Petronas Technical Standards: Liquid-Liquid Separator and 3-Phase Separator

PETRONAS TECHNICAL STANDARDS
Liquid-Liquid Separator And 3-Phase Separator
PTS 16.52.10
September 2015
© 2015 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
PTS 16.52.10
LIQUID-LIQUID SEPARATOR AND 3-PHASE SEPARATOR September 2015
Page 2 of 46
FOREWORD
PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.
Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.
Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.
In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.
PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording
or otherwise) or be disclosed by users to any company or person whomsoever, without the prior
written consent of PETRONAS.
The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information
to PETRONAS that this requirement is met.
PTS 16.52.10
Page 3 of 46
ANNOUNCEMENT
Please be informed that the entire PTS inventory is currently undergoing transformation exercise
from 2013 - 2015 which includes revision to numbering system, format and content. As part of this
change, the PTS numbering system has been revised to 6-digit numbers and drawings, forms and
requisition to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and
where required make reference to other PTS in its revised numbering to ensure consistency. Users
are requested to refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS
numbers for clarity. For further inquiries, contact PTS administrator at
ptshelpdesk@petronas.com.my
PTS 16.52.10
Page 4 of 46
Table of Contents
1.0 INTRODUCTION..................................................................................................... 5
1.1 SCOPE ........................................................................................................................ 5
1.2 GLOSSARY OF TERM .................................................................................................. 5
1.3 SUMMARY OF CHANGES ........................................................................................... 6
2.0 DESIGN REQUIREMENTS........................................................................................ 7
2.1 GENERAL .................................................................................................................... 7
2.2 SEPARATOR SPECIFICATIONS..................................................................................... 9
2.3 LEVEL CONTROL ....................................................................................................... 10
2.4 NOZZLE SIZING ......................................................................................................... 13
3.0 LIQUID-LIQUID SEPARATOR ................................................................................. 15
3.1 MAJOR COMPARTMENT IN LIQUID-LIQUID SEPARATOR ........................................ 15
3.2 INLET COMPARTMENT ............................................................................................ 15
3.3 NOZZLE DESIGN FOR LIQUID-LIQUID SEPARATOR................................................... 16
3.4 HORIZONTAL TWO PHASE SEPARATOR ................................................................... 18
3.5 HORIZONTAL TWO PHASE SEPARATOR WITH PLATE PACK ..................................... 22
3.6 COALESCERS ............................................................................................................ 28
4.0 HORIZONTAL THREE PHASE SEPARATOR (GAS-LIQUID-LIQUID) ............................ 31
4.1 MAJOR SECTIONS OF HORIZONTAL THREE PHASE SEPARATOR .............................. 31
4.2 HORIZONTAL 3-PHASE SEPARATOR WITH BOOT..................................................... 32
4.3 HORIZONTAL 3-PHASE SEPARATOR WEIR ............................................................... 39
4.4 HORIZONTAL 3-PHASE SEPARATOR WITH PLATE PACKS ......................................... 42
5.0 BIBLIOGRAPHY .................................................................................................... 44
APPENDIX 1: DETERMINATION OF CROSS-SECTIONAL AREA OF HORIZONTAL SEPARATOR
AND HORIZONTAL SEPARATOR VOLUME HEAD .............................................................. 45
PTS 16.52.10
Page 5 of 46
1.0 INTRODUCTION
This PETRONAS Technical Standards (PTS) provides selection and design requirements for
liquid-liquid and 3-Phase separators. These requirements will ensure separators are selected
to meet the duty and designed for effective separation performance in upstream and
downstream production and processing facilities.
1.1 SCOPE
The scope covers selection and design of horizontal Liquid-Liquid Separator and 3-Phase
separator for the following applications:
Liquid-Liquid Separator
i. 2-Phase liquid-liquid separator/ Decanter – process plant, deoiling and

dewatering facilities (upstream), produced water effluent treatment
ii. Column Side draw-off separator – Refinery fractionation
iii. Coalescer
3-Phase Separator (Gas-Liquid-Liquid):
i. Front end receiving vessel for production and processing facilities
ii. Degassing-Deoiling-Dewatering separator
This PTS does not cover:
i. The design of settling tanks, buffer vessel with no separation performance

criteria, basin-type equivalent settlers such as API interceptor, separators for
floating facilities and proprietary (licensors) separators
ii. the means of separation for emulsified feed which need to be treated by
chemical or heat prior to separation
iii. vertical separators
1.2 GLOSSARY OF TERM
1.2.1 General Definition of Terms & Abbreviations
Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS
00.01.03 for General Definition of Terms & Abbreviations.
1.2.2 Specific Definition of Terms

No Terms Definition
1 Central height Height from the highest liquid level (LZAHH) in the
separator to the top of vessel.
2 Cut-off droplet diameter Diameter of the smallest droplets that being
removed with 100% efficiency.
PTS 16.52.10
Page 6 of 46
3 Inlet device Feed distributor installed at the separator inlet to

create even flow distribution, enhanced
separation and increase separator capacity.
4 Net Free Area Available cross section area for fluid flow through
baffle or plate pack
Table 1: Specific Definition of Terms
1.2.3 Specific Abbreviations

None.
1.3 SUMMARY OF CHANGES

This PTS 16.52.10 replaces PTS 31.22.05.12 (February, 2011).
PTS 16.52.10
Page 7 of 46
2.0 DESIGN REQUIREMENTS
2.1 GENERAL
2.1.1 Selection of 2-phase Liquid-Liquid Separator
Liquid-liquid separator are used to separate feed liquid which contain two immiscible liquid
of different specific gravity or density. The design and sizing of the liquid-liquid separator is
based on the required separation efficiency and liquid-liquid handling capacity.
i. Separation Efficiency or Cut-Off droplet diameter

The separation efficiency are dependent on the inlet droplet size distribution and
the cut-off diameter of the droplet.
Primary dispersion:
Consist of mainly 30m and larger droplet size and can be separated using gravity
settling.
Secondary dispersion:
Consist of mainly smaller than 30m droplet size which requires to be increased
by coalescent mechanism.
Liquid-liquid separators can be categorized into 2 main application:
i. Bulk separation – designed to achieve cut-off diameter of 150 m with

entrainment rate of ≤1.5 % volume.
ii. Refine separation – designed to achieve cut-off droplet diameter of ≤150 m with
the entrainment rate ≤1.5 % volume.
For a plate pack, cut-off diameter of 50 m with entrainment ≤1.5 % volume. Coalescer will
have lower entrainment rate of 50 ppmv to 500 ppmv.
i. Liquid Handling Capacity

Liquid handling capacity will depend on liquid flux vf:
𝑄𝐿
𝑣𝑓 =
𝐴𝐿
Where
QL Liquid feed flowrate
AL Area available for separation
For a low dispersed phase concentration (≤5%) the liquid flux is directly correspond to cut off
droplet size through the Stoke Law settling velocity.
For higher dispersed phase concentration, the interaction between the dispersed phase
droplets shall be taken into consideration.
PTS 16.52.10
Page 8 of 46
2.1.2 Selection of 3-phase gas-liquid-liquid separator

3-Phase separator is used to separate the feed fluid which contain 3-phase i.e. gas, light
liquid and dense liquid. The design and sizing to meet the separation efficiency of 3-phase
separator are based on:
i. Gas to liquid separation

Separator shall not exceed maximum allowable gas load factor of 0.07.
ii. Light liquid to dense liquid separation

Light liquid to dense liquid separation are based on selection of either bulk or
refine separation.
2.1.3 Selection of Coalescing plate pack

For both 2 phase liquid-liquid and 3 phase separator, plate pack shall be considered to
facilitate separation and improve the separation efficiency to 50 m with entrainment ≤1.5
% volume. Plate pack is not recommended for high fouling service. However if it is deemed
necessary to have the plate pack, a cleaning mechanism such as water spray/jet and drain
shall be installed to remove the accumulated fouling material in the separator.
Refer to Table 2 for guidelines in selection of liquid-liquid and 3 –phase separator.
Type Application
Horizontal Liquid-Liquid Separator i. bulk separation for liquid-liquid
ii. fouling service
iii. droplet size more than 30 m.
Horizontal Liquid-Liquid Separator with
plate pack i. higher separation efficiency of liquid-
liquid
ii. cleaning or moderate fouling service
iii. droplet size more than 30 m
Horizontal 3-Phase Separator with Boot i. bulk separation for liquid-liquid and
gas-liquid
ii. fouling service
iii. dense liquid phase less than 5% by
volume and deoiling is not required
Horizontal 3-Phase Separator with Weir i. bulk separation for liquid-liquid and
gas-liquid
ii. Fouling service
iii. deoiling is required
Horizontal 3-Phase Separator with i. efficient separation for liquid-liquid
Plate Pack and bulk separation for gas-liquid
ii. clean or moderate fouling service
Vertical Three Phase Separator i. Efficient separation for liquid-liquid
and bulk separation for gas-liquid
ii. Fouling service
PTS 16.52.10
Page 9 of 46
iii. High gas load

Vertical 3 Phase Separator with Plate i. Efficient separation for gas-liquid
Pack ii. Clean or moderate fouling service
iii. High gas load
Table 2: Separator Selection Guidelines
2.2 SEPARATOR SPECIFICATIONS

The following separator specifications should be stated:
Design margin
Separation efficiency
Separation efficiently for liquid-liquid separation will be based on:
a) The required particle size diameter of light liquid in the continuous dense
phase.
b) The required particle diameter of dense phase in the continuous light
phase.
Specific fluid consideration (i.e. solid, wax and foaming)
Slug volume – not applicable for liquid-liquid separator
Gas load capacity – not applicable for liquid-liquid separator

Refer to PTS 16.52.09 Two Phase Gas and Liquid Separator for detail definition of each design
parameter. All related requirements stated in PTS 16.52.09 applies for liquid-liquid and 3-
phase separators. PTS 16.52.17 Produced Sand- Design, Operations and Disposal shall be
referred when there is presence of solid in the fluid handle.
2.2.1 Piping Requirement for Separator

Pipe fittings, bends and instruments shall be arranged to condition the feed to facilitate gas
and liquid-liquid separation. Specific considerations for the following piping components are
provided below:
i. Inlet piping configuration
ii. Control valves, Pipe expander and reducer
iii. Bends
iv. Outlet Piping
2.2.2 Inlet Piping

Inlet piping shall be selected to avoid turbulence of the fluid inside the separator. Nature of
feed and flow regime shall be taken into consideration in designing the inlet piping and inlet
device. Slug flow should be avoided because it can cause water hammering and pressure
pulsation and feed inlet piping shall not have pockets. General Piping requirements shall be
referred to PTS 12.30.02 subsection on Pressure Vessel Piping.
PTS 16.52.10
Page 10 of 46
2.2.3 Valves, Pipes expanders and Reducer

Pressure reducing valve, pipe expander and reducer should be located more than 10 times of
pipe diameter from the inlet of the separator.
2.2.4 Bends
Care should be taken to avoid slugging that may occur in a riser system upstream of vessel
especially when there is a loop that could trap liquid pocket.
A bend in the feed pipe is only permitted if this is in the vertical plane through the axis of the
feed nozzle (refer to Appendix 2).
2.2.5 Outlet Piping

A pipe reducer may be used in the outlet vapour line, but it should be placed more than 2
times the outlet nozzle diameter (>2D) from the top of the vessel. The outlet piping for vapour
line shall be sloped to the vessel to avoid accumulation of liquid in the pipe. Pockets shall be
avoided as it could cause slugging.
2.3 LEVEL CONTROL
Abbreviations for liquid levels
LAH high level pre-alarm

LAL low level pre-alarm
LZAHH high level trip
LZALL low level trip
NL normal level
This section is applicable to both vertical and horizontal separator. When designing a
separator, sufficient capacity for liquid handling is critical to allow for liquid surges and to
provide sufficient retention time for efficient liquid degassing process i.e. separation of gas
bubbles from liquid phase, and liquid settling.
Liquid surge is defined as the volume between high and low liquid level.
2.3.1 G-L-L Interface

For the control of the G-L-L interface, the hold-up times of BOTH the light and dense liquid
phases shall be taken into account. This minimum distance is dependent of the type of G-L-L
separator and is addressed in the corresponding section of this PTS. However, the minimum
height, control time and separation retention time shall be compared and the greater value
shall be adopted.
LZAHH high level trip of the G-L  ≥150mm below the feed inlet device
interface  vertical separator with inlet device: ≥ 0.05D of
the vessel
LAH high level alarm of the G-L  ≥100mm below LZAHH and
interface
PTS 16.52.10
Page 11 of 46
 provide sufficient liquid hold up time between

LZAHH-LAH for operator intervention
o 5 minutes in control room
o 10 minutes if require intervention
outside of control room
 if liquid has foaming tendency, increase
distance by 250mm
LAL low level alarm of the G-L  ≥350mm below LAH and
interface  provide sufficient liquid hold up time between
LAH-LAL for control purposes:
o Circulation flows: 1 minute – 2 minutes
o product to storage: 2 minutes
o product to other equipment/vessel: 3
minutes
o product to furnace: 4 minutes
 hold up times shall be specified separately for
light and dense liquid phase
 if slugs are expected, they should be
accommodated between NL and LAH
 if slug volume to be expected is unknown, it is
suggested that:
𝑆𝑙𝑢𝑔 𝑉𝑜𝑙𝑢𝑚𝑒 = 𝑣𝑚𝑎𝑥 × 𝐴𝑝𝑖𝑝𝑒 × 𝑡
Where,
𝑣𝑚𝑎𝑥 is the maximum feed velocity (gas + liquid)
𝐴𝑝𝑖𝑝𝑒 is cross-section area assuming 100% liquid filling of
the pipe
𝑡 with 2-5 seconds of slug flow
 In practice, the total volume to be provided
between LAL-LAH is the sum of the required
control volume and volume of the anticipated
slug
LZALL low level trip of G-L  ≥100 mm below LAL and
LAL-LZALL for operator intervention
PTS 16.52.10
Page 12 of 46
2.3.2 L-L Interface

The L-L interface should be positioned so that above and below this interface adequate L-L
separation can take place. For the control of the L-L interface the hold-up time of the dense
liquid phase only has to be taken into account. However, the minimum height, control time
and separation retention time shall be compared and the greater value shall be adopted.
LZAHHint high level trip of L-L  horizontal L-L separator: shall be ≥0.2D from
interface the top of the vessel
 in the boot of horizontal three-phase
separator:
200 mm below the bottom of the vessel
LAHint high level pre-alarm of L-L  ≥100 mm below LZAHHint and
LZAHHint-LAHint for operator intervention
(dense liquid phase)
 if a dispersion band width is specified, the
distance between LZAHHint and LAHint has to be
extended by half the band width
LALint low level pre-alarm of L-L  ≥350 mm below LAHint and

LAHint-LALint for control purposes (what is short
or long circulation flows):
o circulation flows: 1 to 2 minutes
o product to storage: 2 minutes
o product to other equipment/vessel: 3
minutes
o product to furnace: 4 minutes
LZALLint low level trip of L-L  ≥100 mm below LALint and
LALint-LZALLint for operator intervention
PTS 16.52.10
Page 13 of 46
 if a dispersion band width is specified, the

distance between LZAHHint and LAHint has to be
extended by half the band width
 horizontal L-L separator: shall be ≥0.2D from
the bottom of the vessel
 in the boot of horizontal three-phase
separator: above the bottom tangent of the
boot
2.4 NOZZLE SIZING
2.4.1 Inlet Nozzle

The internal nozzle diameter, d1, may be taken equal to that of the feed pipe, but also a
momentum criterion (dependent on the inlet device, if any) shall be satisfied:
Type of inlet Momentum limit (Pa) Momentum limit (Pa)

For debottlenecking For new design
No inlet device mvm,in2  1 400 mvm,in2  1 000
Half open pipe inlet device mvm,in2  2100 mvm,in2  1500
Vertical vane type inlet mvm,in2  3700 mvm,in2  3700

device
Inlet high momentum device mvm,in2  8000 mvm,in2  6000
Table 3: The momentum criterion for typical separator inlet device
(𝑄𝑙 𝜌𝑙 + 𝑄𝑑 𝜌𝑑 + 𝑄𝐺 𝜌𝐺 ) 𝑘𝑔
𝜌𝑚 = [ ]
(𝑄𝑙 + 𝑄𝑑 + 𝑄𝐺 ) 𝑚3
(𝑄𝑙 + 𝑄𝑑 + 𝑄𝐺 ) 𝑚
𝑣𝑚,𝑖𝑛 = [ ]
(𝜋𝑑 2 /4) 𝑠
Where,
𝜌𝑚 mean density of the mixture in the feed pipe, kg/m3
𝑄𝐺 volumetric flowrate for gas, m3/h
𝑄𝑙 volumetric light liquid respectively, m3/h

PTS 16.52.10
Page 14 of 46
𝑄𝑑 volumetric flowrate for dense liquid, m3/h
𝜌𝑙 density of light liquid, kg/m3
𝜌𝑑 density of dense liquid, kg/m3
𝜌𝐺 Density of gas, kg/m3

𝑣𝑚,𝑖𝑛 velocity of the mixture in the inlet nozzle, m/s
Inlet distributors shall be used for separators with high inlet velocity. The inlet velocity shall
not exceed the limits bellow:
Prevention type Velocity limit (m/s)
To prevent erosion vmix,in erosion velocity
Table 4: Velocity limit for inlet nozzle
Note: V
sonic, G is the sonic velocity if only gas is present (presence of liquid ignored)
RT
v sonic,G 
MWG
[m/s]
𝑅 gas constant, 8314 J/kmol/K

T absolute temperature, K
ĸ ratio of the specific heats, Cp/Cv
MWG mean molecular weight of the gas phase, kmol
2.4.2 Vapour Outlet Nozzle

The gas outlet nozzle diameter, d2, should normally equal the outlet pipe diameter, and the
following limit shall be applied whichever requires larger diameter.
Gv2G,out 4500 [Pa]
Where,
𝜌𝐺 gas density at gas outlet nozzle, kg/m3
𝑣𝐺,𝑜𝑢𝑡 gas velocity at outlet nozzle, m/s
2.4.3 Liquid Outlet Nozzle

To be the same size of the liquid line size connected to the nozzle. However, if the information
is not available, 1m/s should be the maximum flowrate across the nozzle.
PTS 16.52.10
Page 15 of 46
3.0 LIQUID-LIQUID SEPARATOR
The type of liquid-liquid separator which will be covered under this section are:
Horizontal two phase separator
Horizontal two phase separator with plate pack
Coalescers
3.1 MAJOR COMPARTMENT IN LIQUID-LIQUID SEPARATOR

Liquid-liquid separator (except for coalescer) consist of 3 major compartments which are
inlet, separation and outlet compartments.
3.2 INLET COMPARTMENT

The inlet compartment is sized to accommodate the feed inlet device and to allow a
reasonable flow path length of the feed to a perforated calming baffle installed between the
inlet and settling compartment. The baffles will prevent flow misdistribution and facilitate
the liquid phases separation in the settling compartment.
General considerations in sizing the inlet compartment:
A minimum length between the tangent line to the second calming baffle is
0.45D.
Recommended inlet device: elbowed pipe or pipe with slots
Calming baffles shall be mounted with a gasket on a full perimeter support ring
and occupy the whole vessel cross-section. For cleaning purposes, a small
opening ( 150mm) is allowed.
a) The Net Free Area (NFA):
 Horizontal 2-phase separator:

Two baffles required consisting of 12 mm diameter holes ( 0.1
mm):
First Baffle have 30 % NFA) Second Baffle have 50 % NFA
 Horizontal 2- Phase separator with pack

Only one baffle required with NFA of 20%.
b) Excluding corrosion allowance, the baffle thickness should be at least 3

mm.
c) The distance between the baffles is 0.2D.
d) To accommodate the feed inlet device, there shall be sufficient
clearance between the first calming baffle and the tangent line.
Whichever is the larger, the minimum length upstream of the first baffle
is either 0.25D or = 150 mm + ID inlet nozzle + max (150 mm, 0.5*ID inlet
nozzle) whichever is larger
PTS 16.52.10
Page 16 of 46
3.2.1 Separation Compartment

Detail design guideline in designing the separation compartment will be further explained in
next sub-sections dependent on the type of liquid-liquid separator
The separation compartment is divided into three horizontal zones:
Top of vessel
High Interface level trip

Normal Interface level
Low Interface level trip
Bottom of vessel
Figure 1: Separation Compartment
Upper Zone Zone where the dense phase droplet have to be separated from
the light liquid. This zone is above the high interface level trip to
the top of the vessel.
Dispersion Zone Zone for accommodation of dispersion band. This zone is in
between high Interface level trip to Low interface level trip.
Lower Zone Zone where the light phase droplet have to be separated from the
dense liquid. This zone is below the Low interface level trip to the
bottom of the vessel.
3.2.2 Outlet Compartment

To accommodate the outlet nozzles, the outlet compartment shall be sufficiently large.
Typically a minimum length of 0.25D (distance between tangent line outlet nozzle centreline
to the outlet nozzle centre line) is applied.
3.3 NOZZLE DESIGN FOR LIQUID-LIQUID SEPARATOR
3.3.1 Inlet nozzle

Inner diameter of inlet nozzle should be:
The same size as the inner diameter of the piping
Total liquid velocity does not exceed 1m/s
Inlet nozzle should be fitted with elbow pipe or slotted pipe.

PTS 16.52.10
Page 17 of 46
Feed Inlet nozzle

Feed Inlet nozzle
Slotted pipe
Elbowed pipe
 Slot should be on each lateral side and on
the upstream side (as per figure above)
Figure 2: Inlet device arrangement
3.3.2 Liquid Outlet nozzle

Additional criteria in sizing the liquid outlet nozzle:
Minimum diameter is 50mm.
For fouling service, vortex breaker shall be installed at a minimum 150 mm above
the vessel bottom or ½ nozzle diameter away from controlling level LZALL –
LZAHH for interface.
Vortex breaker shall be installed if the following connections are located

downstream of the separator:
a) Pump suction
b) Reboiler inlet
c) Liquid draw off from tray
d) Control valves
PTS 16.52.10
Page 18 of 46
3.4 HORIZONTAL TWO PHASE SEPARATOR
3.4.1 General Description
Figure 3: General layout of horizontal liquid-liquid separator
Figure 3 shows a general layout of a horizontal liquid-liquid separator for cases where both
phases have to be cleaned from the other liquid phase.
It is not necessary to perform the separation in the vessel itself if the separation of only one
phase is required and the other phase is only a small fraction of the total flow (typically less
than 5 %). To collect the dispersed phase, a dome or boot is used (e.g. in a rectifying absorber
side draw-off vessel).
3.4.2 Sizing of Separation Selection

The flowchart below provides the outline in sizing the Horizontal Liquid-liquid Separator
where details of each equation used will be further explained.
PTS 16.52.10
Page 19 of 46
Step 1 – Provide Fluid Parameter
Step 2 – Determine Required Separation Time
Step 3 – Assume Length & Diameter
Repeat step 3
to meet the
Step 4 – Assume Control Band validation
criteria
Step 5 – Validation on the separator size and control

band assumed
Validation criterias are met:

Separator size will be as per assumed separator size
Fluid Parameters – Volumetric flowrate, density, viscosity for both light and
dense liquid
Step 2 - Determine the required retention time

Below are the recommended value for retention time. This will provide initial
guide in sizing the separator vessel.
Type of Separation Retention

Time (minutes)
Hydrocarbon/ Water separator
i. Below 0.85 relative density hydrocarbon 3 to 5

PTS 16.52.10
Page 20 of 46
ii. Above 0.85 relative density hydrocarbon

 38oC and above 5 to 10
 27oC 10 to 20
 15oC 20 to 30
Ethylene Glycol/ Hydrocarbon Separator (Cold Separator) 20 to 60
Amine/ Hydrocarbon Separator 20 to 30
Caustic/ Propane 30 to 45
Caustic/ Heavy gasoline 30 to 90
Table 5: Recommended retention time for separation
Note that there recommended retention time for separation shall be applied for
both upper and lower zone.
For light liquid: from normal interface liquid level to the top of vessel
For dense liquid: from normal interface liquid level to the bottom of vessel
Step 3 – Assume vessel diameter

Require to assume the initial vessel dimension which are diameter and length.
The range of 2.5 ≤ L/D ≤ 6 shall be the preferred ratio of vessel length over vessel
diameter)
Step 4 – Assume Control Band

Control band for the separator shall be assumed. Refer to section 2.4 for details
requirement for each of control band.
Step 5 - Validation on the separator size

a) General requirement
The cross-sectional area of the upper and lower zones shall be minimum
14.2% of the vessel cross-sectional area. (This is equivalent to a minimum
central height of these cross-sectional areas of 0.2D).
b) Retention Time through control band
Available retention time between bands are as step 2 and meeting the
requirement of section 2.4
Height of LZALLint. ≥ nozzle ID of the dense liquid outlet.
Axial Velocity of light and dense phase

Require to determine axial velocity for light and dense liquid. The axial velocity
should not be bigger than 0.015m/s in ensuring the particle size that being
calculated using settling rate equation is not undersized.
PTS 16.52.10
Page 21 of 46
Q𝑙
vl,set =
A𝑙
Where:
vl,set Axial Velocity for light liquid
Q𝑙 Volumetric Flowrate of light phase
Al Cross section area of light phase
Note: refer to Appendix I for detail calculation.
Subscript “l” used in the formula represent light liquid and the same equation
can be used in determining the axial velocity of dense liquid by replacing
subscript “l” with “d” which indicate dense liquid information.
Droplet size required

The calculated droplet size should be smaller or equal to the required droplet size
dependent on the separation requirement.
To achieve the specified separation efficiency in terms of droplet cut off size i.e.
<150m, the horizontal cross section of the settling compartment shall be
sufficient. A practical approximation of this area is Aset=Lset x Dves x 0.8, where the
factor 0.8 accounts for the fact that the interface is generally not located in the
midplane of the separator and provides some allowance for flow misdistribution.
Equation to determine droplet size for light and dense liquid.
18 𝜇𝑑 (vdl, set + 0.05vd, ax )

dl = √
g(𝜌d − 𝜌l )
Where:
dl light-phase droplet diameter, m
𝜇𝑑 Dynamic viscosity of the dense liquid,Pa.s
vd, ax Axial velocity of the dense liquid,m/s
vdl,set Settling velocity for light phase droplet
Q𝑙
vdl,set =
0.8 × Lset × D
Where:
Q 𝑙 = Volumetric Flowrate of light phase
Lset = Length of settling compartment
PTS 16.52.10
Page 22 of 46
D = Diameter of vessel/ settling compartment
can be used in determining the settling velocity of dense liquid by replacing
General criteria
The following main rules apply for a proper sizing of the horizontal liquid-liquid
separator:
a) The cross-sectional area of the upper and lower zones shall be minimum
14.2 % of the vessel cross-sectional area. (This is equivalent to a
minimum central height of these cross-sectional areas of 0.2D).
b) Height of LZALLint. ≥ nozzle ID of the dense liquid outlet.
3.5 HORIZONTAL TWO PHASE SEPARATOR WITH PLATE PACK
3.5.1 General Description
Figure 4: General layout of a horizontal liquid-liquid separator with plate pack
Figure 4 shows a general layout of a horizontal liquid-liquid separator, fitted with a plate pack,
for cases where both phases have to be cleaned from the other liquid phase.
For easy accessibility from both sides, the manholes shall be located so that the plate pack
internals can easily be installed.
Plate packs should be mounted in panels. Gutter is located between the panels to transport
the coalesced separated liquid phase to its bulk phase. Measures shall be taken to prevent
bypassing of the plate pack:
PTS 16.52.10
Page 23 of 46
i. No mounting of plate in front of the gutters.
ii. Caution not to seal the clearance between the plate pack and the vessel wall.
iii. The seal plate underneath the plate pack shall still have a small opening for
cleaning purposes.
iv. If fouling is expected a cleaning system should be installed.
3.5.2 Sizing of separator with a plate pack

Flowchart below will provide outline in sizing the plate pack to be located within the settling
compartment in Horizontal Liquid-Liquid Separator. In sizing the horizontal liquid-liquid
separator with plate pack, steps required as outline in Figure 4 shall be followed first before
use the below outline as per Figure 5.
PTS 16.52.10
Page 24 of 46
Determine Estimated Cross Section Area of the Plate Pack,

Af,gross
Determine Net free Area of the plate pack
Determine distance between plate pack for light and dense Select different
phase region value of dpp
No
𝑑𝑝𝑝,𝑚𝑖𝑛 ≤ 𝑑𝑝𝑝 ≤ 𝑑𝑝𝑝, 𝑚𝑎𝑥
Yes
Select the plate angle
Determine the plate length
Determine the light and dense liquid droplet size
Required droplet size No
Yes
Vessel size and plate pack configuration shall at least bigger or

equal to value selected above
Figure 5: Flowchart on sizing 2 phase separator with plate pack
Flowchart above provide outline in sizing the Horizontal Liquid-liquid Separator where details
of each equation involve will be further explain below:
Estimated Cross Section Area of Plate Pack (Af,gross)

PTS 16.52.10
Page 25 of 46
(𝐴𝑓,𝑔𝑟𝑜𝑠𝑠 )𝑙 = 𝐹𝑝𝑝 𝐴𝑙
Where:
𝐹𝑝𝑝 Correction factor for plate pack for Liquid-liquid separator
𝐴𝑙 Cross section area of light phase
Plate spacing (dpp)
These two criteria shall be met in order to determine the most optimum spacing
between plates.
a) Distance of plate pack within the light liquid regime
𝑅𝑒𝑐𝑟𝑖𝑡 𝜇𝑙 (𝐴𝑓,𝑛𝑒𝑡 )
𝑑𝑝𝑝,𝑚𝑖𝑛 ≤ 𝑑𝑝𝑝 ≤ (𝑑𝑝𝑝,𝑚𝑎𝑥 )𝑙 ≈ 2𝜌𝑙 𝑄𝑙
𝑙
Where:
𝑑𝑝𝑝,𝑚𝑖𝑛 Minimum distance between plates. Below are recommended

minimum distance between plates
i. Non fouling condition = 10 mm

ii. Fouling condition = 40 mm
𝑅𝑒𝑐𝑟𝑖𝑡 Critical Reynolds Number above which deviation from laminar
flow regime will occur. Recommended values are as below:
i. Flat Plates with front and rear contours = 850

ii. Corrugated Plates = 450
(𝑑𝑝𝑝,𝑚𝑎𝑥 )𝑙 Plate spacing within light liquid regime, mm
𝜇𝑙 Dynamic viscosity (Pa.s)
(𝐴𝑓,𝑛𝑒𝑡 ) Net free area within light liquid regime. This can be calculated
𝑙
using the below equation:
(𝐴𝑓,𝑔𝑟𝑜𝑠𝑠 )𝑙 × 𝐹𝑙𝑜𝑠𝑠 × 𝑑𝑝𝑝

(𝐴𝑓,𝑛𝑒𝑡 ) =
𝑙 𝑡𝑝𝑝 + 𝑑𝑝𝑝
Where:
(𝐴𝑓,𝑔𝑟𝑜𝑠𝑠 ) = Gross frontal area within the light liquid regime, m2
𝑙
𝐹𝑙𝑜𝑠𝑠 = Correction factor for part of plate pack face available for
flow
PTS 16.52.10
Page 26 of 46
= Typically in a range of 0.9 to 0.95

𝑑𝑝𝑝 = distance of the plate pack, mm
𝑡𝑝𝑝 = thickness of the plate pack, mm
Re Reynolds number
𝜌𝑙 Density of light liquid, kg/m3
𝑄𝑙 Volumetric flowrate, m3/hr
b) Distance of plate pack within the dense liquid regime
𝑅𝑒𝑐𝑟𝑖𝑡 𝜇𝑑 (𝐴𝑓,𝑛𝑒𝑡 )
𝑑𝑝𝑝,𝑚𝑖𝑛 ≤ 𝑑𝑝𝑝 ≤ (𝑑𝑝𝑝,𝑚𝑎𝑥 )ℎ ≈ 2𝜌ℎ 𝑄𝑑
𝑑
Where:
Recommended Values
𝑑𝑝𝑝,𝑚𝑖𝑛 Minimum distance between plates. Non fouling condition: 10mm
Below are recommended minimum Fouling condition : 40mm
distance between plates
𝑅𝑒𝑐𝑟𝑖𝑡 Critical Reynolds Number above which Flat Plates with front
deviation from laminar flow regime will and rear contours : 850
occur.
Corrugated plates : 450
(𝐴𝑓,𝑛𝑒𝑡 )𝑑 Net free area within dense liquid
regime. This can be calculated using the
below equation:
(𝐴𝑓,𝑔𝑟𝑜𝑠𝑠 )𝑑 , 𝑔𝐹𝑙𝑜𝑠𝑠 × 𝑑𝑝𝑝

(𝐴𝑓,𝑛𝑒𝑡 )𝑑 =
𝑡𝑝𝑝 + 𝑑𝑝𝑝
Where:
(𝐴𝑓,𝑔𝑟𝑜𝑠𝑠 )𝑑 = Gross frontal area within

the dense liquid regime
(𝑑𝑝𝑝,𝑚𝑎𝑥 )𝑑 Plate spacing within dense liquid

regime
𝜇ℎ Dynamic viscosity (Pa.s)
PTS 16.52.10
Page 27 of 46
c) Select angle between plates and Horizontal plane

Recommended angle plate:
45° in non-fouling service
60° in fouling service
d) Determine length of the plate pack:
𝐿𝑝𝑝,𝑚𝑎𝑥 = 𝐿𝑠𝑒𝑡 – 0.65
𝐿𝑝𝑝,𝑚𝑎𝑥 Length of plate pack maximum (m)

𝐿𝑠𝑒𝑡 Length of settling compartment (m)
Distance to calming plate and outlet nozzles 0.15 and 0.5m

respectively:
𝐿𝑝𝑝,𝑚𝑖𝑛 = 0.3
𝐿𝑝𝑝,𝑚𝑖𝑛 Length of plate pack minimum (m)
If Lset < 0.95, the above requirements cannot be met and compromises
shall be necessary.
Determine the plate pack separation performance.
a) Droplet size equation

Require to determine droplet size for light and dense liquid.
18 𝜇𝑑 vdl, set
dl = √
g(𝜌d − 𝜌l )
Where:
dl Settling of light-phase droplet,m
vdl,set Settling velocity for light phase droplet

𝑣ℎ,𝑝𝑝 𝑑𝑝𝑝
vdl,set =
cos 𝜃(𝐿𝑝𝑝 − 8𝑑𝑝𝑝 )
Where:
𝑄ℎ
𝑣ℎ,𝑝𝑝 = (𝐴
𝑓,𝑛𝑒𝑡 )ℎ
𝑑𝑝𝑝 = distance of the plate pack, m
𝐿𝑝𝑝 = Length of the Plate pack, m
𝜃 = angle of the plate packs
PTS 16.52.10
Page 28 of 46
Different values correction factors from the stipulated range mentioned in

subsections shall be substantiated for Technical Authority review and approval.
3.6 COALESCERS
A coalescer is a separator which utilizes similar separation concept and makes use of fibrous
packed beds to merge droplets in dispersion together. These aggregated droplets will grow
in size and will be removed in the settling section.
The settling section can be in a compartment inside the coalescer, either downstream or
upstream of the fibrous packed beds. Alternatively, a separate vessel can also be used to
collect and remove the coalesced droplets.
3.6.1 Requirement at the upstream of Coalescer
Pump at the feed stream

a) Normally centrifugal pumps are selected.
b) Displacement pump and other type of pumps can be used if the fluid is
easily degraded.
Flashing avoidance
Can be achieved through installation of 3-phase separator at higher elevation

relative to coalescer with vent point.
Prefilters
a) Required for fouling service
b) Requirement for maintenance if this system require high availability.
3.6.2 Summary of Coalescer Application and Characteristic

Coalescers are used for coalescence and removal of low concentrations (5% or less) of
dispersed droplet from primary or secondary dispersions and are not suitable for bulk
separation. It should not be applied for liquid with a kinematic viscosity above 15 mm2/s.
Table below will provide a guideline for selection of coalescer type. Removal of very small
droplets may require the use of specialised internals or electrostatic fields to promote
coalescence.
PTS 16.52.10
Page 29 of 46
TYPE OF COALESCERS
SELECTION
In situ compressed Prefabricated coalescer
CRITERIA Cartridge coalescers
coalescer mats mat
CHARACTERISTIC  suitable for the  suitable for the  suitable for the
coalescence of coalescence of primary coalescence of primary
primary and dispersions only and secondary dispersions
secondary  little likelihood of  little likelihood of
dispersions channelling or bypassing because the
 economic, bypassing since it is cartridges are pre-
because of low- pre-fabricated fabricated
cost material and density is lower than sensitive to fouling: pre-
possibility of that of coalescer mats filtering is required, unless
backwashing hence less sensitive to service is absolutely clean
 manually packed: fouling
packing should be
installed by
properly trained
personnel to
avoid channeling
and bypassing
 sensitive to
fouling: pre-
filtering is
required, unless
service is
absolutely clean
RECOMMENDED  for secondary  for primary dispersions  for secondary dispersions
USE dispersions, if  if local phase inversion  (equipped with
properly packed can occur (i.e. the compressed coalescer
and NO dispersed phase bed): with cartridges a
compressed becomes locally the wider choice of packing
continuous phase), use materials is possible
PTS 16.52.10
Page 30 of 46
TYPE OF COALESCERS
SELECTION
In situ compressed Prefabricated coalescer
CRITERIA Cartridge coalescers
coalescer mats mat
crinkled wire-mat dual material (e.g.
is installed stainless steel and
 vertical vessels polymer filaments)
only
NOT
In fouling service without pre-filtering
RECOMMENDED
TYPICAL
PROCESS Dewatering of hydrocarbons (ranging from LPG to gasoil fractions)
APPLICATION
Table 6: Coalescer Application and Characteristic
PTS 16.52.10
Page 31 of 46
4.0 HORIZONTAL THREE PHASE SEPARATOR (GAS-LIQUID-LIQUID)
Type of gas-liquid-liquid separator which will be covered under this section are:
Horizontal 3-Phase Separator with boot
Horizontal 3-Phase Separator with Weir
Horizontal 3-Phase Separator with Plate packs
4.1 MAJOR SECTIONS OF HORIZONTAL THREE PHASE SEPARATOR
4.1.1 Major sections of Horizontal 3-phase separator

Horizontal 3-phase separator consist of:
Inlet Compartment
To accommodate the feed inlet device and to allow a reasonable flow path length
of the feed to the calming baffle.
Below are general information in sizing the inlet compartment:

a) Inlet nozzle should be located at the top of the vessel with inlet device
connected by an elbow.
b) Perforated plates shall be installed between the inlet and settling section
c) The length of the inlet section (i.e. distance from inlet tangent line to
second baffle) is typically minimum 0.45D
d) Recommended design of perforated plates.
Characteristics Recommended Design

Net Free Area (NFA) of first baffle 30%
Note: for 3-phase separator with plate pack, only 1
baffle is required and the NFA is 20%.
Net Free Area (NFA) of second baffle 50%

Baffle hole diameter 12mm
Baffle thickness ≥3mm
Distance between baffle 0.2D
Baffle height From vessel bottom to LZA (HH)
Other requirement Sufficient clearance between the vertical

tangent line and the first baffle to
accommodate the feed inlet device.
The minimum is (5Dinlet nozzle) or 0.25

D, whichever is the larger.
PTS 16.52.10
Page 32 of 46
Separation Compartment
Detail design guideline in designing the separation compartment will be further
explained in next sub-sections dependent on type of gas-liquid-liquid separator
selected.
Outlet Compartment
To accommodate the outlet nozzles, the outlet compartment shall be sufficiently
large.
A minimum length of 0.25D (distance between tangent line outlet nozzle
centreline) shall be required.
4.1.2 General Requirement in sizing the separation compartment

There are two major requirement in sizing the separation compartment which are:
Gas Liquid separation
Refer to 2 Phase Gas Liquid Separator (PTS No: PTS 16 52 09) on details
requirement in determining the gas cap area (as minimum).
Liquid-Liquid Separation
Refer to section 3.0 Liquid-Liquid Separator on the details requirement in
determining the size of liquid-liquid separation section.
Volume consideration on determining the retention time for 3 phase separator
Volume Control Band

For 3 Phase separator with Submersible Weir
From normal level (NLlight) in Oil Phase to the Normal
interface level (NLint)
Volume for light liquid
For 3 Phase separator with Overflow Weir
From the top of weir to the Normal interface level (NLint)
From Normal interface level (NLint) to the bottom of the

Volume for dense liquid vessel
4.1.3 Nozzle Sizing

Refer to previous section on details requirement in sizing the nozzles.
4.2 HORIZONTAL 3-PHASE SEPARATOR WITH BOOT

Below are schematic on the general layout of 3 phase separator with boot.
PTS 16.52.10
Page 33 of 46
Inlet Nozzle Gas Outlet Nozzle
Min 150 mm LZA(HH)

LZA(HH)
LAH
N
LLAL
LZA(LL)
LZA(HH)int
0.2D LAHint Light Phase Outlet
NLint Nozzle ≥ 1.0 m
LALint
LZA(LL) int
Inlet Separation Section Outlet
Section Section
0.45 D 0.25 D
Dense Phase Outlet

Nozzle
≥ 0.4 m
Figure 6: Schematic of 3 phase separator with boot

PTS 16.52.10
Page 34 of 46
4.2.1 Sizing Of the Separation Section
Process Input
New vessel
Vessel Size and Data
Control Level for L-L Interface
Control level for G-L interface Change the Change the

G-L interface L-L interface
control band
control band
Existing
Check G-L criteria No
vessel
Yes
Check L-L criteria No
Yes
Control time for L-L No
Yes
No Control time for G-L
Yes
Sizing Inlet and outlet Compartment
Design validation
Figure 7: Process flow on sizing the separation section of 3 Phase separator with boot
The Flowchart provide the outline in sizing the Separation Section of 3 phase separator with
boots where details of each equation involve will be further explain below.
Process Input
PTS 16.52.10
Page 35 of 46
Below process input are to be provided:

a) Operating pressure and temperature
b) Volumetric flow of gas and liquid phases
c) Density of gas and liquid phases
d) Dynamic viscosity of liquid phases
e) Design Margin
Vessel Size and Data
a) Vessel Diameter and tangent to tangent length

b) Boot height and diameter
Control level for Liquid-Liquid interface

Refer to section 2.4.1 on the control level for liquid-liquid interface.
Control time for Liquid-Liquid

Below are equation used to calculate duration between level control band
within boot
a) Downward liquid velocity in the boot
4 × 𝑄𝑑
𝑣𝑑,𝑏𝑜𝑜𝑡 = 2
𝜋 × 𝐷𝑏𝑜𝑜𝑡
Where:
Qd Dense phase flowrate
2
𝐷𝑏𝑜𝑜𝑡 Diameter of the boot
b) Control duration between control band
Control Time Equation
HH to H 𝐿𝑍𝐴(𝐻𝐻)𝑖𝑛𝑡 − 𝐿𝐴(𝐻)𝑖𝑛𝑡
𝑡𝐻𝐻 𝑡𝑜 𝐻,𝑖𝑛𝑡 =
𝑣𝑑,𝑏𝑜𝑜𝑡
H to L 𝐿𝐴(𝐻)𝑖𝑛𝑡 − 𝐿𝐴(𝐿)𝑖𝑛𝑡 𝑉𝑠𝑙𝑢𝑔

𝑡𝐻 𝑡𝑜 𝐿,𝑖𝑛𝑡 = −
𝑣𝑑,𝑏𝑜𝑜𝑡 𝑄𝑙 + 𝑄𝑑
Where
𝑉𝑠𝑙𝑢𝑔 = Slug volume, m3
𝑄𝑙 = light phase flowrate, m3/hr
𝑄𝑑 = dense phase flowrate, m3/hr
PTS 16.52.10
Page 36 of 46
L to LL 𝐿𝐴(𝐿)𝑖𝑛𝑡 − 𝐿𝑍𝐴(𝐿𝐿)𝑖𝑛𝑡
𝑡𝐿 𝑡𝑜 𝐿𝐿,𝑖𝑛𝑡 =
𝑣𝑑,𝑏𝑜𝑜𝑡
Control time for Gas Liquid
Duration Equation
between
Control Band
HH to H 𝐿𝑠𝑒𝑝 × 𝐴𝐻𝐻 𝑡𝑜 𝐻 + 2 ∆𝑉ℎ𝑑,𝐻𝐻 𝑡𝑜 𝐻 − 𝑉𝑓𝑜𝑎𝑚
𝑡𝐻𝐻 𝑡𝑜 𝐻,𝑙 =
𝑄𝑙 + 𝑄𝑑
Where;
𝑡𝐻𝐻 𝑡𝑜 𝐻,𝑙 Duration between HH to H, s
𝐿𝑠𝑒𝑝 Length of the separator,m
𝐴𝐻𝐻 𝑡𝑜 𝐻 Cross section area between HH to H,m2
∆𝑉ℎ𝑑,𝐻𝐻 𝑡𝑜 𝐻 Volume of head between HH to H, m3
𝑉𝑓𝑜𝑎𝑚 Volume of foam, m3
𝑄𝑙 Volume flowrate of light liquid, m3/hr
𝑄𝑑 Volume flowrate of dense liquid, m3/hr
H to L
𝐿𝑠𝑒𝑝 × 𝐴𝐻𝐻 𝑡𝑜 𝐻 + 2 ∆𝑉ℎ𝑑,𝐻𝐻 𝑡𝑜 𝐻 − 𝑉𝑠𝑙𝑢𝑔
𝑡𝐻 𝑡𝑜 𝐿,𝑙 =
𝑄𝑙 + 𝑄𝑑
Where;
𝑡𝐻 𝑡𝑜 𝐿,𝑙 Duration between H to L, s
𝐴𝐻𝐻 𝑡𝑜 𝐻 Cross section area between H to L,m2
∆𝑉ℎ𝑑,𝐻 𝑡𝑜 𝐿 Volume of head between H to L, m3
𝑉𝑠𝑙𝑢𝑔 Volume of slug, m3
L to LL 𝐿𝑠𝑒𝑝 × 𝐴𝐿 𝑡𝑜 𝐿𝐿 + 2 ∆𝑉ℎ𝑑,𝐿 𝑡𝑜 𝐿𝐿
𝑡𝐿 𝑡𝑜 𝐿𝐿,𝑙 =
𝑄𝑙 + 𝑄𝑑
PTS 16.52.10
Page 37 of 46
Where;
𝑡𝐿 𝑡𝑜 𝐿𝐿,𝑙 Duration between L to LL, s
𝐴𝐿 𝑡𝑜 𝐿𝐿 Cross section area between L to LL,m2
∆𝑉ℎ𝑑,𝐿 𝑡𝑜 𝐿𝐿 Volume of head between L to LL, m3
Sizing of Inlet and Outlet Compartment

Inlet compartment length, Lin = 0.45 D.
Outlet compartment length, Lout = 0.25 D.
Design validation
Design validation is required to be performed to ensure that the separator are
sized as per required function for the removal of the intended droplet size.
a) Separator function: Degassing criteria
Dves*Lves  {4.5*107(Ql + Qd)l/(l - G)}
b) Separator function: Defoaming
Dves*Lves  7000(Ql + Qd){l/(l - G)}0.27
Where;
Dves Vessel diameter, m
Lves vessel tangent to tangent length, m
Ql light liquid phase volumetric flowrate, m3/s
Qd Dense liquid phase volumetric flowrate, m3/s
ρG Gas density, kg/m3
l Light liquid phase density, kg/m3

PTS 16.52.10
Page 38 of 46
Light liquid phase dynamic viscosity, Pa.s

l
The de-gassing and de-foaming criteria (also described in PTS 16.52.09), are based
here on the physical properties of the light liquid and the total liquid flow rate.
The foam has to be accommodated between LAH and LZAHH with an additional
foam allowance of 250 mm.
c) Dense phase droplet size separation section
18𝜇𝑙 (𝑣𝑑𝑑,𝑠𝑒𝑡 + 0.05𝑣𝑙,𝑎𝑥 )

𝑑𝑑 = √
𝑔 (𝜌𝑑 − 𝜌𝑙 )
Where,
𝑑𝑑 Dense liquid phase droplet size, m
𝜇𝑙 Light liquid phase dynamic viscosity, Pa.s
Equation to calculate Droplet settling velocity and axial velocity


vdd,set = dense liquid phase droplet settling velocity, m/s
= Ql/(LsetxDx0.8)
vl,ax = light liquid phase axial velocity, m/s
= (Ql + Qd) / Al
g acceleration due to gravity, m/s2
d dense liquid phase density, kg/m3
l light liquid phase density, kg/m3
Ql light liquid phase volumetric flowrate, m3/s
Qd dense liquid phase volumetric flowrate, m3/s
Lset settling compartment length, m
D separator diameter, m
Al light liquid phase area, m

PTS 16.52.10
Page 39 of 46
It has to be checked that vl,ax does not exceed 0.015 m/s, because this may result
in a larger value of dh than is given by the above formula. vl,ax can be decreased
by selecting a higher NL.
d) Light Phase droplet size
18𝜇𝑑 ∗ 1.05𝑣𝑑,𝑏𝑜𝑜𝑡
𝑑𝑙 = √
𝑔(𝜌𝑑 − 𝜌𝑙 )
Where
dl light liquid phase droplet size, m
𝜇𝑑 dense liquid phase dynamic viscosity, Pa.s
vd,boot liquid velocity in the boot, m/s
g acceleration due to gravity, m/s2

d dense liquid phase density, kg/m3
l light liquid phase density, kg/m3
General requirement
a) The cross section area of the gas cap shall be adequate for liquid knock
out. For a bulk separation, the maximum allowable gas load factor is 0.07
m/s.
b) The gas cap should accommodate inlet device requirement (2 x ID inlet
nozzle) with a clearance of 200 mm above LZAHH.
c) The cross section area for AG (or above LZAHH) and below LZALL shall at
least 14.2% of the vessel cross section area.
d) If slug is expected, volume between NL and LAH shall accommodate light
liquid phase + liquid phase + volume of slug.
e) Axial total liquid dense velocity below the cross section of NL to bottom
of vessel shall not exceed 0.015 m/s.
f) Boot diameter should at least 1/3 of vessel diameter and the length shall
meet the separation performance.
g) Ratio L/D is between 2.5 to 6.
4.3 HORIZONTAL 3-PHASE SEPARATOR WEIR
4.3.1 Separation Section

For a proper sizing of the separation section the following guidelines apply:
The gas cap cross section above LZAHH shall be large enough for sufficient liquid
knockout. For bulk separation the maximum allowable gas load factor, k = 0.07
m/s.
PTS 16.52.10
Page 40 of 46
The central height > 0.3 m.
If there is presence of foaming and liquid slug, it will take up volume in between
NL and LZA(HH). In minimum the foaming allowance is 0.25 m to be added
between LA(H) to LZA(HH).
Axial velocity for each zone (i.e. light and dense zone) should not exceed 0.015
m/s.
Vessel cross section area below the interface level or below the liquid dispersion
band (if present) shall at least 14.2 % or equivalent to minimum central height of
0.2 D.
This separation compartment should meet the requirement of separation

specification which are smallest droplet size separated or/and retention time
required. Requirement for degassing or defoaming shall be checked if it is
required based on the function of the vessel.
Clearance of at least 150mm above LZAHH is required to accommodate the feed

inlet device and high gas load. Typically the vertical space requirement of an inlet
device is 2Dinlet nozzle + 50 mm.
The vessel tangent-to-tangent length/diameter ratio of between 2.5 to 6.0. For

upstream application, the vessel tangent-to-tangent length/diameter ratio can be
optimized to be between 2.0 to 4.5 to avoid liquid re-entrainment into the gas
phase to avoid liquid re-entrainment into the gas phase.
4.3.2 Collection Section

There are several arrangements for collection section:
Single weir (submerged or overflow weir)
Gutter and single weir
Double weir
General requirement:
Weirs shall have hand holes for maintenance purposes.
Minimum thickness of the weirs is 3 mm.
An oil skimming pipe should be installed in water collection compartment. The

height of the pipe should be from the vessel bottom to the LA (H)
PTS 16.52.10
Page 41 of 46
feed inlet gas outlet
light liquid phase
heavy liquid phase

heavy-phase outlet light-phase outlet
Submerged weir hold-up for
control
feed inlet gas outlet
light liquid phase
heavy liquid phase
heavy-phase outlet light-phase outlet
Overflow weir
Figure 8: Differences between overflow and submerge weir control band on oil collection compartment
4.3.3 Nozzles
Feed Nozzle
a) Top feed inlet with inlet device should be used. It shall be located at least
150 mm above LZA (HH)
b) Selection of feed inlet device shall be based on the gas volumetric fraction
Description Type of inlet device

Gas volumetric fraction of the feed Horizontal pipe
is less than 0.15
Gas volumetric fraction of the feed Horizontal half open pipe and
is between 0.15 and 0.7 opening is directed upwards
Gas volumetric fraction is more Vane type Inlet distributor
than 0.7
c) Bottom inlet is preferable if the gas flow is negligible and the separator
has a sealing function
PTS 16.52.10
Page 42 of 46
Outlet Nozzle
a) Typically, the outlet of the light liquid phase are elevated for 150mm from
the bottom of the vessel.
b) Both liquid outlet nozzles shall be equipped with a vortex breaker
c) Velocity at liquid outlet nozzle shall not exceed 1 m/s.
d) Minimum diameter of liquid outlet nozzle is 50 mm
4.4 HORIZONTAL 3-PHASE SEPARATOR WITH PLATE PACKS
4.4.1 Inlet Section

A top feed inlet equipped with an inlet device which could be an open or half open
pipe, or a vane inlet distributor should be used. This device is connected to the inlet
via an elbow and shall be directed to the nearest vessel head. Its location shall be at least
150 mm above LZA(HH).
The choice of the feed inlet device depends on the following factors:
Selection of feed inlet device shall be based on the gas volumetric fraction
One calming baffle is installed, with an NFA of 20 % for horizontal three phase
separator with plate.
Description Type of inlet device
Gas volumetric fraction of the feed is less

Horizontal pipe
than 0.15
Gas volumetric fraction of the feed is Horizontal half open pipe and opening
between 0.15 and 0.7 is directed upwards
Gas volumetric fraction is more than 0.7 Vane type Inlet distributor
Table 7: Selection of inlet feed nozzle
4.4.2 Separation Section

Transversal plate pack (with the face of the plate pack perpendicular to the central vessel axis)
is installed in this section. In general a liquid-liquid interface has to be maintained in this
section via weir arrangement because:
Interface level is independent of the liquid flow rates.
Gas liquid interface is fairly constant which enable economic use of plate pack.
4.4.3 Layout of the Plate Pack is described below:
The distance between the plate pack and the calming baffle = 150 mm.
The distance between the plate pack and the outlet section > 500 mm.
The top of the plate pack = NL.

PTS 16.52.10
Page 43 of 46
The front face of the plate pack shall be fitted with a top cover plate, extending
from the top of the plate pack to typically 50 mm above LZAHH to prevent liquid
bypassing.
It shall also cover the plate pack over its full length.
To facilitate plate pack installation, the manhole shall be upstream of the weir
arrangement.
4.4.4 Sizing Of the Separation Section

For a proper sizing of the separation section the following guidelines apply:
The gas cap cross section above LZAHH shall be large enough for sufficient liquid
knockout. For bulk separation the maximum allowable gas load factor, k = 0.07
m/s.
The central height > 0.3 m.
If a feed inlet device is required and high gas load, clearance of at least 150mm
above LZAHH is required. The gas cap cross section to be verified ensuring
sufficient gap to accommodate the inlet device. The vertical space requirement
of an inlet device = 2Dinlet nozzle + 50 mm.
The vessel cross-section below NL shall be sufficiently large to contain the plate
pack.
The gas cap cross section above LZAHH and below the liquid-liquid interface shall
be at least 14.2 % of the vessel cross-sectional area.
The interface level should be halfway between the top of the underflow passage
of the dense liquid phase underflow weir and the top of the overflow weir of the
light liquid phase in order to minimise the likelihood of carry-over to the liquid
section.
At any rate, under normal flow conditions, the interface level shall be at a distance
of at least 0.2 m from either the lower rim of the dense liquid phase underflow
weir or from the upper rim of the light liquid phase overflow weir. If a dispersion
band is expected but its width cannot be reliably estimated, 0.2 m should be taken
as dispersion band width.
The length of the settling section shall be more than 650 mm + plate pack length.
Verification on vessel to be performed if de-gassing and/or de-foaming are

required to ensure available vessel capacity. Additional foam capacity to be
accommodated between LAH and LZAHH with an additional level allowance of
250 mm.
The vessel tangent-to-tangent length/diameter ratio of between 2.5 to 6.0. For

upstream application, the vessel tangent-to-tangent length/diameter ratio can be
optimized to be between 2.0 to 4.5 to avoid liquid re-entrainment into the gas
phase to avoid liquid re-entrainment into the gas phase.
PTS 16.52.10
Page 44 of 46
5.0 BIBLIOGRAPHY
In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:
PETRONAS TECHNICAL STANDARD
Index to PTS PTS 00.01.01
Requirements, General Definition of Terms, Abbreviations PTS 00.01.03

& Reading Guide
Two Phase Gas Liquid Separator PTS 16.52.09
Piping General Requirement PTS 12.30.02
Alarm Management Guidelines PTS 14.12.08
Produced Sand – Design, Operations and Disposal PTS 16.52.17
INTERNATIONAL STANDARD
Oil and Gas Separators API 12J

PTS 16.52.10
Page 45 of 46
APPENDIX 1: DETERMINATION OF CROSS-SECTIONAL AREA OF HORIZONTAL SEPARATOR AND

HORIZONTAL SEPARATOR VOLUME HEAD
CROSS SECTION AREA
h0 (equivalent to diameter)
AG 𝜋𝐷 2 𝐴∗𝐺
𝐴𝐺 =
4 h1
𝜋𝐷 2 𝐴∗𝐿
𝐴𝐿 =
AL 4
h2
AD 𝜋𝐷 2 𝐴∗𝐷
𝐴𝐷 =
4 h3
Where
AG Cross section area of the gas phase, m2
AL Cross section area of the light phase, m2
AD Cross section area of the dense phase , m2
D Diameter of the horizontal vessel, m
A*G Dimensionless cross section area of the gas phase
A*L Dimensionless cross section area of the light phase
A*D Dimensionless cross section area of the gas phase
Note:
1) A*G+ A*L+ A*D = 1
PTS 16.52.10
Page 46 of 46
DIMENSIONLESS CROSS SECTION AREA CALCULATION
h2
A ∆ℎ
h3
0.5 × (∅ − sin ∅)
𝐴∗ =
𝜋
∆ℎ
∅ = 2 × arccos (1 − 2 × )
𝐷
Where;
∅ Angle
∆ℎ Difference between height, m
D Diameter of the vessel, m

Petronas Technical Standards: Liquid-Liquid Separator and 3-Phase Separator

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Petronas Technical Standards: Liquid-Liquid Separator and 3-Phase Separator

Uploaded by

Copyright:

Available Formats

PETRONAS TECHNICAL STANDARDS

Liquid-Liquid Separator And 3-Phase Separator

© 2015 PETROLIAM NASIONAL BERHAD (PETRONAS)

i. 2-Phase liquid-liquid separator/ Decanter – process plant, deoiling and

ii. Column Side draw-off separator – Refinery fractionation

i. Front end receiving vessel for production and processing facilities

ii. Degassing-Deoiling-Dewatering separator

This PTS does not cover:

i. The design of settling tanks, buffer vessel with no separation performance

iii. vertical separators

1.2 GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

1.2.2 Specific Definition of Terms

3 Inlet device Feed distributor installed at the separator inlet to

1.2.3 Specific Abbreviations

1.3 SUMMARY OF CHANGES

2.0 DESIGN REQUIREMENTS

2.1.1 Selection of 2-phase Liquid-Liquid Separator

i. Separation Efficiency or Cut-Off droplet diameter

Liquid-liquid separators can be categorized into 2 main application:

i. Bulk separation – designed to achieve cut-off diameter of 150 m with

i. Liquid Handling Capacity

2.1.2 Selection of 3-phase gas-liquid-liquid separator

i. Gas to liquid separation

ii. Light liquid to dense liquid separation

2.1.3 Selection of Coalescing plate pack

iii. High gas load

Table 2: Separator Selection Guidelines

2.2 SEPARATOR SPECIFICATIONS

Specific fluid consideration (i.e. solid, wax and foaming)

Slug volume – not applicable for liquid-liquid separator

Gas load capacity – not applicable for liquid-liquid separator

2.2.1 Piping Requirement for Separator

i. Inlet piping configuration

ii. Control valves, Pipe expander and reducer

iv. Outlet Piping

2.2.2 Inlet Piping

2.2.3 Valves, Pipes expanders and Reducer

2.2.5 Outlet Piping

2.3 LEVEL CONTROL

Abbreviations for liquid levels

LAH high level pre-alarm

2.3.1 G-L-L Interface

 provide sufficient liquid hold up time between

2.3.2 L-L Interface

LALint low level pre-alarm of L-L  ≥350 mm below LAHint and

 if a dispersion band width is specified, the

2.4 NOZZLE SIZING

2.4.1 Inlet Nozzle

Type of inlet Momentum limit (Pa) Momentum limit (Pa)

No inlet device mvm,in2  1 400 mvm,in2  1 000

Half open pipe inlet device mvm,in2  2100 mvm,in2  1500

Vertical vane type inlet mvm,in2  3700 mvm,in2  3700

Table 3: The momentum criterion for typical separator inlet device

𝜌𝑚 mean density of the mixture in the feed pipe, kg/m3

𝑄𝐺 volumetric flowrate for gas, m3/h

𝑄𝑙 volumetric light liquid respectively, m3/h

𝑄𝑑 volumetric flowrate for dense liquid, m3/h

𝜌𝑙 density of light liquid, kg/m3

𝜌𝑑 density of dense liquid, kg/m3

𝜌𝐺 Density of gas, kg/m3

Prevention type Velocity limit (m/s)

To prevent erosion vmix,in erosion velocity