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Raising a new Generation of Leaders

Unit Operations in Natural Gas

Engineering
PET 417

Dr. G. A. Adeyemi
 LEARNING OBJECTIVES
Having worked through this topic students will:
• the student with the phenomenon of heat transfer in fluids and to
understand the medium used to achieve cooling and heating (Heat
Engines).
• In addition, the student would be made to understand the principles and
dynamics of separation processes and the design of oil and gas
separators.
• At the end, the student will understand the various technicalities that
have to do with the design, transfer of heat and separation of petroleum
fluids.
2
 Course Content or Outline
• Heat transfer Theory and Energy Equations.
- Heat Transfer Mechanisms
- Fluid flow continuity Equations
- Energy equations for steady state laminar flow in
cylindrical conducts
• Heat Transfer to and from fluids without a phase
CHANGE
3
 Course Content or Outline (Contd)
• Heat Exchangers
- Introduction
- Overall Heat Transfer coefficient.
- Fouling Factors Types of Exchangers
- Exchanger analysis
- Coolers.
• Separation Process (6th – 9th week)
- Introduction
- Principles and Dynamics
- Multi component Separation
- Dehydration

4
 Course Content or Outline (Contd)
• Gas sweetening
- Principles
- Dynamics
- Equipment
.

5
 Method of Grading Continuous Assessment
• Continuous Assessment Test 1 - 15%
• Continuous Assessment Test 2 (Mid-Semester
Examination) - 15%
• End of Semester Examination - 70%
.

6
 Recommended Reading/Text
• McCabe, W.L; Smith, J.C. & Harriott, P. (2005). Unit operations of
chemical engineering (7th Ed.). McGraw-Hill. ISBN: 0-07124-710-8.
• Stewart, M., Arnold, K. (2007) Surface production operations. Vol. 1,
3rd Ed, Gulf Pub. Co.
• Dr. Boyun Guo & Dr. Ali Ghalambor. Natural Gas Engineering
Handbook
• Lake, L. (2006) Facilities and construction engineering. Petroleum
engineering handbook. Vol. 3. Society of Petroleum Engineers,
[Link]: 1-55563-116-1.
7
 Reservoir Fluid
Complex, High temperature, High Pressure, High Velocity, Quite
Turbulent, and Constantly Expanding Mixture of
 Hydrocarbon Liquid

 Water Vapour

 Free Water

 Solids

 Other Undesirable Compounds Considered Contaminants.

9
Reservoir Fluid
 During Flowing Process

It Undergoes Continuous Temperature and Pressure Reduction

Gases Evolve

Water Vapour Condenses

Some Hydrocarbon Change their Characteristics Resulting in

Foaming

Bubbles

Mist

Hydrates

Free Gas

10
 Reservoir Fluid
Reservoir Fluid Processing
Processing of Separated Products to Sellable, Reusable or Disposable Quality

Gas Processing
 Removal of Contaminants
 Removal of Water Vapour
 Removal of Condensate and Hydrocarbon Vapour

Crude Oil Processing

 Removal of Water
 Removal of Contaminants

Water Treatment
 Removal of Hydrocarbons
 Removal of Contaminants

Sediments (Solids) Treatment

 Removal of Hydrocarbons
 SEPARATORS
 Pressure Vessels or Equipment Used to Separate Reservoir Fluids
Into Gas, Liquid and Sediments.
 Components of Separator

.....................
 Separator Sections/Components/Functions

 Primary Separation Section

 Removes Bulk of Liquid Slugs and Particles

 Removal Achieved Through Momentum Reduction

 Reduction Achieved by Stream Inlet Baffling(Regulating) or/and Inlet Diverter Devices

Inlet Diverter Devices

Cause Rapid Change in Inlet Stream Velocity

Results in Liquid and Gas Disengagement.

 Separator Sections/Components/Functions

 Types of Inlet Diverter Devices

 Mechanical Agitation Inlet Devices
 Mechanism
 Well Stream Strikes Device

 Reduction in Velocity

 Change in Direction of Flow.

 Types of Mechanical Agitation Inlet Devices

 Deflector Baffles
 Hemispherical Disc

 Flat Plate

 Piece of Angle Iron

 Metal Cone.

Inlet Diverters
Flow Through Baffle
.
Flow Against Plate

Gas Entry With Deflector Inlet Diffuser

Cyclone Inlet Diverter

 Separator Sections/Components/Functions

 Cyclone Inlet.
 Mechanism
Creates a High Fluid Velocity

Fluid Get Spun Around the Wall on Entry

Spinning Subjects Fluid to High Centrifugal Forces up to 500

Times the Force of Gravity

Forward Motion of Heavy Liquid is Stopped and It Falls to

Flow Along That Wall to Bottom.
 Separator Sections/Components/Functions
 Secondary Separation Section .
Reduces Fluid Velocity From the Primary Section.

Minimises the Turbulence.

Creates Room for Gravity Settling.

Thus Removes Gas Vapour From Oil.

It Removes Water (in the 3– Phase Separator).

Should Be Large and of Sufficient Height or Length.

There Should Be Proper Positioning of Straightening Vanes for Uniform Flow.

Orienting Plates/baffles
 Reduces Turbulence
 Separator Sections/Components/Functions

 Liquid Accumulation Section

 Recovery and Disposal of Collected Liquid (s)

 Should Have Sufficient Volume to Handle Surges and Prevent Liquid Carry Over to Gas Outlet.

 Arrangement Should Prevent Gas Flow From Disturbing Liquid.

 Should Have Level Controller /Dump Valve.

 Meters Oil & Water in Metering Separators.

 Provides Necessary Retention Time For Gas Breaking Out of Oil and Water Settling Out Of Oil

 Vortex Breakers at Liquid Outlet to Prevent Gas Re-entry

Separator Sections
 Vertical Separator Accumulation Section
i
 .
 Horizontal Separator Accumulation Section
 .
 Spherical Separator Accumulation Section

 .
 Accumulation Section Accessories.

 Wave Breakers(Arresters).
 Perpendicular Vertical Baffles in the
Gas-liquid Interface Which Prevents
Waves Caused by Liquid Surge.

 Defoaming Plates
 Inclined Parallel Plates or Tubes in the
Gas-Liquid Interface Which Break
Foams.

 Foam is Forced Through Them and Gets

Coalesced to Form Liquid.

 Degassing Elements
 Specially designed Devices Meant to
Remove Gas from Crude thereby
Preventing or Breaking Foam
 Accumulation Section Accessories.
 Vortex Breakers.
Metal Plate Devices
Which Prevent Vortex
Formation When Control
Valve is Open.


Vortices Develop When

the Control Valve is Open
Resulting in Gas Being
Sucked Out of the Vapour
Space and Getting Re-
entrained Into Liquid
 Separator Mist Extractors/Eliminators

 Mist Extractor /Eliminator.

 Eliminates Entrained Liquid Droplets From
Gas Stream.

 Droplets Density is Quite Close to That of

Gas.

 Droplets Hit Impingement Surface,

Coalesce and Collect to Form Larger
Droplets.

 Eliminates Droplets of size equal to or

greater than 100 microns but less than 200
microns
 Types of Mist Extractors/Eliminators

 Vane – Type Mist Extractor.

 Consisting of Labyrinth of Metal Plates Laid Parallel With Liquid Collection Pockets
Leading to Drain Pipe

 Mechanism of Separation
Impingement With High Centrifugal Force.

Obstruction to Entrained Liquid Particles.

Change in Direction of Flow.

Gas Stream Veers Around Obstruction While Liquid Drops.

Droplets Collide With the Walls and Get Separated From the
Gas.
 Types of Mist Extractors/Eliminators
 Wire-Mesh Mist Extractor
 Employs Impingement Mechanism Primarily to Remove Liquid Droplets.

 Entrained Liquid Particles Strike the Metal Surface Then Flow Down the
Capillary Space Provided by Wires.

 Surfaces Tension Holds the Liquid at the Lower Face of the Pad Until Such a
Time That the Droplets Weight Let Go Under Gravity.

 Liquid Collects in the Spaces and Continue Downward.

 Stainless Steel Woven-wire Mesh Has Highest Gas and Liquid Separation
Capacity.

 Liquid Carry-over  0.1 gal/mscf

 Efficiency  90%.
 Types of Mist Extractors/Eliminators
 Chevron Vane Mist Extractor
 Demister Wire-Mesh Mist Extractor

 Serpentine Vane Mist Extractor

………………………………….
 Separator External Components
 Control Devices
 Level Control.
 Done by Level Controller in Either the Gas/oil or
Oil /Water Interface.

 Generally Float-operated Pilots

 Prevents Damages Caused by Separator Low or

High Level

 Normally Activates
 Dump Valve on Sensing High
Liquid Level.

 Block Valve on Inlet

 Bypass Valve

 An Alarm
 Separator External Components

 Pressure Control
 Done in the Vapour Space With a Pressure Controller and Back Pressure Control Valve.

 Control Valve is Located on Gas Exit Line.

 Controller Senses Abnormality and Regulates the Control Valve to Release Gas.

 Controls Can be Mechanical, Pneumatic or Electric

 Normally Activates
A Shut-in Valve
A Bypass Valve
An Alarm
 Separator External Components

 Temperature Controls
 Mostly on Special cases Separators

 Functions to
Shut-in the Separator

Open or Close a Bypass to Heater

Activates an Alarm
 Separator Operating Pressures

Maximum Allowable Working Pressure (MAWP)

Maximum Pressure on Top of the Separator at Its Normal
Operating Condition for That Designated Temperature.

Pressure Beyond Which Vessel or Pipe Should NOT be Operated

It Is Normally Stipulated by the ASME.

Determined by Vessel Material, Thickness and Temperature

 Separator Operating Pressures

 Set Pressure
 Pressure at Which Safety Device Gets Activated

 Normally Equals or Greater than MAWP

 Operating Pressure (OP)

 Pressure in the Vessel During Normal Operation

 OP  90% MAWP
  Pressure Relief
 Device Pressure.
 Separator External Components
 Safety Devices
 Prevent Accidents and Damage such as Vessel Rupture

 Generally Prevent
Over- or Under-pressure

Low or High Liquid Levels

Low or High Temperature

 Relief Valve
Spring-Loaded Valve that Raises Slowly with Pressure Increase

Used Mainly for Liquid Pressure Control

 Separator External Components
 Safety Valve
 Spring-Loaded Valve that Pops Open with Pressure Increase.

 Mostly Applicable with Gas or Vapour Pressure Controls.

 Safety Relief Valve.

 Spring-Loaded Valve Designed to Work as Both Safety and Relief
Valves.

 Sized and Designed to Open Before or at MAWP

 Pressure > Separator Maximum Operating Pressure.

 Separator External Components

 Ruptures Disc or Safety Head.

Bursts a Rupture Disc Designed for Specific Pressure Rating.

Works in Conjunction With Safety Relief Valve or Independently.

Burst Pressure > Relief Valve Pressure

Burst Pressure < 1 ½ Separator Working Pressure

 Separator External Components
 Other External Components
 Valves
 Oil discharge Control Valves
 Water-discharge Control Valve
 Drain Valves
 Block Valves
 Sight Glasses Valves

 Accessories
 Pressure Gauges
 Thermometers
 Pressure-Reducing Regulators
 Level Sight Glasses
 Piping and Tubing
 Types of Separators
 Types of Separators
Free-Liquid Removing Vessel
Removes Free-Water From Well Fluids

Removes Free-Liquid From Gas Stream

Removal is Preferably Before Pressure Reduction

Removal Reduces Process Load

Removal Prevents:
 Corrosion
 Types of Separators
 Types of Free-Liquid Knock-out
 Trap
 Knock-out Trap
 Knock-out Vessel
 Knock-out Drum
 Free-Water Knock-out
 Liquid Knock-out

 Producing Field Vessels

 Used in Processing Lease or Platform Reservoir Fluids

 Types Include
 Oil & Gas Separators
 Stage Separators
 Types of Separators
 Separators by Configuration Vertical Separator
 Vertical Separator
 Horizontal Separator
 Spherical Separator

Horizontal Separator
Spherical Separator

.....................
 Types of Separators
 Regular Separating Vessels
Operates at Low Temperature and Pressure

Feed Fluid Normally Flashed Into Vessel From High Pressure Separator

Always Last on Stage Separation From Which Liquid Goes Into Storage

Types Include:
Flash Chamber

Flash Vessel

Flash Trap
 Types of Separators
 First Stage Separation Vessels
Expansion Separator

Expansion Vessel

 Liquid Removing Vessel(from Gas)

Removes Water(Liquid) From Gas OR Filter the Gas Before
Other Main Stream Equipment

Types Include:
 Scrubber or Gas Scrubber

 Dry-Scrubber

 Wet-Scrubber (Remove Low Level Liquid)

 Types of Separators
 Dust and Dirt Removing Vessels
Removal Generally From Gas Stream

Types Include:
Filter(Dry or Wet)

Gas Filter

Filter-Separator
 Vertical Separators
 Major Internal Features.  The Vertical Separator

Tangential Inlet Device or
Deflector.

Conical Baffle Separating

Liquid Accumulation
Section From the Primary
Section.

Quieting Baffle
 Vertical Separators
 Operating Mechanism
Gas Got Separated From the Fluid at Primary Section With Primary Separation Devices.

Liquid Falls to Liquid Accumulated Section.

Sediments Accumulate at the Bottom and Gets Flushed Out.

Liberated Gas Moves Upwards Through Secondary Section Where Heavy Entrained Liquid
Droplets Get Removed by Gravity Settling Due to Reduction in Gas Velocity and Turbulence.

The Mist Extractor Removes the Rest Liquid Droplets up to100 microns (1 micron =
0.001mm or 1/25,400 in) and Above in Diameter.

Efficiency of Vertical Separator Secondary Section is Quite Reduced Because it is

Transversed by the Rising Gas.
 Vertical Separators
 Characteristics of the Vertical Separator.
The Depth of Liquid is Low from Primary Section and
Distance Travelled by Mist is Great, Thus Providing a LONG
Retention Time.

Liberation of Gas is Small Due to Small Primary and

Almost Non-existent Secondary Sections

Gas Oil Ratio is Between Low to Intermediate  Large

Slugs of Liquid are Generally Expected.
 Vertical Separators
 Advantages
Less Tendency for Liquid to Re-vaporize into Gas Phase Due to Long
Distance Between Gas Out-let and Liquid Level

 It is Generally Good for Large Liquid Slugs Without Carry-over to

Gas Outlet.

Liquid Level Controls are Not Critical Due to Above.

It Occupies Less Floor Space.

It is Easy to Clean.

It is Highly Recommended for Fluid With Sediments and High Liquid
Loading.
 Vertical Separators
 Disadvantages
It is More Expensive to Construct than Other Types of
Separators.

It is also More Expensive to Ship in Skid-mounted

Assemblies.

Gas Separation Efficiency Is Low Because of Falling

Droplets Motion Opposing Natural Upward Gas Flow.

Larger Diameter Vertical Separators are Therefore

Desired for the Same Capacity Compared to Horizontal
Separator.
 Applications of Vertical Separators
 Well Fluids Containing Appreciable Quantity of Sand, Mud, and Similar
Finely Divided Solids.

 Well Where Liquid Volumes are great and May Vary Widely and
Instantaneously, Such As Slugging Wells and/or Intermittent Gas Lift Wells.

 Well Fluids Having a Low Gas/oil Ratio.

 Facilities With Limited Horizontal Space but No Vertical Height Limitation,

Such As Crowded Tank Batteries And/or Offshore Platforms.

 Downstream of Other Production Equipment that Allows or Causes Liquid

Condensation or Coalescence, Due to Poor Gas Separation Efficiency.

 Upstream of Other Production Equipment that Will Not Perform Properly

With Entrained Liquid in Gas.

 Other Situations Where Economics Favour the Vertical Separator

 Horizontal Separators
 Major Internal Features
 Primary Section Consists of Inlet Diverter, a Baffle, Dished Deflector or Diffuser.

 Perforated Partition Platform (Separation Partition)

 Secondary Section Consists of

Tranquillising Section With Straightening Vanes.
Large Long Baffle or Divider Plates Gas-separation Section.

 Mist Extractor.

 Liquid Accumulation Section Consisting of Wave Breakers.

Single-Tube
Horizontal Separator
 Horizontal Separators
 Characteristics of Single-tube Horizontal Separator.
There is No Centrifugal Separation and Tangential or Swirling Liquid
Entry.

There is a Tranquillising Section Which is Absent in the Vertical

Section.

Has Small Retention Time Because of Small Liquid Depth and Small
Distance Travelled by Mist Before Mist Extractor.
 Horizontal Separators
 Advantages
 It is More Efficient than Vertical Separator and Can Handle Greater Volume of Gas-liquid
Separation Because of Large Gas-liquid Interface.(ie Higher GOR)
 It Permits Enough Time for the Liquid Droplets to Separate From Gas.
 It is Less expensive and Easy to Transport.
 It is Easy to Skid-mount and Service.

 It Requires Smaller Diameter for Given Gas Capacity and Less Piping for Field Connections.

 Several Horizontal Separators Can Be Stocked Into Stage-separation Assemblies to Minimise

Space.

 It is Also Easier to Insulate in Cold Region Ensuring Liquid to Remain Warmer Thus Preventing
Freezing and Paraffin Deposit.

 In High Pressure Gas-distillate Wells With High GOR, It Gives Most Efficient Operation.

 It is Used for Foaming Fluids

 Disadvantages
It Cannot Handle Fluid With Sediments.

It is Difficult to Clean.

Liquid Level Control is Very Critical.

It Occupies More Floor Space than Vertical Separators.

 Horizontal Separators
 Applications of Horizontal Separators.
Installation Where There is Vertical Height Limitation.

Well Fluids With High GOR.

Wells With Relatively Constant Flow Rate and With Little or No Liquid
Heading or Surging.

Separating Foaming Crude Oil Where the Larger Liquid/Gas Contact

Area Allows or Cause Faster Foam Breakdown and More Efficient
Gas/Liquid Separation.

Liquid/Liquid Separation in Three-phase Separator Installation to

Obtain More Efficient Oil/water Separation.
 Horizontal Separators
 Applications of Horizontal Separators.
 Where Multiple Units Can Be Stacked to Conserve Floor Space.

 Installations Where the Operator and/or Conditions Require(s) or Indicate Internal Water-weir
and Oil-bucket Construction to Eliminate the Use of Oil/water Interface Liquid Level Controller.

 Where Portable Units (Either Skid or Trailer Mounted) are Required for Either Test or
Production Use
 Horizontal Separators
 Double-Barrel Horizontal
 Major Features.
Top cylinder does all the separation.
Bottom cylinder accumulates all liquid.

Down corners collect the liquid from the top to the bottom cylinder.

 Advantages
Better separation of solution gas in the quiescent lower chamber

Better separation of gases and liquid of similar densities.

More stable liquid-level control.

Handle greater volume of fluid.

• Double-Barrel Horizontal
 Advantages Over Single-Tube
Ease of Insulation in cold weather operations.

Liquid remains warmer, minimizing freezing and paraffin

deposition.

Double-Barrel
 Major Disadvantage Horizontal
More expensive than single-tube  It is rarely used
 Horizontal Separators
 Triple-Barrel 3-Phase Horizontal

Gas

Oil

Water Water
 Spherical Separators
 Major Features.
 Spherical Shape.
 Spherical Separators
 Major Features.
Three Section of Separation are on Top While the
Accumulation Section is at the Bottom.

Dome-shape Deflector That Covers the Mist Extractor.

Movement of Gas is Down Outside the Dome Then up

inside the Dome Through the Mist Extractor and Down
Through the Downcorner.

The Gas Rising Through the Larger Section Before the Mist
Extractor Actually Loses its Entrained Liquid Due to Loss of
 Twister Supersonic Separator

Basic Features
Gas Expansion By Gas Flow Velocity Increase To Supersonic Level

Supersonic gas Velocity Results In Astronomical Pressure Drop

Pressure Drop Attended With Subsequent Temperature Drop

 Liquid Hydrocarbon and Water Condenses out of Gas Stream

 Twister Supersonic Separator
Basic Components
 Multiple Inlet Guide Vanes Generate A High Vorticity, Concentric Swirl of gas

 Laval Nozzle Expands Saturated Feed Gas Thereby Transforming Pressure Drop To Kinetic Energy
(i.e Supersonic Velocity).

 Pressure Drop Results In A Low Temperature.

 Mist of Water and Hydrocarbon Condensation Droplets Form.

 Cyclic Separator High Vorticity Swirl Centrifuges Droplets to Equipment Wall While Gas Travels in
Middle

 Diffuser Slows Down gas Stream Velocity Gaining Back About 70 - 75% Of The Initial Pressure.

 The Liquid Stream Typically Contains Slip-gas, Which Is Degassed at Compact Liquid De-gassing
Vessel and Then Recombined With The Dry Gas Stream.

 Separated Liquids Get Discharged at About 7 0C. At

Twister Supersonic Separator
 Twister Supersonic Separator
Applications:
Condense and separate water and heavy hydrocarbons from natural gas

Water Dewpointing (Dehydration)

Hydrocarbon Dewpointing

Natural Gas Liquids extraction (NGL/LPG)

Heating Value Reduction

Fuel gas treatment

Other New Applications such as;

 Offshore fuel gas treatment for large aero-derivative gas turbines,
 Pre-treatment upstream CO2 membranes and
 Bulk H2S removal upstream sweetening plants .
 Separator Design
 Factors For Consideration.
 Maximum Allowable Working Pressure (MAWP)

 Operating Pressure (OP)

 Reliable Field Data for the Design.

 Always Over Size  Traditional

 Approach.

 Special Internal Devices as Par Separation Problems Envisaged.

 Design to Achieve Optimum Separation of Liquid and Vapour.

 Anticipated Field Conditions.

Ono SLIDE 65

 Separator Design
 Characteristics of the well stream

 Corrosion Considerations.
 Considerations are mainly only for Pressure Parts of the vessel
  Outside Shell.

 Any Stream with Water or any of the underlisted, needs

Corrosion Consideration.
O2

CO2

Ono SLIDE 66
 Guideline for Corrosion Consideration of
Carbon Steel with O2, CO2 and H2S Streams

COMPOUND CONCENTRATION NON REQUIRE QUITE

CORROSIVE CONSIDERATION CORROSIVE
 These Considerations do not apply to Stainless Steel.

O 2 0.005 ppm Ye s _ _

0.005 - 0.025 ppm _ Yes _

> 0.025 ppm _ _ Yes

CO 2 < 600 ppm Yes _ _

600 - 1200 ppm _ Yes _

> 1200 ppm _ _ Yes

H 2S No Lower Limit Has _ _ Yes

Been Determined, but
Generally Quite Corrosive
Ono SLIDE 67
 Separator Design
 Gas Capacity.  Gas flow rate

 Gas Capacity Equation Considerations:

 Liquid Particle Falling under Gravity has Fictional Forces acting
on it due to Gas Particles Flowing Out.

 Acceleration Due to Gravity on the Particle Stops When the

Frictional Force is Equal to the Weight of the Particle.

 The Liquid Particle then Falls at a Constant Velocity called

Settling Velocity.

 The Smaller the Particle Diameter, the Quicker it Attains its

Settling Velocity.
Ono SLIDE 68
 Separator Design
 Gas Capacity.
 The Larger the Particle, the more rapidly they fall and the more
Turbulence they cause.

 General Separator Capacity Ratings Assume Gravity Separation of

200 microns and Above Particle Size.

 Smaller Diameter Particles are Removed at Mist Extractor.

 The Applied Law to Calculate Settling Velocity is Modified Stoke’s

Law.

 Modified Stoke’s Law Depends on the Particle Diameter and Fluid

System It Falls through.

Ono SLIDE 69
 Separator Gas Capacity
 Sounders and Brown Relation
 Gas Capacity is Related to Liquid Droplets Entrainment
(Suspension) Velocity V

 V  Maximum Allowable Upwards Gas Velocity Required:

To Keep the Droplet in Suspension.

It is Proportional to square root of the difference

of the liquid and gas densities divided by the gas
   1

density.  
V a  o g 2

 g 

Ono SLIDE 70
 Separator Gas Capacity
 Liquid Droplet Settling Method for Gas Capacity Calculation.
 For Liquid Droplet to be in Suspension

 Fa = Fg  Eqn. 3-1
Fa  Total Upwards Force Exerted by the Gas Stream on the
Liquid Droplet.

  Drag Force on Liquid droplet by Gas stream.

  The Liquid droplet Resistance in the Gas stream Flow

 Fg  Total Downward Gravitational Force on the Liquid

Droplet. Ono SLIDE 71
 Separator Gas Capacity
 C  g  d 2 Vd2  Eqn. 3-2
F a 
4

 and

F g 
 L  g   d3 g
 6 Eqn. 3-3

 C = Drag Co-efficient (dimensionless)

 d = Liquid Drop Diameter (ft)
 Vd = Liquid drop-settling Velocity (ft/sec)
 L = Liquid Density at Operating Condition lb/ft3

  g= Gas Density at Operating condition lb/ft3

 g = Acceleration due to Gravity 32.2 ft/sec3

Ono SLIDE 72
 Separator Gas Capacity
 Substituting for Fa and Fg in Eqn. 3-1

C  g  d 2 Vd2

 L  g   d3 g
 Eqn. 3-4
4 6

 Solving for Vd
 2d g   
Vd2  L g

3C g

 Vd  Vg  Liquid Droplet Falls

 Vd = Vg  Liquid Droplet Remains in Suspension
 Vg  Superficial Upward Bulk Gas Velocity.

 Sounders and Brown Taking:

 2dg= K Constant
3C
 Equation 3-4 Becomes
    g  1
 Eqn. 3- 5
Va  K  o  2
  
 g 
Ono SLIDE 73
 Separator Gas Capacity
 Separator Outlet Gas Stream Capacity q is Given as:
 D 2V q sc  gsc

 q = AV = 4 g Eqn 3-6

 q = ft3/sec
 qSC = scf/sec
q sc  gsc
 = Eqn 3-7
86400  g
 qSC = scf/day

 Now from Eqn. 3-6,

 q = D2 Eqn 3-8
 V 4
 Substituting eqn. 3-7 and 3-5 in eqn. 3-8
q D 2
q sc  gsc 1
   Eqn. 3  9
V 4 86400  g 1
   g 2
K o  SLIDE 74
   Ono
 g 
 Separator Gas Capacity
 Now;
 gscPT sc
g  for real gases
ZP scT
 sc ZP scT
 Eqn. 3  10
g PT sc
 Substituting eqn.3-10 in eqn. 3-9
1/ 2
     
67,858 KD 2 PT  L g  Eqn 3-11
 qSC     scf/day
sc  g 

ZP scT
 Substituting for Standard Conditions and Expressing qSC in mm scf/day
    
1/ 2

2.40 KD 2 P L g
 Eqn 3-12
 g 
q sc   
ZT
 Substituting eqn. 3-10 in eqn. 3-7 with Standard Conditions and q SC in
mm scf/day
q ZT
q  0.327 sc Eqn. 3  13
P
Ono SLIDE 75
 The K-Factor
 Va
 Max. Allowable Superficial Upward Gas Velocity. ft/sec
 Should be able to Let Go droplets larger than 100 microns.

 K-Factor depends on:

Type of Mist extractor Present.

Configuration and Operating Empirical

Factors.

Also Referred to as:

Separation Co-efficient.
Ono SLIDE 76
 The K-Factor
 Includes All Factors Affecting Liquid separation from Gas.
 Gas Compressibility Factor – z.

 Base and Operating Pressure.

 Base and Operating Temperature.

 Density of Fluids to be Separated.

 Separator Configuration.

 Separator Liquid Depth.

 Oil Foaming Tendency.

 Steady or Pulsating Gas Flow.

Ono SLIDE 77
 The K-Factor
 Liquid Heading or Steady Flow.

 Gas/Liquid Ratio.

 Impurities and Foreign Material Presence.

 Degree of Separation Required.

 Separator Internal Design.

 K-Factor and Separation Capacity are increased by
 Straightening Vanes.

 Baffling.

 Special Inlet Degassing Elements, etc.

Ono SLIDE 78
 K-Factor

VESSEL WITH MIST W/O MIST GENERAL RANGE

Vertical (General) 0.167 0.117 0.06 – 0.35

Height – 5ft 0.12 - 0.24
 10ft 0.18 – 0.35

Horizontal(General) 0.382 - 0.4 – 0.50

Length - 10ft 0.4 – 0.5
Other Lengths 0.4 to 0.5 x (L/D)0.56

Spherical - All 0. 2 - .35

Wire mesh mist Extractor - - 0.35

Bubble Cap Tray Columns - - 0.16 for 24’ spacing

Valves tray column - - 0.18 for 24’ spacing

Ono SLIDE 79
 Separator Liquid Capacity qL
 Depends on:
 Separator Liquid Volume.

 Gas-Oil Interface.
 Provides Enough Area for Gas in Liquid to Break Out.

 Retention Time tr

Ono SLIDE 80
 Separator Liquid Capacity qL
 Depends on:
 Retention Time tr
 Time required for the Liquid to Stay in the Vessel.

 Time Required for Gas to come out of Liquid.

 Time to obtain an Equilibrium Condition between the Liquid and Gas

Phase at Operating Press. and Temp.

 Time Required for Water to settle out of Oil and Oil to settle out of
Water in 3-phase separator.

 Normally 1 min for Oil-Gas Separator with Non-Foaming Oil.

 Low for Crude with 350 API and Above.

 High for Crude with Low API. Ono SLIDE 81

 Retention-Time Method
for Liquid Capacity qL Calculation
 General Recommendation
 Oil and gas Separation  1 min

 Oil-Water-Gas High Pressure Separation  2 – 5 min

 Oil –Water-Gas Low Pressure separation  5 - 10 min

(at . 100 0F and above)

@ 90 0F  10 - 15 min
@ 80 0F  15 - 20 min
@ 70 0F  20 - 25 min
@ 60 0F  25 - 30 min

Ono SLIDE 82
 Retention-Time Method
for Liquid Capacity qL Calculation
 API Spec. 12J (1980) Recommended Liquid tr
 (If there is no foaming, Wax accumulation, Slug flows etc.)

 2-Phase Separator
 Oil Gravity Liquid Retention Time
 (0API) (Min)
 Above 35 1
 20 – 35 1 to 2
 10 – 20 2 to 4

3-Phase Separator
 Above 35 3 to 5
 Below 35
 100+ 0F 5 to 1
 80+ 0F 10 to 20
 60+ 0F 20 to 30
Ono SLIDE 83
 Retention-Time Method
for Liquid Capacity qL Calculation

 Basic Equation
257
VEqn. 3-19
qL 
 t
 V = Separator Settling Volume. ft3
 t = Retention Time min.
 qL = Separator Liquid Capacity. bbl/day

 qL 
1440 V  Eqn. 3-20
t
 V = Separator Settling Volume bbl
 t = Retention Time min.
 qL = Separator Liquid capacity. bbl/day

Ono SLIDE 84
 Retention-Time Method
for Liquid Capacity qL Calculation

 V and qL Values for Different Separators

 Separator V (bbls) qL
 Vertical 0.785 D2 h 100.5 D2 h
t
 Horizontal 0.785 D2 h 50.24 D2 L
 (Single Tube) t t
 Horizontal 0.785 D2 h 100.5 D2 L
 (Double Tube ) t t

d d3 d
 Spherical 0.2618 d 3
33.51 t 2
2

 h - Height of oil column above the oil outlet (ft)

 d - Diameter of the vessel (ft)
 L - Length of the Horizontal Separator (ft)

Ono SLIDE 85
 Retention-Time Method
for Liquid Capacity qL Calculation
 Oil Column Height(h) Vs Total Height (H) for vertical separator
 H (ft) h (ft)
 5.0 2.5
 10.0 3.25
 15.0 4.25

Ono SLIDE 86
 Retention-Time Method
for Liquid Capacity qL Calculation
 Factors Influencing Gas and Oil Capacity
 Well Stream Physical and Chemical Properties.
 Gravity.
 Viscosity.
 Phase equilibrium, etc.

 Size and Distribution of Liquid Particles in Gas in the Upstream of

the Separator Mist Extractor.

 Operating Pressure(Above Hydrate Point of Gas)

 Operating Temperature (Above Cloud Point of Liquid).

 Varying Gas-Liquid Ratio.

Ono SLIDE 87
 Basic Sizing Calculation Procedure
 1. Calculate Oil Density at Operating Conditions

 OT  62.4  OT lb / ft
3
at

  specific gravity at Op. Temp.

   thermal co-efficient of expansion

  OT   O 60 1    T  60  

  specific gravity Std. Cond. 60 0F

141.5
 O 60 
131.5  API

Ono SLIDE 88
 Basic Sizing Calculation Procedure
2. Calculate Gas Density at Operating Conditions.
 asc  P T SC

g  lb / f
Z P SC T  given 
 gsc P T SC
 lb / ft  given.gsc
Z P SC T

 P SC 28.97
 gsc  lb / ft 3  0.0764  lb / f
Z R T SC
 air = 0.0764 lb/ft3 ( at 14.7 psia & 60 0F)
 Mg = 28.97lb/lb-mole  Air Molecular Weight
 T  0R, P  psia, For ideal gas, Z = 1

 3. Calculate Allowable Velocity.
  o  g  1
V  K  2
    ft/sec
 g 
Ono SLIDE 89
 .
 Basic Sizing Calculation Procedure
 4. Calculate Gas Flow Rate at Operating Condition.
 i. With Given qsc in mm scf/day
Z q sc T
 q g  0.3273 ft 3 / se
P
 ii. With Given qsc in scf/day

 Z q sc R T
qg  ft 3 / se
 379.4  86400 P
 iii. With Given Separator Diameter.

 scf/day
67,858 K D P  T SC  460   o   g 
2
q gsc   
Z P SC  T  460   g 
 5. Calculate Separator Area.

 AS =
qg
 ft 2
Va Ono SLIDE 90
 Basic Sizing Calculation Procedure
 6. Calculate Separator diameter.
 I. For Vertical separator
 DS = 13.53  AS in.
 ii. For Horizontal Separator
 Ag = ½ AT  Ag = AL
 iii. For Spherical Separator

q sc T Z
 D = 9.93 4 in.
K L P
 7. Calculate Liquid Capacity.
 Vertical qL = 100.5 d2 h

 t
Horizontal
= 50.24 d2 L
 (Single Tube) t
 Horizontal = 100.5 d2 Ld 3 d
Ono SLIDE 91
 (Double Tube) tt 2
 Basic Sizing Calculation Procedure
 8. Apply Basic Consideration.

 Vertical Separator
Distance from Oil Inlet to Mist Bottom  1 D (min.)

Inlet Located About 1/3 Shell Length from Separator Top.

Distance from Oil Inlet to Normal Liquid Level 24 in (min.)

Modify Calculated D from qsc for 5ft and 7ft Vertical Separator
by 0.8 correction factor since they cannot meet above
conditions

Ono SLIDE 92
 Basic Sizing Calculation Procedure
 8. Apply Basic Consideration.
 Vertical Separator
 A  Inlet Located About 1/3
Shell Length from Separator Top.

 B  Distance from Oil Inlet to A

Mist Bottom 1 D (minimum.) B

 C  Distance from Inlet to

Normal Liquid Level 24 in
(min.) C
 D  Distance from Outlet to
Normal Liquid Level 1/3L

D
 Modify Calculated D from qsc
Equation for 5ft and 7ft Vertical
Separator by 0.8 correction
factor since they cannot meet
above conditions
Ono SLIDE 93
 Basic Sizing Calculation Procedure
 8. Apply Basic Consideration.
 Horizontal Separator
As mentioned in the diameter consideration.

 Spherical Separator
Mist Extractor diameter = ½ Separator diameter
Ono SLIDE 94
 Dm = ½ Ds for Gas Capacity Calculation
 Basic Sizing Calculation Procedure
2. Calculate Gas density at Operating
Example 3-1 Conditions.
Calculate the Gas and Liquid Capacities of a  asc  P T SC
Vertical Separator with the following data: g  lb / ft 3
Z P SC T
Shell Height. = 10 ft
= 0.0764)(0.8)(400)(520) = 1.66 lb/ft3
Separator internal diameter. = 24 inches (1)(14.7)(520)
Gas Gravity. = 0.8
Liquid Gravity. = 45 0API.
3. Calculate Allowable Gas Velocity.
Operating Pressure. = 400 psia.
     1 ft/sec
Operating Temperature. = 60 0F  K 
o g
V 2
 g 
 
Mist Extractor. = wire-mesh type.
Assume Ideal Behaviour. = 0.167
1
 50.02  1.66  2 = 0.902 ft/sec.
 
1. Calculate Oil Density at Operating  1.66 
Condition. 4. Calculate Gas Capacity.
OT = 141.5 = 0.81 scf/day
1

131.5 + 45 67,824 K D P  T SC  460   o   g

2 

2
q gsc   
o = 62.4 OT = 0.81 x 62.4 = 50.02 Z P SC  T  460   g 


lb/ft3
Ono SLIDE 95
 Basic Sizing Calculation Procedure
1

 67,824  0.167   4  400   60  460  50.02  1.66 

2
7. Calculate Oil Capacity.
1 14.7   60  460  1.66 
H = 10 ft  h = 3.25 ft
 = 6.654 mm scf/day t = 1 min.  Oil-Gas Separator

Z q sc T
qg  0.3273 ft 3 / sec
P
qo = 100.5 D2 h = 100.5 x 22 x 3.25
1  6.654 520 
 0.3273 ft 3 / sec
= 2.83 ft3/sec t 1.0
400

5. Calculate Separator Area. = 1306.5 bbl/day

As = qg = 2.830 = 3.139 ft2
Va 0.902

6. Calculate Separator Diameter.

D = 13.53 As = 13.533.139
= 23. 97 = 24 in

For Confirmation Purposes Only

Ono SLIDE 96
Basic Sizing Calculation Procedure

 OT   O 60 1    T  60 
Example 3-2

Calculate the Diameter of a Horizontal
Separator with the following data:

  1 1  0.0004 90  60  
Shell Length. = 10 ft  = 0.988
Gas capacity. = 70 mm scf/day.  o = 62.4 oT = 0.988 x 62.4 = 61.65 lb/ft3
Gas Gravity. = 0.64
Liquid Gravity. = 10 0API at 60 0F.  2. Calculate Gas density at Operating
Operating Pressure. = 775 psia. Conditions.
Operating Temperature. = 90 0F   g   asc  P T SC lb / ft 3
Compressibility factor = 0.881 Z P SC T
Thermal Expansion Co-efficient = 0.0004  = 0.0764)(0.64)(775)(520) = 2.77 lb/ft3
Mist Extractor. = wire-mesh type.  (0.881)(14.7)(550)
3. Calculate Allowable Gas Velocity.
1. Calculate Oil Density at    1 ft/sec
 K 
o g
V 2
Operating Condition. 
 g 

o,60 = 141.5 = 1.00 1
= 0.382  61.65  2.77  2 = 1.761 ft/sec.
131.5 + 10  
 2.77 
97
97
Ono SLIDE
SITP / O & G
 Basic Sizing Calculation Procedure
4. Calculate Gas Capacity. 7. Calculate Oil Capacity.
Z q sc T
qg  0.3273 ft 3 / sec
P qo = 50.24 D2 L = 50.24x 4.552 x 10
t 1.0
 0.3273
 0.881  70 550 ft 3 / sec
775 = 10,401 bbl/day
= 14.325 ft3/sec

5. Calculate Separator Area.

As = qg = 14.325 = 8.135 ft2
Va 1.761

 AT = 2 x 8.135 = 16.27 ft2

6. Calculate Separator Diameter.

D = 13.53 As = 13.5316.27
= 54.57in = 4.55ft
Ono SLIDE 98
 Basic Sizing Calculation Procedure
 Three-Phase Separators
 General Requirements
 Liquid and Gas Separation Must be Completed at The
Secondary Separation Section

 Low Va Required to Allow Liquid Droplets Fall out of Gas

 Efficient Mist Extractor Required to Scrub Gas

 Liquid Delivered to Turbulent Free Accumulation Section

 Discharge of Water and Oil to be Done Separately

Ono SLIDE 99
 Basic Sizing Calculation Procedure
 Gas Capacity
  as in Two-Phase

 Retention Volume
 Vessel Volume Where Oil and Water Remain in Contact

 Water and Oil Resting in their Separate Compactment are Not

in Retention Volume

 Retention Time
 Must be Assigned in Relation to:
 Liquid Retention Volume
 Relative Gravity of Oil and Water
 Time for Oil and Water Separation from One another

 Achieved with Interface Level Controllers

Ono SLIDE 100
 Basic Sizing Calculation Procedure
 Oil Settling Time(tro)
 Time Required for Water to Settle out of Oil

 Water Settling Time(trw)

 Time Required for oil to Settle out of Water

 VL = qo tro + qwtrw

 q o, q w  Outlet Flow of Oil and Water Phases (ft3/min)

tro, trw  Retention Time for Oil and water Phases (min)

VL  Settling Volume ft3

Ono SLIDE 101

 Separator Sizing Through Charts
 Sivall,s Method
 Operational Data Required
 Operation Pressure
 Oil Flow Rate
 Gas Flow Rate
 Gas-Oil Ratio
 Reservoir Fluid Flow Rate
 From test separator

 Gas Capacity Charts

 Available for Various Sizes of Separators
 Correction for Horizontal Separators Liquid Levels
 1/2 Full
 1/3 Full
 1/4 Full
Ono SLIDE 102
 Separator Sizing Through Charts
 Manufacturers Charts
 Estimate Separators Capacities with Given:
 Designed Pressure
 Operation Pressure
 Separator Diameter

 Charts Sizing Procedure

 Given:
 Operating Pressure
 Gas Production Ratio(GOR)
 Enter Gas Capacity Chart With P and qg to get Separator
Specifications that will Give

 qg  qgg qgg = Given Gas Capacity

Ono SLIDE 103
 Separator Sizing Through Charts
 With Chart Separator Specs go to
Low or High Pressure Settling
Volume Table and Get V

 qL = 1440 V
 t
 Compare qL and qLg adjust your
separators specifications up or
down to handle
 qL  q Lg

Ono SLIDE 104

 Separator Sizing Through Charts
 Guiding Factors in Separator Selection
 Same as those in Sizing Calculations
Example 3-4
Using Sivall,s charts, size a separator that Will be used for a well stream
undergoing the following test separation conditions:
Operating pressure 900 psig
Liquid flow rate 20 bbl/mm scf Gas flow rate per
Gas Flow rate 10 mm scfd

Solution
Total liquid flow rate (capacity) = 20 x 10 = 200 bbl/day

 Sizing for Horizontal separator

From fig.3-19a, a 10 ft by 20in horizontal separator will handle 12 mm
scfd gas capacity at 900 psig when half full.

Ono SLIDE 105

Separator Sizing Through Charts

12

900
Ono SLIDE 106
 Separator Sizing Through Charts
From Table 3-5b, a 10 ft by 20 in. will have settling volume of 1.80 bbl.
when half full;

 qL = 1440 V = (1440)(1.80)
t 1.0
= 2592 bbl/day

 Sizing for Vertical separator

Now, from fig. 3-17a and table 3-4. a 7.5ft by 30 in. vertical Separator
will give 13.5 mm scfd at 900 psig and 2361.6 bbl/day.

Ono SLIDE 107

 Separator Sizing Through Charts
 Table 3-5b
 Horizontal Separator
 Settling Volume of High-Pressure(230-2000psi)

Ono SLIDE 108