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INTRODUCTION
Separation of oil and gas is a critical field-processing operation.
Technically easier and less costly to process gas, crude oil, and produced water separately.
The water is often corrosive. It is important to remove water upfront to be able to use less costly materials of
construction at the downstream.
SEPARATOR TYPES
Wellhead separators are often classified by their geometrical configuration (vertical, horizontal, horizontal double
barrel, or spherical) and by their function (two-phase), or three phase (gas-oil-water) separation.
COMPONENTS OF SEPARATORS
Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
COMPONENTS OF SEPARATORS
Secondary or Gravity Settling Section:
Velocity is reduced; liquid droplets can settle out by
gravity.
Internal baffling: inhibit foams, reduce turbulence,
and accelerate droplet removal.
Vanes: droplet collectors
Process Controls: The separator pressure is typically regulated by a backpressure regulator in the exit gas line, or to
control pressure loss across the valve. The two phase separators have a liquid level controller to activate a dump
valve to maintain desired liquid level. Three phase separators have two liquid level controllers.
Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
VERTICAL SEPARATORS
Vertical separators are usually selected when the gas-liquid ratio is high or total gas volumes are low.
Horizontal separators are most efficient when large volumes of total fluids and large amounts of dissolved gas are present
with the liquid
Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
HORIZONTAL SEPARATORS
The length of horizontal separator has a greater effect on capacity than the height of a vertical type. The required length
depends on droplet size, gas velocity, droplet density, vessel diameter, and the degree of turbulence.
Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
HORIZONTAL SEPARATORS
Single and Double Barrel Horizontal Separator: The double barrel separator consists of an upper separation section
and a lower liquid chamber. The single barrel type combines both into a single chamber. In single barrel type, the
diameter must be larger to compensate for the volume occupied by the liquid.
Mist eliminators are used to aid gravity settling by changing the momentum of the stream and also by impaction. To be
effective, a mist extractor must accomplish two basic functions
Vane with pockets, allow a higher gas throughput (capacity) per flow area due to the enhanced drainage, but are not
typically used in highly fouling service.
Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
MIST EXTRACTOR
Mesh mist eliminators or pads are made by knitting wire, metal, or plastic into tightly packed layers, which are then
crimped and stacked to achieve the required pad thickness.
VERTICAL SEPARATORS: In the top section of a vertical separator the downward flow of any liquid drops is inherently
countercurrent to the rising vapor flow. In horizontal separators, the flows are crosscurrent; liquid drops fall downward as gas
flows horizontally.
PHASE SEPARATION THEORY
For vertical vessels, a dispersed liquid droplet will settle out when the vertical continuous phase velocity (gas phase
velocity for gas-liquid separation) is less than the terminal velocity of the droplet.
PHASE SEPARATION THEORY
DRAG COEFFICIENT
The drag coefficient is a function of the shape of the particle and the Reynolds number of the flowing fluid.
Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
PHASE SEPARATION THEORY
HORIZONTAL SEPARATORS
In a horizontal separator, the drop’s downward velocity is perpendicular to the horizontal gas flow. The time, , for most
remote liquid droplet to fall through the entire gas phase is set equal to the theoretical residence time for gas flow through
the separator ,.
GPSA (1987) recommended adjustment of for high pressures for separators with mist eliminator.
GPSA (1987). Engineering Data Book, Vol I, Section-7, 10 th Edition, Gas Processors Suppliers Association, Tulsa, OK.
PHASE SEPARATION THEORY
EMPIRICAL METHODS
Otto H. York Company suggested the following relations for values for separators with York Demister.
•
•
•
Pressure in above equations are in psig.
Otto H. York Company Inc. Mist Elimination in Gas Treatment Plants and Refineries. Engineering, Parsipanny, NJ.
PHASE SEPARATION THEORY
LIQUID-LIQUID SEPARATION
Gravity Settling Method: The flow of rising light droplets in the heavy liquid phase or settling heavy liquid droplets in the
light liquid phase is considered laminar and is governed by Stokes’ law;
Residence Time: Residence time is defined as the amount of time a fluid remain within the settling compartment of the
separator
PHASE SEPARATION THEORY
LIQUID-LIQUID SEPARATION
GPSA (1987) Engineering Data Book, Vol I, Section-7, 10 th Edition, Gas Processors Suppliers Association, Tulsa, OK
PRESSURE VESSEL SPECIFICATIONS
VESSEL SHELL THICKNESS
The ASME BPV (American Society of Mechanical Engineers, Boiler and Pressure Vessel) code will be considered here. It is
the standard used in North America and most commonly referenced internationally.
Design Pressure: It is typically either the operating pressure with 15 – 30 psi added to it or the operating pressure
+10%, whichever is greater.
Design Temperature, T (F): The strength of metals decreases with increasing temperature so the maximum allowable
stress will depend on the material temperature.
PRESSURE VESSEL SPECIFICATIONS
VESSEL SHELL THICKNESS
Maximum allowable Stress, (psi): The maximum allowable stress values for ASME BPV Code Sec. VIII D.1 are given
in ASME BPV Code Sec II Part D Table 1A for ferrous metals and Table 1B for nonferrous metals .
Towler, G. and Sinnott, R. (2013). Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design, Second Edition, Elsevier
PRESSURE VESSEL SPECIFICATIONS
VESSEL SHELL THICKNESS
Joint Efficiency, E:
The strength of welded joint will depend on the type of joint and quality of welding.
Towler, G. and Sinnott, R. (2013). Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design, Second Edition, Elsevier
PRESSURE VESSEL SPECIFICATIONS
HEAD TYPES
The major types of heads are Ellipsoidal, Torispherical and Hemispherical. They are collectively referred to as domed heads
Hemispherical head is the strongest shape, capable of resisting about twice the pressure of torispherical head of the same
thickness.
• Can be used for high pressures
• Costlier than shallow torispherical head
PRESSURE VESSEL SPECIFICATIONS
Head Thicknesses for Different Head Types
Ellipsoidal Heads (2:1): Most standard ellipsoidal heads are manufactured with a major and minor axis ratio of 2:1. For
this ratio, the following equation ca be used to calculate the minimum thickness required by ASME BPV Code Sec. VIII D.1
Part UG-32
Torispherical Heads: A torispherical shape is formed from a part of a torus and part of a sphere. The shape is close to
that of an ellipse but is easier and cheaper to fabricate. The ASME Code gives the design equation
Hemispherical Heads: In the ASME BPV Code Sec. VIII D.1, the equation specified is the same for a spherical shell
PROMAX SEPARATOR SIZING TOOL
PROMAX SEPARATOR SIZING TOOL
Vessel Type
PROMAX SEPARATOR SIZING TOOL
Vapor-Liquid Droplet Diameter
Vapor-Liquid
PROMAX SEPARATOR SIZING TOOL
Terminal Velocity in Vapor
Liquid-Liquid C*
PROMAX SEPARATOR SIZING TOOL
Light Liquid Surge Time /Volume /Depth Light Liquid Low Level Shutdown Depth
PROMAX SEPARATOR SIZING TOOL
Heavy Liquid Holdup Time / Volume / Depth
PROMAX SEPARATOR SIZING TOOL
Heavy Liquid Surge Time Heavy Liquid Surge Volume Heavy Liquid Surge Depth Heavy Liquid Low Level Shutdown Depth
PROMAX SEPARATOR SIZING TOOL
PROMAX SEPARATOR SIZING TOOL