THREE-PHASE SEPARATOR (V-300)

As mentioned in Chapter 2, a horizontal three phase (gas-liquid-liquid) separator is chosen to

split up the organic liquid phase product from the heavy liquid phase and the vapour phase
product from the vapour-liquid inlet feed. A horizontal knock out separator is chosen mainly
due to its smaller plan area, has best separation efficiency among other shape of separator,
and also less expensive area compared to other configurations.

The sizing of three phase separator V-300 in this section refers to the type selection and
design rules of gas/liquid separators provided by Design and Engineering Practice (DEP)
code 31.22.05.12-Gen and code 31.22.05.11-Gen (SHELL, 2007). Prior to the sizing of three
phase separator, several parameters must be extracted from Aspen HYSYS simulation and
are tabulated in Table 1.

Table Error! No text of specified style in document..1 Data and Information required for
Three Phase Separator V-300 Sizing

Parameters Liquid Aqueous Vapour Reference

phase phase phase
Operating Temperature, T (ºC) 50 50 50 HYSYS
Operating Pressure, P (kPa) 135 135 135 HYSYS
Design Pressure, Pd (kPa) 189 189 189 Chapter 6
Design Temperature, Td (ºC) 70 70 70 Chapter 6
Inlet Volumetric Flow Rate, Q feed 86.37 101.1 1.179 × 104 HYSYS
(m3/h)
Inlet Volumetric Flow Rate, Q feed 2.399× 10- 2.808 × 10-2 3.275 HYSYS
2
(m3/s)
Outlet Liquid Volumetric Flow Rate, - - - HYSYS
Q out (m3/h)
Mass Density, 𝜌 (kg/m3) 870.8 988.3 0.4615 HYSYS
Dynamic Viscosity, ηL (Pa⸱s) 4.979 × 5.442 × 10-4 -
1.107 × 10 HYSYS
10-4 5

THREE PHASE SEPARATOR INTERNAL DIAMETER

Firstly, flow parameter, ɸ is an important criterion in separator design used to characterize the
type of vapour-liquid feed into the vessel (SHELL, 2007).
 QL ρL
ɸ=
QG √ ρG

Where,

ɸ = flow parameter

QL = volumetric flow rate of liquid inlet (m3/s)

QG = volumetric flow rate of gas inlet (m3/s)

ρL = mass density of liquid inlet (kg/m3)

ρG = mass density of gas inlet (kg/m3)

Since there are two liquid phases on three-phase separator, the liquid phases are assumed to
be homogeneously mixed, they can be considered to be a single liquid phase and use can be
made of available two-phase flow maps to characterise the G/L flow regime in the feed pipe.

Q L ρL +Q A ρ A
ρ L=
QL + Q A

10−2 m3 870.8 kg 10−2 m 3

ρ=
( 2.399 ×
s )( m3 )(
+ 2.808×
s )( 988.3
m3 )
kg

L −2 −2
10 m3 10 m3
2.399 × +2.808 ×
s s

kg
ρ L=934.164
m3

Substitute the mixed density into the flow parameter formulae.

m3 m3 kg
( )
√
−2
2.399 ×10 + 2.808× 10−2 934.164
s s m3
ɸ=
m3 kg
3.275 0.4615
s m3

ɸ=0.7153

If flow parameter is less than 0.01, the liquid will generally enter the separator as a
combination of a film and droplets. Slugs would not be expected. Since flow parameters is
quite large (0.7), in absolute terms, the liquid carry-over in the gas stream is large and slug
would be expected.

For horizontal wiremesh demisters, the vessel diameter is derived after considering the
requirements for both gas and liquid.

Vertical cross-sectional area for gas flow

The minimum vessel cross-sectional area for gas flow, A G,min, is taken above the LZA(HH)
liquid level and is computed as follows:

Q ¿max
AG ,min = And
λmax

λ max=0.09 f η f ɸ

Then

Q ¿max
AG ,min =
0.09 f η f ɸ

Where,

λ max = gas load factor (m/s)

Q ¿ MAX = design gas flow rate (m3/s)

𝐷𝑖 = vessel inner diameter (m)

fη = derating factor allowed for the viscosity of liquid phase

fɸ = derating factor related to flow parameter, ɸwm

The design gas flow, Q MAX can be calculated by using equation below.

ρG
Q ¿ MAX =Q g , MAX
√ ρ L− ρG

Where,

Q¿ MAX = design gas flow rate (m3/s)

Q g ,MAX = highest envisaged gas flow rate (m3/s)

ρG = mass density of vapour inlet (kg/m3)

 ρL = mass density of liquid inlet (kg/m3)

SHELL (2007) stated that the highest envisaged gas flow rate, Q g ,MAX incorporates a margin
for surging and other uncertainties, also known as the design margin which ranges between
1.15 to 1.25 for refineries and chemical plants. Based on Appendix IV as provided in DEP
31.22.05.11, a design margin of 1.2 should be chosen as the location of process plant is in a
flat and low rolling country (SHELL, 2007). However, in order to standardise with the design
margin of other equipment, design margin of 1.4 is used.

Q g ,MAX =QG × designmargin

Q g ,MAX =3.275 ×1.4

m3
Q g ,MAX =4.585
s

ρG
Q ¿ MAX =Q g , MAX
√ ρ L− ρG

m3
Q¿ MAX =4.585
kg

√
0.4615
m3
s
kg kg
934.164 −0.4615
m3 m3

m3
Q ¿ MAX =0.102
s

Next, the derating factor allowed for the viscosity of liquid phase, f η strongly depends on the
dynamic viscosity of liquid phase, ηL. If ηL ≤ 0.001 Pa·s, then f η= 1; if ηL > 0.001 Pa·s, f ηis
computed by using Eq. 8.10. In this case, the viscosity of liquid phase at inlet, ηL = 0.0004979
Pa·s, which is less than 0.001 Pa·s, f η = 1.

f η=1 if η L≤ 0.001 Pa·s

On the other hand, the derating factor relating to the flow parameter at the face of the
wiremesh, f ɸ can be computed by using Eq. 8.21. Where, the flow parameter at the face of
wiremesh, ϕwm is depending on the type of feed inlet device used. The value of ϕwm can be
obtained by the following criteria:
ϕ wm=0.05 ϕfeed ; if a Schoepentoeter isused

ϕ wm=0.2 ϕfeed ; if ahalf open pipe isused

1
f ɸ≈
1+10 ϕ wm

The choice of the feed inlet device depends on the following factors:

 If the gas volumetric fraction of the feed is less than 0.15, the inlet device is a
horizontal pipe section.
 If the gas volumetric fraction of the feed is between 0.15 and 0.7 the inlet device is a
horizontal half-open pipe and its opening is directed upwards.
 If the gas volumetric fraction is larger than 0.7, then a Schoepentoeter should be
selected.

Since gas volumetric in this case is 0.98 which is larger than 0.7, Schoepentoeter is selected
as inlet device.

ϕ wm=0.05 ϕfeed

ϕ wm=0.05× 0.7153

ϕ wm=0.0358

Sub ϕ wm into Eq. 8.21:

1
f ɸ≈
1+10 ϕ wm

1
f ɸ≈
1+10 × 0.0358

f ɸ ≈ 0.736

Sub Q*max, fη and fɸ into Eq. 8.18:

m3
0.102
s
AG ,min =
0.09 ( 1 ) ( 0.736 )
 m3
0.102
s
AG ,min =
[ 0.09 ( 1 ) ( 0.736 ) ] ms

AG ,min =1.540 m2

Then, the minimum vessel diameter can be determined required to accommodate A G,min using
Figure 1, which gives AG,min as a function of the vessel diameter D and LZA(HH). In this
Table it has been indicated for each of the three separators which (D-LZA(HH))
combinations are allowed (left or below the demarcation step lines in the figure).

Figure 1 : AG (m2) as a function of D and LZA(HH) in horizontal separators

(SHELL, 2007)
Since, AG,min is 1.54 m2, 1.55m2 is assumed as AG and from the figure we can get the diameter
of the three phase separator and LZA(HH) as 2.4 m and 1.5 m.
D=2.4 m

Thus, internal diameter is 2.4 metres.

THREE PHASE SEPARATOR LEVEL CONTROL SYSTEM

The height between each liquid level can be determined by referring to the standards as
shown in Figure 2. Although there is liquid slug and no liquid foaming in this system, the
slug allowance and foaming allowance not are considered in determining the liquid level.
Therefore, based on the guidance given in Figure 2, the liquid height at each level is obtained
and tabulated in Table 3
 Figure 2 :Liquid level control in a gas/liquid/liquid separator (SHELL, 2007)
Table Error! No text of specified style in document..2 :Height of Liquid Level in Three
Phase Separator V-300

Compartmen Level Standard Height Level

t (m) Diagram
Height (m)
Gas LA(H) to 0.10 m or hold-up height 0.10 1.5
LZA(HH) for operator intervention +
foaming allowance
LA(L) to LA(H) 0.35 m or hold-up height 0.35 0.95
for control + slug
allowance
 LZA(LL) to LA(L) 0.10 m or hold-up height 0.10 0.6
for operator intervention
LZA(HH) of liquid 0.2D 0.48 0.5
compartment to
LZA(LL) of gas
compartment
Liquid LA(H)int to 0.10 m or hold-up height 0.10 -0.20
LZA(HH)int for operator intervention +
dispersion bond allowance
(LZA(HH)int is typically
located 200 mm below the

bottom of the vessel.)

LA(L)int to LA(H)int 0.35 m or hold-up height 0.35 -0.30
for control
LZA(LL) to 0.10 m or hold-up height 0.10 -0.65
LA(L)int for operator intervention +
dispersion bond allowance
Bottom of L/L 0.2D 0.48 -1.13
settler to LZA(LL)
int

Total Height of Level Control, h 1.96

LA(H): High Level Alarm; LA(L): Low Level Alarm; LZA(HH): High Level Trip; LZA(LL): Low
Level Trip; LZA(HH)int: High Level Trip of L/L Interface; High Level Trip; LZA(LL): Low
Level Trip of L/L Interface; LA(H): High Level Alarm of L/L Interface; LA(L): Low Level Alarm
of L/L Interface

The minimum boot length between the bottom of the vessel and the boot bottom tangent line
and the boot diameter should be 1 m and 0.4 m, respectively. By implementing level control,
boot length should at least 1.13 m in order to fulfil level control diagram.

THREE PHASE SEPARATOR LENGTH

The tangent-to-tangent length of vessel, V-300 can be computed by using Appendix VII DEP
31.22.05.11-Gen (SHELL, 2007).

V slug +Q L t H −2 ∆ V hd , H
L= L L

AH L

V slug = The volume of the anticipated slug to be accommodated (assume no slug)

tH L
= The required control time between the levels LA(L) and LA(H)

tH L
= 6 min/ 360 sec

∆ V hd , H L
= The volume of the vessel head between LA(L) and LA(H) and can be
calculated with the relationships presented in the second part of Appendix VI
DEP 31.22.05.11-Gen (SHELL, 2007).

From Appendix VI DEP 31.22.05.12-Gen (SHELL, 2007).

3 3
απ D3 0.75 × ( h¿ H −h ¿ L ) −( h¿ H −0.5 ) + ( h¿ L −0.5 )
[ ]
∆ V hd , H = L
6

Where,

α = 0.5 (Semi-elliptical head)

hH
h¿ H ¿ = 0.3958 where HH = 0.95
D

hL
h¿ L ¿ = 0.25 where HH = 0.96
D

0.5 × π ×2.4 3 [ 0.75 × ( 0.3958−0.25 ) −( 0.3958−0.5 )3+ ( 0.25−0.5 )3 ]

∆ V hd , H = L
6

∆ V hd , H =2.3991 m 3
L

On the other hand,

A H =cross sectionalarea between LA ( L )∧LA ( H )

L

A H =area of chord at LA ( H ) −area of chord at LA ( L )

L
Through calculation, by using geometric relationship at Appendix VI DEP 31.22.05.12-Gen

0.5 ( φ−sinφ ) φ
¿
(SHELL, 2007), A =
π (
and h =0.5 1−cos
¿
2 ( )) where by A is fraction of high
¿

and low alarm cross sectional area to vessel cross sectional area respectively,

A H =0.7817 m 2
L

By substitute A H and ∆ V hd , H into the tangent-to-tangent length of vessel equation,

L L

0+2.808 ×10−2 m 3 / s ×6 min ×60 s /min−2 ×2.3991 m3

L=
0.7817 m 2

L=6.79 m

And the L/D ratio is 2.83 which is less than 6, thus tangent-to-tangent length of vessel = 6.79
m.

THREE PHASE SEPARATOR VOLUME

The volume of separator V-300 is equal to 30.72 m2, which is calculated from equation as
shown below:

V = AL

π D2
¿ ( )4
×L

π
¿ ×2.4 m2 × 6.79 m
4

¿ 30.72 m3

⸫ The volume of three phase separator V-300 is 30.72 m2.

THREE PHASE SEPARATOR SHELL WALL THICKNESS

The shell wall thickness of cylindrical shape three phase separator is computed similar as
horizontal cylindrical pressure vessel. The maximum allowable stress strongly depends on the
type of material as well as the design temperature of three phase separator. As mentioned,
carbon steel is chosen as the material of three phase separator V-300. According to ASME
Code Section II, Part D, Table 1A, the maximum allowable stress for carbon steel at 158 ºF
(70.0 ºC) is 17100 psi (117.9 MPa). Furthermore, the welding joints for separator is assumed
to be spot radiographed, and hence the joint efficiency is 85% (Seider et al., 2009b).

Table Error! No text of specified style in document..3: Data Required for Wall Thickness
Calculation for V-300

Parameter Value Reference

Construction Material Carbon Steel -
Design Pressure, Pd 189.0 kPa / 27.41 psi -
Design Temperature, Td 70.0 ºC /158 ºF -
Tangent-to-tangent Length, 6.79 m / 267.32 in. -
H
Inner Diameter, Di 2.4 m / 94.49 in. -
Corrosion Allowance - -
Inner Radius, R 1.2 m / 47.24 in. -
Maximum Allowable 117.9 MPa / 17100 psi ASME Code Section II, Part
Stress, S D, Table 1A
Joint Efficiency, E 0.85 (Seider et al., 2009b)

First to compute the minimum wall thickness to withstand internal pressure by using equation
below,

Pd R
t P=
SE−0.6 P d

t P =30.46 psi × 47.24∈ ¿ ¿

17100 psi× 0.85−0.6 × 30.46

t P =0.09912∈¿

The calculated t P is less than the minimum wall thickness required to provide sufficient
rigidity for three phase separator with internal diameter, Di = 2.4 m (7.874 ft). Based on
Appendix A8.1, the minimum wall thickness of separator to withstand the internal pressure,
t P is 0.3750 in. Then, the outer diameter of the separator, Do can be estimated by equation
below,

Do =Di+2 t P
D o =94.49∈+ 2¿

Do =95.24∈¿

Next, consider the wall thickness required to withstand wind load or earthquake, 𝑡𝑊 for
additional safety purpose. The location of process plant at Shanghai Chemical Industry Park,
Shanghai has very low risk of earthquake, there is still potential high wind load since it is
located near the sea side. Eq. below is used to calculate the wall thickness to withstand wind
load:

0.22 ( DO +18 ) H 2
t W=
S D O2

267.32∈¿2
t W =0.22 ( 95.24∈+18 ) × ¿
17100 psi × 95.24∈¿2 ¿

t W =4.089× 10−3 ∈¿

Lastly, the average shell wall thickness, t S can be calculated by using equation below.
Assume 0.15 in (3.81 mm) as for non-corrosive stream of corrosion allowance for carbon
steel construction material of three phase separator.

t S= ( 2t 2+ t )+ t
P W
C

t S=¿

t S=0.527∈¿

Separator vessels are generally fabricated from metal plate which require the general
increments in wall thickness as tabulated in Appendix A8.2. Since 0.527 in. falls in the range
between 5/8 in and 2 in, the steel plate comes in an increment of 1/8 in. As 0.527 in. falls
between 1/2 in. (0.5 in.) and 9/16 in. (0.5625 in.), by rounding up to the next increment, the
specify shell wall thickness, t S is 9/16 in. or 0.5625 in.

The shell wall thickness of three phase separator, V-300 is equal to 1.429 × 10 -2 m (14. 2875
mm).

Hence, the updated shell outer diameter is calculated as shown:

Do =Di+2 t S
D o =94.49∈.+ 2¿

Do =95.615∈¿

D o =2.429 m ( 2429 mm )

THREE PHASE SEPARATOR ELLIPSOIDAL HEAD SIZING

Assume 2:1 ellipsoidal head for top and bottom of separator. The diameter of the ellipsoidal
head is similar to that of the cylindrical shell’s diameter which is 2.4 m. The design
conditions and material of ellipsoidal head is similar to that of the shell, the data tabulated in
Table 3can be utilised for head sizing.

Firstly, the inside dished depth of the ellipsoidal head is determined by using Eq. below:

I .D
I . D . D=
4

2.4 m
I . D . D= =0.6 m
4

The wall thickness for the ellipsoidal head to withstand internal pressure is calculated by
using Eq.:

Pd R
tP=
2 SE−0.2 Pd

t P =30.46 psi ×94.49∈ ¿ ¿

2× 17100 psi ×0.85−0.2× 30.46

t P =0.0990∈¿

Similarly, the t P obtained for ellipsoidal head is way too thin to give sufficient rigidity to the
vessel and hence the minimum wall thickness of 0.3750 in. is used by referring to Appendix
A8.1. The corrosion allowance of three phase separator V-300 is 0.15 in (3.81 mm).

t S=t P +t C

t S=0.525∈¿

The head wall thickness calculated is 0.525 in. which is approximate to 9/16 in. or 1.429 ×
10-3 m. As observed, the wall thickness of ellipsoidal head of three phase separator (1.429 ×
10-3 m) is same as shell thickness (1.429 × 10 -2 m), therefore thickness of ellipsoidal head can
be assumed to be the same as that of shell.
The wall thickness of 2:1 ellipsoidal head for three phase separator V-300 is 1.429 × 10 -2 m
(14.2875 mm).

Next, the straight flange of ellipsoidal head is calculated by using Eq. below:

S . F .=2 ×t h

S . F .=2 ×1.429 ×10−2 m

S . F .=0.0286 m

S . F .=0.05 m (50 mm )( minimum )

Lastly, the overall length of ellipsoidal head is computed by using Eq. below:

O . A . H .=S . F .+ I . D. D .+t h

O . A . H .=0.05 m+0.6 m+ 1.429× 10−2 m

O . A . H .=0.05 m+0.6 m+ 1.429× 10−2 m

O . A . H .=0.6643 m ( 664.3 mm )

THREE PHASE SEPARATOR WEIGHT

As the head thickness, t his equals to the shell thickness, t S, the weight of separator with two
2:1 ellipsoidal head can be approximated by equation. However, only the weight of
horizontal separator is considered without considering the weight of boot. The data required
for weight computation are tabulated in Table 4.

Table Error! No text of specified style in document..4: Data Required for Weight
Computation

Parameter Value Reference

Inner Diameter, Di 2.4 m -
Shell Thickness, ts 1.429 × 10-2 m -
Tangent-to-tangent Length, 6.79 m -
H
Density of Carbon Steel, 𝜌 7.8 × 103 kg/m3 Matmatch (n.d.)

W =π ( Di +t s ) ( H +0.8 Di ) t s ρ
 −2 −2 ( 7.8 ×103 ) kg
W =π ( 2.4 m+1.429 ×10 m) ( 6.79 m+ 0.8 ×2.4 m ) ×1.429 ×10 ×
m3

W =7363.50 kg

Table 5: Summary Table of Three Phase Separator V-300 Specifications

Parameter Dimension Units

Volume, V 30.72 m3.
Vessel Length, H 6.97 m
Vessel Inner Diameter, D 2.40 m
Height-to-diameter (H/D) Ratio 2.904 -
Cylindrical Shell Thickness, t S 1.429 × 10-2 m
Vessel Outer Diameter, Do 2.429 m
2:1 Ellipsoidal Head Thickness, tH 1.429 × 10-2 m
Inner Depth of Dish, I.D.D. 0.6 m
Straight Flange Height, S.F. 0.05 m
Overall Height of Head, O.A.H. 0.6643 m
Material of Construction Carbon Steel
Weight of Separator, W 7363.50 kg

APPENDIX A

Cylindrical Vessel Shell Wall Thickness Guideline (Seider et al., 2009b)

Appendix A8.1: Minimum Wall Thickness Guideline

Vessel Inside Diameter (ft) Minimum Wall Thickness (in.)

Up to 4 0.2500
4–6 0.3125
 6–8 0.3750
8 – 10 0.4375
10 – 12 0.5000

Appendix B8.2: Shell Wall Thickness Increments for Different Inclusive Thickness

Thickness Increment (in.) Inclusive Thickness (in.)

1/16 3/16 to 1/2
1/8 5/8 to 2
1/4 2 ¼ to 3
APPENDIX B
Design Margins for Separator Design
To determine the highest envisaged gas and liquid load for vessel design, design margins
(surge factors) are required:

The design margins shall be supplied by the Principal.

Typical values are:

: IN EXPLORATION AND PRODUCTION APPLICATIONS

1. Offshore service Design margin
Separator handling natural-flowing from:
1.2
a) Direct Vertical Access (DVA) wells on
their own platform

1.3
b) another platform or well jacket in shallow
water

1.4
c) another platform or well in deep water

Separator handling gas lifted production from:

1.4
a) DVA wells on their own platform

1.5
b) wells on another platform, or well jacket

1.5
c) subsea wells

2. Onshore service
 Separator handling natural flowing production, or gas plant inlet separator in:
1.2
a) flat or low rolling country

1.3
b) hilly country

Separator handling gas lifted production in:

1.4
a) flat or low rolling country

1.5
b) hilly country

IN REFINERIES AND CHEMICAL PLANTS:

The design margin ranges typically from 1.15 to 1.25.
REFERENCE

SHELL, 2007. MANUAL GAS / LIQUID SEPARATORS - TYPE SELECTION AND

DESIGN RULES. 2007(December).

SHELL, 2007. LIQUID/LIQUID AND GAS/LIQUID/LIQUID (THREE-PHASE)

SEPARATORS - TYPE SELECTION AND DESIGN RULES. 2007(December).

Matmatch. n.d. ASTM A350 Grade LF1 Class 1 Heat-Treated. [online] Available at: <
https://matmatch.com/materials/minfm66870-astm-a350-grade-lf1-class-1-heat-treated>
[Accessed 28 March 2021].

Seider, W.D., Seader, J.D., Lewin, D.R. and Widagdo, S., 2009b. Production and Process
Design Principles | Synthesis, Analysis and Evaluation. 3rd ed. John Wiley & Sons, Inc.