A new approach for sizing finger-type

(multiple-pipe) slug catchers

H. R. Kalat Jari, P. Khomarloo and K. Assa, Sazeh Consultants, Tehran, Iran

A slug catcher, which is a part of the gas pipeline system, is essential equipment at the receiving
terminal of a multiphase-flow processing plant. In the past, sizing of multiple-pipe slug catchers
was based primarily on experience and rules of thumb. Not surprisingly, most of the existing
slug catchers are oversized.

Multiple-pipe slug catchers are the obvious choice for long, large-diameter pipes, especially
those that undergo pigging. They are cost effective and simple to construct and operate. This
article presents a new, innovative approach for the prediction of the required dimensions of slug
catcher fingers. The new approach has been used to design a multiple-pipe slug catcher for actual
field conditions.

Slug catcher types. Slug catchers can be broadly classified into three following categories:

 Vessel type
 Stored-loop type
 Finger (multiple-pipe) type.

A vessel-type slug catcher is a simple two-phase separation vessel. The geometry of the vessel-
type slug catcher could range from a simple knockout vessel to a more sophisticated layout.

A stored-loop-type slug catcher combines features of the vessel-type and finger-type slug
catchers. The gas/liquid separation occurs in the vessel, while the liquid is stored in the stored-
loop-shaped fingers. A possible hybrid design can be used, with a vessel designed for the
vapor/liquid separation and finger pipe work as the storage medium, as illustrated in Fig. 1.

Fig. 1. Stored-loop-type slug catcher.

The counter-current flow of a gas and a liquid in the same conduit is possible due to gravity,
which drives the fluid of higher density downward, while the lighter fluid flows upward.
Consequently, for given geometry and fluids, the counter-current flow is only stable up to a
maximum relative velocity, known as onset of flooding.

During this flow regime, called counter-current flow limitation, a part of the downward-flowing
liquid is carried over by the gas and entrained in the opposite direction. The counter-current flow
limitation is mainly characterized by:

 A sudden increase of the pressure drop over the conduit

 The generation of large waves and slugs
 The entrainment of liquid droplets by the gas flow.

A finger-type slug catcher uses pieces of large-diameter pipe instead of a conventional vessel to
provide a buffer volume (Fig. 2). Since pipe can be more easily designed to withstand high
pressures compared to a vessel, this design is better suited for large-diameter pipes.

Fig. 2. Finger-type (multiple-pipe) slug catcher.

If a pipe-finger slug catcher has been selected, then the number of standard large-diameter pipes
to handle the vapor flow, as described above, is calculated—e.g., 36-in., 42-in., 46-in. and 48-in.
pipes. However, the result must be a power of 2—i.e., 2, 4, 8, etc.—so that appropriate dead-end
tees may be used to subdivide the flow as uniformly as possible. Furthermore, regarding space
limitations and economic reasons, six-bore pipes may be used in the unit.
Slug flow. Most of the gas is located in large, bullet-shaped bubbles that have a diameter close to
that of the pipe diameter, and that move upward. The bubbles are separated by slugs of
continuous liquid that bridge the pipe and usually contain small gas bubbles. Between the
bubbles and the pipe wall, liquid falls downward in the form of a thin film. When the flow is
low, well-defined gas-liquid boundaries appear, and the liquid slug is free of bubbles. This case
is often referred to as “plug flow.”

When the flow is faster, boundaries are not clearly discerned and froth is generated, and the term
“slug flow” is used. Normal slug flow (or hydrodynamic slugging) is a pure hydraulic
phenomenon that is usually obtained at medium flowrates for any horizontal pipe section; under
these flow conditions, the stratified flow pattern is not stable, and an intermittent flow pattern
appears that is characterized by permanent high-frequency oscillations between two flow
patterns: stratified (gas pocket) and dispersed (liquid slug).

A stable maximum slug length, after some distance, can be established. The Brill correlation can
be used to determine the mean slug length. The Brill correlation is based on Prudhoe Bay field
results. Slug length is correlated as a function of the pipeline diameter, D, and the no-slip
mixture velocity, Vm, as shown in Eq. 1:

Ln(Lslug) = –3.781 + 5.441 [Ln(D) + 3.673]0.5 + 0.059 Ln(Vm) (1)

Note: The Brill correlation always calculates the maximum slug length to be 4.7 times the mean.

As a consequence, the ratio of maximum to mean slug length varies with flow conditions. Near
the stratified wavy boundary, the maximum slug length may be calculated at 4 to 5 times the
mean. However, near the elongated bubble transition, maximum slug lengths are only calculated
at 2 times the mean.

The Gregory and Scott correlation gives the trend of minimum stable slug length in a simplified
form, as shown in Eq. 2:

(Lslug)min= 32 D (2)

The Gregory and Scott correlation was developed for carbon dioxide/water flow in a small-
diameter pipe. The mean slug frequency is related to pipeline diameter, mixture velocity and
superficial liquid velocity, as shown in Eq. 3:

(3)

where:

VSL = QL ÷ AS = Superficial liquid velocity, m/s.

For permanent increases of the maximum slug length of the pipeline outlet, severe slugging
criteria must be determined.

In 1987, Fuchs developed a criterion based on the “release” of a severe slug, equivalent to the
blowdown of the riser. Severe slugging is expected in a vertical riser. The basic form of the
criterion for the acceleration of a gas bubble entering the riser base is shown in Eq. 4:

(4)

where:

P=Pressure at riser bottom, barg

L=Pipe length upstream of riser, m.

Slug-catcher sizing. The first step in sizing a slug catcher is to determine the terminal velocity
and particle diameter. In reference to the Gas Processors and Suppliers Association’s
Engineering Data Book, settling velocity can be described mathematically using the terminal or
finite-settling velocity calculation, as shown in Eq. 5:

(5)

The drag coefficient is a function of the shape of the particle and the Reynolds number (NRe) of
the flowing gas. The Reynolds number is defined as shown in Eq. 6:

(6)

When the expressions for “C’ vs. Re” are substituted in Eq. 5, three settling laws are obtained:
Stokes’ law, the intermediate law and Newton’s law.

Stokes’ law. At low Reynolds numbers of less than 2, a linear relationship exists between the
drag coefficient and the Reynolds number. Stokes’ law applies in this case, and the calculation
from Eq. 5 can be expressed as shown in Eqs. 7 and 8:

(7)
 (8)

where:

KCR = Proportionality constant, dimensionless.

The droplet diameter corresponding to a Reynolds number of 2 can be found using a value of
0.025 for KCR. By inspection of the particle Reynolds number equation shown in Eq. 6, it can be
seen that Stokes’ law is typically applicable for small droplet sizes and/or relatively high-
viscosity liquid phases.

Intermediate law. For Reynolds numbers between 2 and 500, the intermediate law applies, and
the terminal settling law can be expressed as shown in Eq. 9:

(9)

The droplet diameter corresponding to a Reynolds number of 500 can be found using a value of
0.334 for KCR in Eq. 8. The intermediate law is usually valid for many of the gas-liquid and
liquid-liquid droplet settling applications encountered in the gas business.

Newton’s law. Applicable for a Reynolds range of approximately 500 to 200,000, Newton’s law
finds applicability mainly for the separation of large droplets or particles from a gas phase. The
limiting drag coefficient, at approximately C’ = 0.44 in Eq. 5, produces the Newton’s law
equation as shown in Eq. 10:

(10)

For the Newton’s law region, the upper limit to the Reynolds number is 200,000, and KCR =
18.13 in Eq. 8.

Determination of gas-liquid separation section length. The function of separation at high flow
velocities in a multi-phase slug catcher is assigned to the horizontal parts of the primary bottles
before the gas riser; therefore, these parts of the primary bottles required for liquid separation
will be longer.

In the hindered settling (dispersed-phase concentration), the terminal velocity is reduced due to
the increase in the apparent viscosity and density of the suspension. This effect results in less
than a 1% reduction in the terminal velocity for particle volumetric concentrations below 0.1%.
For a spherical shape suspension, the terminal settling velocity in a hindered area can be
calculated as shown in Eq. 11:

(Vt)hindered = Vt (1 – Vd)n(11)

where n = the index, n is a function of Re (based on the terminal velocity of a free-falling single
sphere) and is given in Fig. 3. In Stokes’ law region, n = 4.65; in the Newton’s law region, n =
2.33.

Fig. 3. Values of the exponent n for use in Eq. 11.

The estimation of drop size can be useful in determining separation techniques, scaling
equipment and piping sizing. For engineering calculations, the following form of the Rosin-
Ramler equation for drop size estimation in turbulent pipe flow is shown in Eq. 12:

(12)

where:

Vd = Cumulative volume fraction of the dispersed phase with a diameter greater than Dp

D95 = The drop diameter, such that 95% of the volume of drops is smaller than D95, it may be
estimated by Eq. 13:

(13)

where We is based on the particle diameter Dp and is defined by Eq. 14:

 (14)

Settling time (tsettles) is a function of the droplet diameter for several values of Vd, as shown in
Eq. 15:

(15)

where:

D = Bottle diameter (travel droplet inside bottle, m).

Therefore, the length of the primary bottles between the inlet and the first gas outlet riser is
determined by the desired settling and separation efficiency, as shown in Eq. 16:

(16)

(17)

where:

Cdist. = Non-uniformity stream distribution coefficient in the bottles, equal to 1.2.1, 2

Furthermore, the inlet splitter diameter is determined by Eq. 18:

(18)

Determination of intermediate section length. The intermediate section is located between the
gas-liquid separation section and the slug-receiving section. This section should be designed
based on the prohibition of liquid entry to the gas riser. The maximum liquid level mark in the
primary bottle for both the single-slope and the dual-slope concept should be at the intersection
of the center line of the lowest gas riser (if there are two risers per bottle), at the lower inner wall
surface of the bottle.
 Fig. 4. The location of the gas riser distance.

For the dual-slope concept, the gas riser was located at a distance of Db/tan θ from the
intersection of the two different slopes, where θ is the slope angle of the steeper bottle (Fig. 4).
For the purpose of determining the maximum capacity of the slug catcher, the volume in the
partly filled part of the bottle can be assumed to be:

where θ is the slope of the bottle under the riser. This calculation shown in Eq. 19 is valid for
both the single-slope and dual-slope concepts:

(19)

where:

θ = bottle angle with gas riser (2.5% to approximately 5%).

Determination of slug receiving section length. To determine the slug receiving section length,
Eqs. 20 and 21 can be used:

Volbuffer = QL tres (20)

(21)

where:

θ = bottle angle in the slug receiving section

(1% to approximately 1.5%).

Volholdup = Volslug + Volbuffer (22)

Therefore, Eq. 23 can be used to determine the length of the slug-receiving section:

(23)

where:

Cf = Overdesign coefficient factor for slug receiving section (equal to 1.15).

Determination of secondary bottle numbers. Due to space limitations in the slug catcher area,
bottle length should be reduced and several secondary bottles should be installed parallel with
the primary bottles. Eq. 24 is used for calculation of the number of secondary bottles (if needed)
in the slug catcher:

(24)

where:

Ltot=Slug catcher total length, m

Lpermit=Recommendation of slug catcher length with respect to plot space, m.

Determination of gas riser sizing. The gas riser should be sized to prevent liquid carryover at
the highest flowrate. In the approach suggested here, the riser must be sized to prevent carryover
during pig arrivals when the slug catcher may be nearly full.

Load factor is an important parameter for gas riser sizing. Based on process criteria, the
maximum value for load factor parameter (ξ) is 0.5 m/sec, as shown in Eqs. 25 and 26:

(25)

(26)

Process assumptions for the calculation of superficial velocity include:

1. uring normal operation, each bottle receives more than 20% of the distribution rate of
120/NPB
2. evere slug formation occurs based on pigging operation.

Eq. 27 can be used to calculate superficial velocity:

(27)

Then, Eq. 28 can be used to determine the bottle height from the ground level:

Hs = (Lf + Ls) sinθs + Ht(28)

Ht = (Lt) sinθt

where:

Sin θs = Separation section bottle slope

Sin θt = Slug receiving section bottle slope.

Eq. 29 can be used to determine bottle thickness:

(29)

where:

E=Longitudinal weld joint parameter (E = 1 for seamless; E = 0.85 for electrical resistance
welded)

Y=Steel coefficient (Y = 0.4 for T ≥ 480°C; Y = 0.5 for T = 510°C; Y = 0.7 for T ≥ 540°C)

Фe=External diameter, mm

C=Allowable corrosion value, mm.

Eq. 30 can be used to determine liquid-liquid bottle sizing:

(30)

where:

tres = Residence time in the liquid bottle—8 min.

Table 1 provides values for determining the liquid level in the liquid-liquid bottle.

Case study: Slug catcher sizing in South Pars phases 22, 23 and 24. The South Pars onshore
complex is located on the Persian Gulf in the Akhtar field, approximately 230 km southeast of
Bushehr, Iran. The total capacity of phases 22, 23 and 24 of the onshore facility is 2,000 MMscfd
of reservoir fluid.

From each main platform, a 32-in. subsea pipeline is planned to transfer the offshore gas
production to the onshore slug catcher facilities. Specifications for these facilities are presented
in Table 2.

Inlet header sizing criteria. For preliminary mixed-phase fluid line size calculations, the
average density method will be used while considering the following project criteria, and as
shown in Eq. 31:

 Apparent fluid velocity, Vm, in the inlet pipeline = 7 m/s–10 m/s

 ρmVm2 : 5,000 Pa–6,000 Pa

(31)

The apparent mean fluid velocity, Vm, can be expressed as shown in Eq. 32:
 (32)

Table 3 shows the slug catcher sizing results in the South Pars facility phases 22, 23 and 24.
Takeaway. Multiple-pipe slug catchers are frequently used in the industry due to the ease of
manipulation of the fingers and their ability to handle large volumes of slugs, which is the case
for all of the fields under investigation.

One of the advantages of finger-type slug catchers is that they are classified as pipework for the
purposes of design and inspection, with less onerous requirements. However, this classification
may be lost and the system reevaluated as a vessel if the design becomes too complex,
particularly if internals are added.

Even if slug flow does not occur in a multiphase pipeline operating under normal conditions, it
should be remembered that startup, upset, low-flow and shutdown conditions may result in the
productions of slugs, which must be addressed at the design stage.

Several parameters contribute to the design of the slug catcher. The diameter of the pipeline
should be designed at the minimal diameter size first, and then increased to maintain a stratified
flow at the inlet of the buffer. The liquid accumulation volume, along with the length of the
fingers and their inclination, are essential factors for determining an accurate and optimal size
and design for the slug catcher.

The calculations in this article have the potential to recommend a larger-size slug catcher, which
may be considered as a safety margin. GP
 Nomenclature

As Pipe cross-section, m2

C’ Drag coefficient of particle

D Diameter, m

g Gravity constant, m/s2

ho Average liquid fraction holdup

Hs Separation section bottle height, m

Ht Slug receiving section bottle height, m

L Length, m

Lf Gas/liquid separation length, m

Ls Intermediate section length, m

Lt Slug collector section length, m

N Number of bottles or splitters

P Pressure, barg

Q Volume flow rate, m3/s

S Allowable tension, bar

t Time, s

th Thickness, mm

V Velocity, m/s

Vt Terminal velocity, m/s

W Total mass flowrate, kg/hr

θ Bottle angle

µ Viscosity, cP
ν Mean slug frequency, s-1

ξ Load factor, m/s

ρ Density, kg/m3

σ Surface tension, N/m

b Bottle

d Design

G Gas

HL Heavy liquid

L Liquid

LL Light liquid

m Mean

p Particle

pb Primary bottle

rb Risers per bottles

res Residence

sb Secondary bottle

SG Superficial gas

SL Superficial liquid