN-00-00L-G0004

DOC. NO: 1902-01GN-00-00L-G0004

DOC. NO: 1902-01GN-00-00L-G0004

b) Liquid Processing Plant (LPP) in Nagote;

Figure 1-1 Kasuri Block Plan of Development

DOC. NO: 1902-01GN-00-00L-G0004

Term Definition of Term

 Gas/Liquid 2-Phase Separators

 Gas/Liquid/Liquid 3-Phase Separators

4.1 International Code and Standard

Code and Standard No. Code and Standard Title

DOC. NO: 1902-01GN-00-00L-G0004

Code and Standard No. Code and Standard Title

Document Document Title

Will : used normally in connection with an action by

May : used if alternatives are equally acceptable

Should : used if a provision is preferred

Shall : used if a provision is mandatory by COMPANY

Must : used only if a provision is a statutory requirement

DOC. NO: 1902-01GN-00-00L-G0004

6. DESIGN AND SIZING

Three Phase Separator

DOC. NO: 1902-01GN-00-00L-G0004

6.2 Basic Design

a. To accommodate vapor or liquid for:

 stable operation of the unit

b. To separate entrained liquid/solid from vapor or heavier liquid to

6.3 Design Margin

DOC. NO: 1902-01GN-00-00L-G0004

Table 6-1 Typical Surge Factors

6.4 Selection Criteria

6.4.1 Vertical Separator

 Selected when gas-liquid ratio is high

6.4.2 Horizontal Separator

 Large liquid have to be accommodate

DOC. NO: 1902-01GN-00-00L-G0004

 A large liquid surface area is required for degassing purposes

6.5 Gas/Liquid 2-Phase Separator Design

6.5.1 With Wire Mesh Mist Extractor

Refers to API Specification 12J, K-Factor for determining maximum allowable

Table 6-2 K-Factor

Adjusments of K-Factor for pressure condition are shows in table below.

Table 6-3 Adjusment of K-Factor for Pressure Condition

Gas capacities of separators can be determined by a modification of Stoke’s Law. When

DOC. NO: 1902-01GN-00-00L-G0004

Following equations used to calculate terminal gas velocity.

Applicable at low Reynold numbers (less than 2) and droplet diameter of

1000 𝑔 𝐷𝑝2 (𝜌𝑙 −𝜌𝑔 )

DOC. NO: 1902-01GN-00-00L-G0004

𝒈𝑫𝒑 (𝝆𝒍 −𝝆𝒈 )

W = liquid hold-up capacity (m3/day) (m3/day = 6.2898 bpd)

DOC. NO: 1902-01GN-00-00L-G0004

Table 6-4 L/D Ratio at High Pressure

6.5.1.1 Vertical Separator with Wire Mesh Mist Extractor

6.5.1.2 Horizontal Separator with Wire Mesh Mist Extractor

The liquid collection shall consider:

DOC. NO: 1902-01GN-00-00L-G0004

6.5.2 Separator Without Mist Extractor