Three Phase Separator

Production Engineering II
Three Phase Separation Process

Course Learning Outcomes (CLO)
1. Differentiate between various types of offshore
structure.
2. Analyze the HSE requirement for oil and gas

fields operation.
3. Propose suitable processes and treatment

equipment to manage produced oil, gas and water.
4. Perform standard engineering calculations for

the design of separator, storage tanks and
pipelines.
Recap
 The separator design concepts presented in the previous lecture relates to the
two phase separation of liquid and gas.
 Two Phase Separation Theory

 Liquid Droplet Settling
 Droplet Size
 Liquid Retention Time
 Liquid Re-Entrainment
 Horizontal / Vertical Separator Sizing Design

 Gas Capacity Constraint
 Liquid Capacity Constraint
 Seam to Seam Length
 Slenderness Ratio
Lecture Outcomes
At the end of this lecture, students should be able to :
 Understand the three phase separation theory.
 Identify and understand the constraints involved in sizing the

horizontal three phase separator.
 Perform separator design calculation for horizontal three phase

separators
Overview
(i) Introduction
(ii) Horizontal Three Phase Separator Overview
- Equipment Description
- Level Control Methods
- Vessel Internals
- Potential Operational Problems
(iii) Three Phase Separation Design Theory
(iv) Horizontal Three Phase Separator Sizing
Introduction
 In almost all production operations, the produced fluid stream consists of three
phases: water, oil and gas.
 Generally, water produced with the oil exists partly as free water and partly as
water-in-oil emulsion.
 When oil and water are mixed with some intensity and then allowed to settle, a
layer of relatively clean free water will appear at the bottom.
 Free water produced with the oil is defined as the water that will settle and
separate from the oil by gravity.
 Figure 1 illustrates the growth of water layer with time.
 After a period of time (30 seconds to 3 minutes) , the change in water

height will
be negligible.
Introduction
Figure 1. Growth of water layer with

time
Introduction
 The oil and emulsion is treated using heat treatment, chemical treatment,
electrostatic treatment or any combination of the treatments mentioned after the
separation stage.
 Therefore, it is advantageous to first separate the free water from the oil to
minimize the treatment costs of the emulsion.
 Three phase separators may be either horizontal or vertical similar to the two
phase separators described in the previous chapter.
 However, three phase separators have additional control devices and

internal components.
Horizontal Three-Phase Separator
Figure 2. Schematic of a horizontal three-phase separator with interface level controller and weir.
 Three-phase separators differ from two-phase separators in that the liquid
collection section of the three-phase separator handles two immiscible liquids
(oil and water).
 The fluid enters the separator and hits an inlet diverter.
 The inlet diverter contains a down-comer that directs the liquid flow below the
oil-water interface.
 This forces the inlet mixture of oil and
water to mix with the water continuous
phase in the bottom of the vessel and
rise through the oil-water interface.
(water washing)
 This step promotes coalescence of

water droplets which are entrained in the
oil continuous phase.
Figure 3. Down-comer inlet diverter.
 The liquid collection section provides sufficient retention time to allow oil and
emulsion to form a layer of “oil pad” on top of the free water level.
 There are two methods to control the levels of oil and water phases (illustrated
in Figure 2 and 4)
 In the first type (Figure 2), an interface controller and a weir provide the
control.
 In the second type (Figure 4), the bucket and weir design, the need for an
interface controller is eliminated.
i. Horizontal three-phase separator with interface level controller and weir.
 Weir maintains the oil level.
 Level controller maintains the

water level.
 Level of the oil downstream of the

weir is controlled by a level
controller that operates the oil
dump valve.
 The interface controller senses

the height of the oil water
interface and sends signal to the
Figure 2. Schematic of a horizontal three-phase separator
with interface level controller and weir. water dump valve.
 This process allows the right amount of water to be removed from the vessel to maintain the
oil water interface at the designed height.
 Gas flows horizontally and out through the mist extractor to a pressure control valve that
maintains constant vessel pressure.
How does an interface level controller work ?
ii. Horizontal three-phase separator with bucket and weir.
 Doesn’t require a liquid
level interface controller.
 Oil and water flow over respective

weirs
 Level control is achieved by a

simple float operated level switch.
 Oil overflows into the oil bucket

where its level is controlled by a
level controller that operates
the oil dump valve.
Figure 4. Schematic of a horizontal three-phase separator
with a “bucket and weir’.
 Water flows under the oil bucket and then over a water weir.
 The level downstream of the weir is controlled by a level controller that operates the
How does a float operated level switch work ?
Vessel Internals
 Most of the vessel internals for three phase separators are common to both two-phase and
three phase separator such as inlet diverters, wave breakers, de-foaming plates, vortex
breakers, sand jets and drains, and mist extractors. (covered in two phase oil and gas
separation section and will not be repeated here)
 However, coalescing plates are used in three phase separators to aid in the separation of oil
and water.
 The installation of coalescing plates in the liquid section will cause the size of the water
droplets entrained in the oil phase to increase. This would enhance the gravity settling of the
water droplets
Figure 6. Schematic of a horizontal 3P separator with coalescing plates

Potential Operation Problems
 Three-phase separators may experience the same operating problems as two-phase
separators.
 In addition, three-phase separators may develop problems with emulsions which can be
particularly troublesome in the operation of three-phase separators.
 Over a period of time an accumulation of emulsified materials may form at the interface of the
water and oil phases.
 In addition to adverse effects on the liquid level control, this accumulation will also decrease
the effective oil or water retention time in the separator, with a resultant decrease in water–oil
separation efficiency.
 Addition of chemicals and/or heat often minimizes this difficulty.
 It is possible to appreciably lower the settling time necessary for water–oil separation by
(i) Application of heat in the liquid section of the separator

(ii) Adding de-emulsifying chemicals.
What is an Emulsion ?
What is an Emulsion ?
 Oil emulsions are mixtures of oil and water
 An emulsion can be defined as a mixture of two immiscible liquids, one which is dispersed as
droplets in the other and is stabilized by an emulsifying agent.
 In the oil field :
Immiscible Fluid : Water and Oil (form water in oil emulsion)
Energy of Agitation : From the agitation that occurs throughout the oil production system.
Emulsifying Agent : Particles which are found naturally in the crude oil or water (in
reservoir) and which have been introduced in the system such as contaminants during
drilling or workover.
Three Phase Separation Theory
 The basic separation concepts and settling equations developed for two-
phase separators are, in general, valid for three-phase separators.
 In particular, the equations developed for separation of liquid droplets from the gas
phase, which determined the gas capacity constraint, are exactly the same for
three-phase separators.
 However, the treatment of the liquid phase for three-phase separators is

different from that used for two-phase separators.
 The liquid retention time constraint was the only criterion used for determining
the
liquid capacity of two-phase separators.
 For three-phase separators, the settling and separation of the oil droplets
from water and of the water droplets from oil must be considered in addition
to the retention time constraint.

Design Theory
(i) Gas Separation
 The concepts and equations related to the two phase separation is valid for
the three phase separation
(ii) Oil Water Settling
 The flow around settling oil drops in water or water drops in oil is laminar
and is governed by Stoke’s Law. The terminal drop velocity is calculated
using the following equation :
1.78 × 10−6 ∆𝑆𝐺 𝑑2 Where,

𝑚
𝑉𝑡 = 𝜇 (1)
Vt = terminal settling velocity, ft/s (m/s),
𝖡SG= difference in specific gravity between the oil
and water phases,
dm= drop size, microns,
µ= viscosity of continuous phase, cP.
Design Theory
(iii) Water Droplet Size in Oil
 Unless laboratory or nearby field data are available, good results have been obtained
by sizing the oil pad such that water droplets 500 microns and larger settle out.
 If this criterion is met, the emulsion to be treated by downstream equipment should
contain less than 5% to 10% water.
(iv) Oil Droplet Size in Water
 From Equation 1 it can be seen that the separation of oil droplets from the water is
easier than the separation of water droplets from the oil.
 The oil’s viscosity is in the order of 50-200 times that of water.
 Therefore, the Vt of an oil droplet in water is larger than the Vt of a water droplet in
oil.
 The primary purpose of a three phase separator is to prepare oil for further
treating.
 Sizing for oil droplet removal from water phase does not appear to be a meaningful
criterion.
 The separation of oil from the water phase rarely governs the vessel size and can be
ignored in most cases.
Design Theory
(v) Retention Time
 A certain amount of oil storage is required to assure that the oil reaches equilibrium
and that flashed gas is liberated.
 An additional amount of storage is required to assure that the free water has time to
coalesce into droplet sizes sufficient to fall in accordance with Equation 1.
 It is common to use retention times ranging from 3 minutes to 30 minutes depending

upon laboratory or field data.
Horizontal Three-Phase Separator Sizing
 For sizing a horizontal three-phase separator it is necessary to specify a vessel
diameter and a seam-to-seam vessel length.
 The gas capacity and retention time considerations establish certain acceptable
combinations of diameter and length.
 The need to settle 500-micron water droplets from the oil and 200-micron oil
droplets from the water establishes a maximum diameter corresponding to the
given liquid retention time.
(i) Gas Capacity Constraint
 The principles of liquid droplets settling through a gas, which were derived in the two
phase separator sizing section can be used to develop an equation to size a
separator for a gas flow rate.
 By setting the gas retention time equal to the time required for a drop to settle to the
liquid interface, the following equation can be derived :
Where
𝑇𝑍𝑄𝑔 1/2
𝑑𝐿𝑒𝑓𝑓 = 420 𝜌𝑔 𝐶𝐷 d = vessel internal diameter, in.
𝑃
𝜌𝑙 − 𝜌𝑔 𝑑𝑚 (2) Leff = effective length of the vessel, ft
T = operating temperature, oR,
Qg = gas flow rate, MMscfd,
P = operating pressure, psia ,
z = gas compressibility,
CD = drag coefficient,
dm = liquid droplet to be separated,µ
ρg = density of gas, lb/ft3
ρl = density of liquid, lb/ft3
(ii) Retention Time Constraint
 Liquid retention time constraints can be used to develop the following equation,
which may be used to determine acceptable combinations of d and Leff :
Where
𝑑2𝐿𝑒𝑓𝑓 = 1.42 𝑄𝑤 𝑡𝑟 𝑤 + 𝑄𝑜 𝑡 𝑟 𝑜 (3)
Qw = water flow rate, BOPD
(tr)w = water retention time, min,
Qo = oil flow rate, BOPD
(tr)o = oil retention time, min.
Derivation of Equation 3
1 𝜋𝐷2𝐿𝑒𝑓𝑓
𝑄 = 𝑄 𝑜 × 5.61𝑓𝑡 × 𝑑𝑎𝑦 × 1 ℎ𝑟
3
𝑉 𝑉= 4
2
𝑡=𝑄 𝑏𝑎𝑟𝑟𝑒𝑙 24 ℎ𝑟
1 𝜋𝑑2𝐿𝑒𝑓𝑓 10−5𝑠𝑄 𝑜
𝑄 = 6.49 ×3600
𝑉=
2 4(144)
For Oil
𝑉 = 2.73 × 10−3 𝑑2𝐿 𝑒𝑓𝑓
5.61𝑓𝑡3 𝑑𝑎𝑦 1 ℎ𝑟
𝑉𝑜𝑙 𝑜 2 𝐴𝑜 𝐴𝑜 𝑄=𝑄
𝑡𝑜 = = 42 𝑑 𝐿 𝑒𝑓𝑓 𝑉𝑜 = 2.73 × 10−3 𝑑2 𝐿 𝑒𝑓𝑓
× × ×
𝑄𝑜 𝑄𝑜 𝐴𝑙 𝐴𝑙 𝑤
𝑏𝑎𝑟𝑟𝑒𝑙 24 ℎ𝑟 3600 𝑠
𝑄 = 6.49 × 10−5𝑄 𝑤
𝑉𝑤 = 2.73 × 10−3 𝑑2 𝐿 𝑒𝑓𝑓 𝐴𝑤
For Water 𝐴𝑙
𝑉𝑜𝑙 𝑤 2 𝐴𝑤
𝑡𝑤 = = 42 𝑑 𝐿 𝑒𝑓𝑓
𝑄𝑤 𝑄𝑤 𝐴𝑙
Rearranging the equation for to and tw :
𝐴𝑜 𝑡𝑜 𝑄𝑜 𝐴𝑤 𝑡𝑤 𝑄𝑤
42 = 42
𝐴𝑙 𝑑 2 𝐿 𝑒𝑓𝑓
=
(tr)o and (tr)w are in minutes
𝐴𝑜 (𝑡𝑟)𝑜𝑄𝑜 𝐴𝑤
0.7 0.7 (𝑡𝑟 )𝑤𝑄𝑤
= 𝐴𝑙 =
𝐴𝑙 𝑑 2 𝐿 𝑒𝑓𝑓 𝑑 2 𝐿 𝑒𝑓𝑓
Adding the two equations :
𝐴𝑜 + 𝐴 𝑤 (𝑡𝑟)𝑜𝑄𝑜 + (𝑡𝑟)𝑤𝑄𝑤 𝐴𝑜 + 𝐴 𝑤 =𝐴𝑙

0.7
=
𝑑2𝐿𝑒𝑓𝑓 = 1.42 𝑄𝑤 𝑡𝑟 𝑤 + 𝑄𝑜 𝑡 𝑟 𝑜 (3)

(iii) Settling Water Droplets from Oil Phase
 The velocity of water droplets settling through oil can be calculated using Stokes’
law.
 From this velocity and the specified oil phase retention time, the distance that a
water droplet can settle may be determined. This settling distance establishes a
maximum oil pad thickness given by the following formula:
0.00128 𝑡𝑟 𝑜 ∆𝑆𝐺 𝑑𝑚2
ℎ𝑜 = (4)
𝜇𝑜
 This is the maximum thickness the oil pad can be and still allow the water droplets
to settle out in time (tr)o. For dm = 500 microns, the following equation may be
used.
ℎ 320 𝑡𝑟 𝑜 ∆𝑆𝐺 (5)

𝑜 𝑚𝑎𝑥 = 𝜇𝑜
For a given oil retention time (tr)o and a given water retention time (tr)w, the maximum oil pad
thickness constraint establishes a maximum diameter in accordance with the following
procedure:
1. Compute (ho)max. ( 500-micron droplet unless stated otherwise)
2. Calculate the fraction of the vessel cross-sectional area occupied by the water
phase.
(𝑡𝑟)𝑤𝑄𝑤
𝐴𝑤 (6)
𝐴 = 0.5 (𝑡𝑟)𝑜𝑄𝑜 + (𝑡𝑟)𝑤𝑄𝑤
3. From Figure 1, determine the coefficient β
4. Calculate dmax from the following equation

ℎ𝑜 𝑚𝑎𝑥
𝑑𝑚 𝑎 𝑥 = (7)
𝛽
5. Any combination of d and Leff that satisfies all three of Equations 2, 3 and 4 will meet
the necessary criteria.
Figure 1. Coefficient “β” for a cylinder half filled with liquid

Derivation of Equation 6 :
𝑄×𝑡
𝐴=
𝐿 𝑒𝑓𝑓
𝑄 = 6.49 × 10−5𝑄𝑜 𝑄 = 6.49 × 10−5𝑄𝑤
𝑡𝑜 = 60 𝑡𝑟 𝑜 𝑡𝑤 = 60 𝑡𝑟 𝑤
−3
𝑄𝑜 𝑡𝑟 𝑜
𝐴𝑜 = 3.89 × 10 𝑄𝑤 𝑡𝑟 𝑤
𝐴𝑤 = 3.89 × 10−3
𝐿𝑒𝑓𝑓 𝐿𝑒𝑓𝑓
For A vessel ½ full of liquid :

1
( )𝐴 = (𝐴𝑜 + 𝐴𝑤)
2
𝐴 = 2(𝐴𝑜 + 𝐴𝑤)
(𝑡𝑟)𝑤𝑄𝑤
𝐴𝑤 (6)
𝐴 = 0.5 (𝑡𝑟)𝑜𝑄𝑜 + (𝑡𝑟)𝑤𝑄𝑤
(iv) Settling Oil Droplets from Water Phase
 Oil droplets in the water phase rise at a terminal velocity defined by Stokes’ law.
 It is rare that the maximum diameter determined from a 200-micron oil droplet rising
through the water phase is larger than a 500-micron water droplet falling through the
oil phase. Therefore, the maximum diameter determined from a 500-micron water
droplet settling through the oil phase normally governs the vessel design.
 For dm = 200 microns, the following equations may be used:
51.2 𝑡𝑟 𝑤
ℎ𝑤 𝑚𝑎𝑥 = (8)
∆𝑆𝐺 𝜇𝑤
 The maximum diameter can be obtained from the following equation
ℎ𝑤 𝑚𝑎𝑥
𝑑 𝑚𝑎𝑥 = (9)
𝛽
(iv) Seam to Seam Length
 The effective length may be calculated from Equation 3. From this, a vessel seam-to-
seam length may be estimated.
 The seam to seam length of a separator can be calculated using the following
formula (from whichever is larger) :
𝐿𝑠𝑠 = 𝐿 𝑒 𝑓𝑓 + 𝑑 * For gas capacity

12 (10)
 For separators sized on liquid capacity basis, the seam to seam length of a separator
should not exceed the following :
4 * For liquid capacity

𝐿𝑠𝑠 = 3 𝐿𝑒 𝑓𝑓 (11)
(iv) Slenderness Ratio
 For each vessel design, a combination of Leff and d exists that will minimize the cost
of the vessel.
 However, decreasing the diameter increases the fluid velocities and turbulence.
 As a vessel diameter decreases, the likelihood of the gas re-entraining

liquids or destruction of the oil/water interface increases.
 Experience indicates that the ratio of the seam to seam length divided by the outside
diameter should be between 3 and 5.
* Slenderness ratio is the ratio between length and diameter. Its calculated using the formula
: 12Lss/d
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Q&A
Session
Procedure for Sizing a Three Phase Horizontal Separator (Half Full)
1. The first step in sizing a horizontal separator is to establish the design basis. This
includes specifying the maximum and minimum flow rates, operating pressure and
temperature, droplet size to be removed, etc.
2. Select suitable (tr)o and (tr)w
3. Calculate (ho)max. Use a 500-micron droplet if no other information is available. (Equation

4)
4. Calculate Aw/A . (Equation 6)
5. Determine β from curve. (Figure 1)
6. Calculate dmax (Equation 7)
7. Calculate combinations of d, Leff for d less than dmax that satisfy the gas capacity
constraint. Use 100-micron droplet if no other information is available.
(Equation 2)
Procedure for Sizing a Three Phase Horizontal Separator (Half Full)
8. Calculate combinations of d, Leff for d less than dmax that satisfy the oil and water
retention time constraints. (Equation 3)
9. Estimate seam-to-seam length. (Equation 10 or 11)
10. Select a reasonable diameter and length. Slenderness ratios (12Lss/d) on the order of 3
to 5 are common.
11. When making a final selection, it is always more economical to select a standard vessel
size.
Example 1
Qo = 6500 BOPD
Qw = 2500 BWPD
Qg = 5 MMscfd
P = 850 psia
T = 90 oF
Oil = 27 OAPI
SG𝑤 = 1.04
SGg = 0.65
(tr)o = (tr)w = 15 min
µo = 10 cP
µw = 1 cP
µg Droplet removal=100 microns liquid, 500
= 0.013 cP
microns water, 200 microns oil.
CD = 1.194
Z = 0.84
Solution
1) Difference in Specific Gravities :
𝑜 141.5
𝐴𝑃𝐼 = (𝑆𝐺)𝑜− 131.5
(SG)o = 0.876
Given (SG)w = 1.07
Δγ = 1.07-0.876 = 0.194
2) Maximum Oil Pad Thickness (*use 500 micron droplet size if no other information is given)
0.00128 𝑡𝑟 𝑜 ∆𝛾 𝑑𝑚2
(ℎ𝑜 ) 𝑚𝑎𝑥
𝜇𝑜
=
(ℎ𝑜 ) 𝑚𝑎𝑥 = 0.00128 10 0.194 500 2
10
(ℎ𝑜)𝑚𝑎𝑥 = 62.1
3) Calculate Aw/A :
(𝑡𝑟)𝑤 𝑄𝑤
𝐴𝑤
𝐴 = 0.5 (𝑡𝑟)𝑜𝑄𝑜 + (𝑡𝑟)𝑤 𝑄𝑤
(10)(3000)
𝐴𝑤 = 0.1875
𝐴 = 0.5 (10)(5000) + (10)(3000)
4) Determine from Figure 1, read off for Aw/A = 0.1875 to determine β
β =0.257
5) Calculate dmax :
𝑑 𝑚𝑎𝑥 =
𝛽
62.1
𝑑 𝑚𝑎𝑥 = 0.257 = 241.6
6) Calculate combinations of d, Leff for d less than dmax which satisfies the gas capacity
constraint (*use 100 micron droplet size if no other information is provided)
1/2
𝑇𝑍𝑄𝑔 𝜌𝑔 𝐶𝐷
𝑑𝐿𝑒𝑓𝑓 = 420
𝑃 𝜌𝑙 − 𝜌𝑔 𝑑𝑚
1/2
550 0.99 (5) 0.3 2.01
(100) 54.7 − 0.3 100
𝑑𝐿𝑒𝑓𝑓 =120.39
d(in) vs Leff (ft) for Gas Capacity Constraint

d (inches) Leff (ft)
60 2.0
72 1.7
84 1.4
96 1.3
108 1.1
7) Calculate combinations of d, Leff for d less than dmax which satisfies the oil and water
retention time constraints
𝑑2𝐿𝑒𝑓𝑓 = 1.42 𝑄𝑤 𝑡𝑟 𝑤 + 𝑄𝑜 𝑜
𝑡𝑟
𝑑2𝐿𝑒𝑓𝑓 = 1.42 (3000)(10) + (5000)(10)
𝑑2𝐿𝑒𝑓𝑓 = 113600
8) Estimate the seam to seam length

𝑑 4
𝐿𝑠𝑠 = 𝐿 𝑒𝑓𝑓 + * For gas capacity 𝐿𝑠𝑠 = 𝐿 * For liquid capacity
12 3 𝑒𝑓𝑓
9) Select slenderness ratio in the range of 3-5
10)Choose a reasonable size that does not violate gas capacity restraint or oil pad thickness
restraint. Possible choice is 84 in diameter by 25 ft seam-by-seam.
d (in) Leff (ft) (Gas Leff (ft) (Liq Retention Lss(ft) Slenderness
Constraint) Time Constraint) Ratio
60 2.0 31.6 42.1 8.4
72 1.7 21.9 29.2 4.9
84 1.4 16.1 21.5 3.1
96 1.3 12.3 16.4 2.1
108 1.1 9.7 13.0 1.4
Example
Determine the diameter and height of a three phase horizontal separator for the
following operating conditions :
Qo = 6500 BOPD
Qw = 2500 BWPD
Qg = 5 MMscfd
P = 150 psia
T = 90 oF
Oil = 27 OAPI
SG𝑤 = 1.04
SGg = 0.65
(tr)o = (tr)w = 15 min
µo Droplet removal=100 microns liquid, 500
= 10 cP
microns water, 200 microns oil.
µw = 1 cP
µg = 0.013 cP
CD = 2.6506
Z = 0.84
Solution
𝑜 141.5
𝐴𝑃𝐼 = (𝑆𝐺)𝑜− 131.5
(SG)o = 0.8927
Given (SG)w = 1.04
Δγ = 1.07-0.876 = 0.1473
2) Maximum Oil Pad Thickness (*use 500 micron droplet size if no other information is given)
0.00128 𝑡𝑟 𝑜 ∆𝛾 𝑑𝑚2
(ℎ𝑜 ) 𝑚𝑎𝑥
𝜇𝑜
=
(ℎ𝑜 ) 𝑚𝑎𝑥 = 0.00128 15 0.1473 500 2
10
(ℎ𝑜)𝑚𝑎𝑥 = 70.7
3) Calculate Aw/A :
(𝑡𝑟)𝑤 𝑄𝑤
𝐴𝑤
𝐴 = 0.5 (𝑡𝑟)𝑜𝑄𝑜 + (𝑡𝑟)𝑤 𝑄𝑤
(15)(2500)
𝐴𝑤 = 0.1389
𝐴 = 0.5 (15)(6500) + (15)(2500)
4) Determine from Figure 1, read off for Aw/A = 0.1875 to determine β
β =0.305
5) Calculate dmax :
𝑑 𝑚𝑎𝑥 =
𝛽
70.7
𝑑 𝑚𝑎𝑥 = 0.305 = 231.7
6) Calculate combinations of d, Leff for d less than dmax which satisfies the gas capacity
constraint (*use 100 micron droplet size if no other information is provided)
1/2
𝑇𝑍𝑄𝑔 𝜌𝑔 𝐶𝐷
𝑃 𝜌𝑙 − 𝜌𝑔 𝑑𝑚
1/2
550 0.84 (5) 0.5698 2.6506
(150) 55.71 − 0.5698 100
𝑑𝐿𝑒𝑓𝑓 =107.05
d(in) vs Leff (ft) for Gas Capacity Constraint

d (inches) Leff (ft)
60 1.8
72 1.5
84 1.3
96 1.1
108 1.0
7) Calculate combinations of d, Leff for d less than dmax which satisfies the oil and water
retention time constraints
𝑑2𝐿𝑒𝑓𝑓 = 1.42 𝑄𝑤 𝑡𝑟 𝑤 + 𝑄𝑜 𝑜
𝑡𝑟
𝑑2𝐿𝑒𝑓𝑓 = 1.42 (2500)(15) + (6500)(15)
𝑑2𝐿𝑒𝑓𝑓 = 191700
8) Estimate the seam to seam length

𝑑 4
𝐿𝑠𝑠 = 𝐿 𝑒𝑓𝑓 + * For gas capacity 𝐿𝑠𝑠 = 𝐿 * For liquid capacity
12 3 𝑒𝑓𝑓
9) Select slenderness ratio in the range of 3-5
10)Choose a reasonable size that does not violate gas capacity restraint or oil pad thickness
restraint. Possible choice is 96in diameter by 28 ft seam-by-seam.
d (in) Leff (ft) (Gas Leff (ft) (Liq Retention Lss(ft) Slenderness
Constraint) Time Constraint) Ratio
60 1.8 53.3 71.0 14.2
72 1.5 37.0 49.3 8.2
84 1.3 27.2 36.2 5.2
96 1.1 20.8 27.7 3.5
108 1.0 16.4 21.9 2.4
Vertical Three-Phase Separator
 Flow enters the vessel through the side as in the
horizontal separator.
 The liquid flows downward through a downcomer and

a flow spreader that is located at the oil–water
interface.
 The downcommer is required to ensure that the oil

skimming process is not affected.
 The chimney serves as a pressure equalizing

equipment between the lower section and the gas
section.
 The spreader outlet is located below the oil water

Figure 5. Schematic of a vertical interface. (water washing of the incoming fluids)
three-phase separator with interface
level controller .  Oil rises to the oil pad and the water droplets
entrapped in the oil settle down and flow,
countercurrent to the rising oil phase.
Vertical Three-Phase Separator
 Similarly water flows downwards and water droplets
trapped in water phase tend to rise countercurrent to
the water flow
 The oil flows over a weir into an oil chamber and out
of the separator through the oil outlet valve.
 A level controller controls the oil level in the

chamber
and operates the oil outlet valve.
 An interface controller that operates the water outlet

valve controls the water level.
Figure 5. Schematic of a vertical

three-phase separator with interface
level controller and oil chamber .
Vertical Three-Phase Separator Sizing
 Sizing of a vertical three-phase separator is done in a similar manner to that used
in sizing vertical two-phase separators.
 As with vertical two-phase separators, a minimum diameter must be maintained to

allow liquid droplets to separate from the vertically moving gas.
 The vessel must have a large enough diameter to allow water droplets to settle in
the upward-flowing oil phase and to allow oil droplets to rise in the downward-
moving water phase.
 The liquid retention time requirement specifies a combination of diameter and

liquid volume height.
 Any diameter greater than the minimum required for gas capacity and for
liquid
separation can be chosen..
(i) Gas Capacity Constraint
 The principles of liquid droplets settling through a gas, which were derived in the two phase
separator sizing section can be used to develop an equation to size a separator for a gas
flow rate.
 By setting the gas retention time equal to the time required for a drop to settle to the liquid
interface, the following equation can be derived :
1/2
𝑇𝑍𝑄𝗀 𝜌𝗀 𝐶𝐷
d2 = 5040 (12)
𝑃 𝜌𝑜 − 𝜌𝗀 𝑚
𝑑
For 100-micron droplet removal,
1/2
𝑇𝑍𝑄𝗀 𝜌𝗀 𝐶𝐷
d2 = 504 (13)
𝑃 𝜌𝑜 − 𝜌𝗀 𝑚
𝑑
(ii) Settling Water Droplets from Oil Phase
 The requirements for settling water droplets from the oil requires that the following equation
is satisfied
Qo μ𝑜
d = 6690
2
(∆SG)dm
2
(14)
 For 500 micron droplets,
Qo μ𝑜
d = 0.0267
2
(∆SG) (15)
Derivation of Equation 14 :
Vt = Vo
𝑄 𝜋𝐷2 𝜋𝑑2
𝑄 = 𝑄 𝑜 × 5.61𝑓𝑡 × 𝑑𝑎𝑦 × 1 ℎ𝑟
3
𝑉𝑜 = 𝐴=
𝐴 =
𝑏𝑎𝑟𝑟𝑒𝑙 24 ℎ𝑟 4 (4)
𝑄 = 6.49 ×3600
10−5𝑠𝑄𝑜 (144)
𝑄𝑜
𝑉𝑜 = 0.0019
𝑑2
1.78 × 10−6 𝑆𝐺 𝑑2𝑚 𝑄

=
𝜇𝑜 𝑑2
0.0019 𝑜
𝑄𝑜 𝜇𝑜
𝑑2 = 6690 (14)
𝑆𝐺 𝑑2𝑚
(iii) Settling Oil Droplets from Water Phase
 The requirements for settling oil droplets from the water requires that the following equation
is satisfied.
Qw μ𝑤
d2 = 6690
(∆SG)d2m (16)
 For 200 microns droplets, Equation 16 become :
Q𝑤μ𝑤 (17)
d2 = 0.167
(∆SG)
(iv) Retention Time Constraint
 The requirements for settling oil droplets from the water requires that the following equation
is satisfied.
ℎ𝑜 + ℎ𝑤 = (𝑡𝑟)𝑜𝑄𝑜 + (𝑡𝑟) 𝑤 𝑄𝑤 (18)

0.12𝑑2
Where
ho = height of oil pad (inches)

hw = height of water outlet to interface (inches)
Derivation of Equation 18
From two phase separator design :
𝑡 𝑄
𝑟 𝑙
𝑑 2 ℎ = 0.12
𝑡𝑟 𝑄 𝑡𝑟 𝑄
𝑑2 ℎ 𝑜 = 𝑜 𝑜 𝑑2 ℎ 𝑤 = 𝑤 𝑤
0.12 0.12
𝑡 𝑟 𝑜 𝑄𝑜 + 𝑡 𝑟 𝑄
ℎ𝑜 + ℎ𝑤 = 𝑤 𝑤
0.12𝑑 2 (18)
(v) Seam to Seam Length
 The seam-to-seam length (Lss) of vertical vessels may be estimated based on the diameter
and liquid height.
 Allowance must be made for the gravity settling (gas separation) section, inlet diverter, mist
extractor, and any space below the water outlet.
 Use the larger of the Lss values calculated.
𝐿𝑠𝑠 = ℎ𝑜 + ℎ𝑤 + 76 (for diameters ≤ 36 inches) (19)

12
𝐿𝑠𝑠 = ℎ𝑜 + ℎ𝑤 + 𝑑 + 40 (for diameters > 36 inches) (20)

12
Where
ho = height of oil pad (inches)

hw = height of water outlet to interface (inches)
d = vessel’s internal diameter (inches)
(vi) Slenderness Ratio
 As with horizontal three-phase separators, the larger the slenderness ratio, the less
expensive the vessel.
 In vertical separators whose sizing is liquid dominated, it is common to choose slenderness

ratios no greater than 4 to keep the height of the liquid collection section to a reasonable
level.
 Choices between 1.5 to 3 are common, although height restrictions may force the
choice of a lower slenderness ratio.
* Slenderness ratio is the ratio between length and diameter. Its calculated using the
formula
: 12Lss/d
Procedure for Sizing a Three Phase Vertical Separator
1. The first step in sizing a vertical separator is to establish the design basis. This includes
specifying the maximum and minimum flow rates, operating pressure and temperature,
droplet size to be removed, etc.
2. Equation 12 is used to calculate the minimum diameter for a liquid droplet to fall through
the gas phased.
3. Equation 13 is used for 100-micron droplets if no other information is provided.
4. Equation 14 is used to calculate the minimum diameter for water droplets to fall
throughout the oil phase.
5. Equation 15 is used for 500-micron droplet if no other information is available.
6. Equation 16 is used to calculate the minimum diameter for oil droplets to rise through
water phase.
7. Equation 17 is used for 200-micron droplets if no other information is available.

Procedure for Sizing a Three Phase Vertical Separator
8. The largest of the three diameters calculated from step 2-7 is selected as the minimum
diameter. (any value larger than the minimum diameter may be used for the vessel
diameter)
9. For the selected diameter, assume the values for (tr)o and (tr)w to be used to determine
ho+hw from Equation 18.
10. After calculating d and ho+hw the seam to seam length may be estimated using Equation
19 and 20 depending on the diameter. The larger value of the Lss is to be used.
11. The slenderness ration is calculated. Slenderness ratio between 1.5 to 3 is common to
be selected.
12. A standard-sized diameter and seam to seam length has to be chosen.

Example 2
Given
Qo = 5000 BOPD (tr)o = (tr)w = 10 min

Qw = 3000 BWPD µo = 10 cp
Qg = 5 MMscfd, µw = 1 cp
P = 100 psia µg = 0.013
T = 90 F cp
Oil = 30 API CD = 2.01
(SG)w = Z = 0.99
1.07
Sg = 0.6
(for d of 84”90”,96” and102” )

Droplet removal = 100 microns liquids, 500 microns water, 200 microns oil
Solution
𝑜 141.5
𝐴𝑃𝐼 = (𝑆𝐺)𝑜− 131.5
(SG)o = 0.876
Given (SG)w = 1.07
Δγ = 1.07-0.876 = 0.194
2) Calculate the minimum diameter required to settle a liquid droplet through the gas phase :
1/2
𝑇𝑍𝑄𝗀 𝜌𝗀
𝑑 2 = 5040
𝐶𝐷𝑃 𝜌 𝑜 − 𝜌𝗀 𝑑𝑚
1/2
(550)(0.99)(5) 0.3 2.01
𝑑 2 = 5040 100 54.7 − 0.3 100
𝑑 = 38 𝑖𝑛𝑐ℎ𝑒𝑠
3) Calculate the minimum diameter required for water droplets to settle through the
oil phase: (*use 500 micron droplet size if no other information is given)
Qo μ𝑜
d2 = 6690
(∆SG)𝑑𝑚2
(5000)(10)
d2 = 6690
(0.194) 500 2
d = 83.1 𝑖𝑛𝑐ℎ𝑒𝑠
4) Calculate the minimum diameter required for water droplets to settle through the oil phase:
(*use 200 micron droplet size if no other information is given)
Q 𝑤 μ𝑤
d2 = 6690
(∆SG)𝑑𝑚2
(3000)(1)
d2 = 6690
(0.194) 200 2
5) Select the largest diameter from steps 2-4
dmin =83.1 inches
6) Compute ho + hw :
0.12𝑑 2
(10)(5000) + (10)(3000)
ℎ 𝑜 + ℎ𝑤 = 0.12𝑑2
666667
ℎ 𝑜 + ℎ𝑤 =
𝑑2
7) Compute seam to seam length (Lss)
𝐿𝑠𝑠 = ℎ𝑜 + ℎ𝑤 + 76 𝐿𝑠𝑠 = ℎ𝑜 + ℎ𝑤 + 𝑑 + 40
12 12
(for diameters ≤ 36 inches) (for diameters > 36 inches)
8) Compute the slenderness ration. Choose ration between 1.5-3.
9) Make final selection: compute combinations of d and ho + hw for diameters greater than
the minimum diameter.
All combinations of diameter and seam-to-seam length in the table below are acceptable
because the slenderness ratio falls between 1.5 and 3 for all of them.
The final selection would, therefore, depend on cost and availability.
do (in) ho+hw (in) Lss (ft) Slenderness Ratio

84 94.5 18.2 2.6
90 82.3 17.7 2.4
96 72.3 17.4 2.2
102 64.1 17.2 2.0
Example
Determine the diameter and height of a three phase horizontal separator for the
following operating conditions (for d of 90”,96”,102” and 108”):
Given
Qo = 6000 BOPD (tr)o = (tr)w = 10 min
Qw = 3000 BWPD µo = 10 cp
Qg = 8 MMscfd, µw = 1 cp
Po = 485psia µg = 0.013
To = 90 F cp
Oil = 30 API CD =
(SG)w = 1.605
1.07 z = 0.88
Sg = 0.6
Droplet removal = 100 microns liquids, 500 microns water, 200 microns oil
Solution
𝑜 141.5
𝐴𝑃𝐼 = (𝑆𝐺)𝑜− 131.5
(SG)o = 0.8499
Given (SG)w = 1.07
Δγ = 1.07-0.8499 = 0.22
2) Calculate the minimum diameter required to settle a liquid droplet through the gas phase :
1/2
𝑇𝑍𝑄𝗀 𝜌𝗀
𝑑 2 = 5040
𝐶𝐷𝑃 𝜌 𝑜 − 𝜌𝗀 𝑑𝑚
1/2
(550)(0.88)(8) 1.623 1.605
𝑑 2 = 5040 485 53.03 − 1.623 100
𝑑 = 30 𝑖𝑛𝑐ℎ𝑒𝑠
3) Calculate the minimum diameter required for water droplets to settle through the
oil phase: (*use 500 micron droplet size if no other information is given)
Qo μ𝑜
d2 = 6690
(∆SG)𝑑𝑚2
(6000)(10)
d2 = 6690
(0.22) 500 2
4) Calculate the minimum diameter required for water droplets to settle through the oil phase:
(*use 200 micron droplet size if no other information is given)
Q 𝑤 μ𝑤
d2 = 6690
(∆SG)𝑑𝑚2
(3000)(1)
d2 = 6690
(0.22) 200 2
5) Select the largest diameter from steps 2-4
dmin =85.4 inches
6) Compute ho + hw :
0.12𝑑 2
(10)(6000) + (10)(3000)
ℎ 𝑜 + ℎ𝑤 = 0.12𝑑2
750000
ℎ 𝑜 + ℎ𝑤 =
𝑑2
7) Compute seam to seam length (Lss)
𝐿𝑠𝑠 = ℎ𝑜 + ℎ𝑤 + 76 𝐿𝑠𝑠 = ℎ𝑜 + ℎ𝑤 + 𝑑 + 40
12 12
(for diameters ≤ 36 inches) (for diameters > 36 inches)
8) Compute the slenderness ration. Choose ration between 1.5-3.
9) Make final selection: compute combinations of d and ho + hw for diameters greater than
the minimum diameter.
All combinations of diameter and seam-to-seam length in the table below are acceptable
because the slenderness ratio falls between 1.5 and 3 for all of them.
The final selection would, therefore, depend on cost and availability.
do (in) ho+hw (in) Lss (ft) Slenderness Ratio

90 106.3 19.2 2.7
96 92.6 18.5 2.5
102 81.4 18.1 2.3
108 72.1 17.8 2.1
THANK YOU
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Three Phase Separator

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Production Engineering II

Three Phase Separation Process

2. Analyze the HSE requirement for oil and gas

3. Propose suitable processes and treatment

4. Perform standard engineering calculations for

 Two Phase Separation Theory

 Horizontal / Vertical Separator Sizing Design

 Understand the three phase separation theory.

 Identify and understand the constraints involved in sizing the

 Perform separator design calculation for horizontal three phase

 Figure 1 illustrates the growth of water layer with time.

 After a period of time (30 seconds to 3 minutes) , the change in water

Figure 1. Growth of water layer with

 However, three phase separators have additional control devices and

 The fluid enters the separator and hits an inlet diverter.

 This step promotes coalescence of

 Level controller maintains the

 Level of the oil downstream of the

 The interface controller senses

level interface controller.

 Oil and water flow over respective

 Level control is achieved by a

 Oil overflows into the oil bucket

Figure 6. Schematic of a horizontal 3P separator with coalescing plates

 Addition of chemicals and/or heat often minimizes this difficulty.

(i) Application of heat in the liquid section of the separator

 In the oil field :

Immiscible Fluid : Water and Oil (form water in oil emulsion)

 However, the treatment of the liquid phase for three-phase separators is

(ii) Oil Water Settling

1.78 × 10−6 ∆𝑆𝐺 𝑑2 Where,

(iv) Oil Droplet Size in Water

 It is common to use retention times ranging from 3 minutes to 30 minutes depending

(tr)o and (tr)w are in minutes

Adding the two equations :

𝐴𝑜 + 𝐴 𝑤 (𝑡𝑟)𝑜𝑄𝑜 + (𝑡𝑟)𝑤𝑄𝑤 𝐴𝑜 + 𝐴 𝑤 =𝐴𝑙

𝑑2𝐿𝑒𝑓𝑓 = 1.42 𝑄𝑤 𝑡𝑟 𝑤 + 𝑄𝑜 𝑡 𝑟 𝑜 (3)

ℎ 320 𝑡𝑟 𝑜 ∆𝑆𝐺 (5)

1. Compute (ho)max. ( 500-micron droplet unless stated otherwise)

3. From Figure 1, determine the coefficient β

4. Calculate dmax from the following equation

Figure 1. Coefficient “β” for a cylinder half filled with liquid

For A vessel ½ full of liquid :

 For dm = 200 microns, the following equations may be used:

𝐿𝑠𝑠 = 𝐿 𝑒 𝑓𝑓 + 𝑑 * For gas capacity

4 * For liquid capacity

 As a vessel diameter decreases, the likelihood of the gas re-entraining

2. Select suitable (tr)o and (tr)w

3. Calculate (ho)max. Use a 500-micron droplet if no other information is available. (Equation

4. Calculate Aw/A . (Equation 6)

5. Determine β from curve. (Figure 1)

6. Calculate dmax (Equation 7)

9. Estimate seam-to-seam length. (Equation 10 or 11)

Given (SG)w = 1.07

(ℎ𝑜 ) 𝑚𝑎𝑥 = 0.00128 10 0.194 500 2

4) Determine from Figure 1, read off for Aw/A = 0.1875 to determine β

d(in) vs Leff (ft) for Gas Capacity Constraint

8) Estimate the seam to seam length

9) Select slenderness ratio in the range of 3-5

Given (SG)w = 1.04

(ℎ𝑜 ) 𝑚𝑎𝑥 = 0.00128 15 0.1473 500 2

4) Determine from Figure 1, read off for Aw/A = 0.1875 to determine β

d(in) vs Leff (ft) for Gas Capacity Constraint

8) Estimate the seam to seam length