INDEX:

1
2
3
4
5
5A
5B
5C
5D
6
6A
6B
6C
6D

Discussion
Nomenclature
References
StandardSeparatorSizesasperAPI
Separatorsizingwithmistextractor
TwoPhase(GasOil)VerticalSeparatorasperAPI12J
TwoPhase(GasOil)HorizontalSeparatorasperAPI12J
ThreePhase(GasOilWater)VerticalSeparatorasperAPI12J
ThreePhase(GasOilWater)HorizontalSeparatorasperAPI12J
Separatorsizingwithoutmistextractor
TwoPhase(GasOil)VerticalSeparatorAsperPetroleumandGasFieldProcessing
TwoPhase(GasOil)HorizontalSeparatorasperPetroleumandGasFieldProcessing
ThreePhase(GasOilWater)VerticalSeparatorasperPetroleumandGasFieldProcessing
ThreePhase(GasOilWater)HorizontalSeparatorasperPetroleumandGasFieldProcessing

Preparedby:
AjayS.Satpute
Sr.ProcessEngineer
RambollConsultingEngineering,Qatar

DISCUSSION
Thisspreadsheetprovidesaneasyandsimpleapproachto(2/3phaseandvertical/horizontal)separator
sizing.Formulaeandreferencesarealsoprovidedforprocessengineerstoedit/duplicatethiswork(fileis
NOTpasswordprotected).
Thereisasmuchartasthereissciencetoproperlydesignaseparator.Threemainfactorsshouldbe
consideredinseparatorsizing:1)
vaporcapacity,2)Liquidcapacity,and3)operability.The
vaporcapacitywilldeterminethecrosssectionalareanecessaryforgravitationalforcestoremovetheliquid
fromthevapor.Theliquidcapacityis
typicallysetbydeterminingthevolumerequiredtoprovideadequateresidencetimetodegastheliquidor
allowimmiscibleliquidphasestoseparate.Operabilityissuesincludetheseparatorsabilitytodeal
withsolidsifpresent,unsteadyflow/liquidslugs,turndown,etc.Finally,theoptimaldesignwillusuallyresult
inanaspectratiothatsatisfiestheserequirementsinavesselofreasonablecost.Thesefactorsoftenresultin
aniterativeapproachtothecalculations.

Twosetsofcalculationsarecarriedouthere.
1.SeparatorswithMistExtractorsand2.
SeparatorswithoutMistExtractors
Severalusefulguidelinesforseparatordesignareprovidedbelow;
Momentum&Velocitycriteriafornozzles(Source:DEP31.22.05.12Gen.2008)
InletNozzle
MomentumorVelocityLimit
Max.Momentum,mV2m1400Pa
NoInternal
Halfopenpipe

Max.Momentum,mV2m2100Pa

Schoepentoeterusedasinletdevice

Max.Momentum,mV2m8000Pa

GasoutletNozzle

Max.Momentum,gV2g,out4500Pa

LiquidoutletNozzle

Maximumvelocity,1m/s

Selectionguidelineforseparatortypes
SystemCharacteristics
Largevapour,lessliquidLoad(byvolume)
Largeliquid,lessvapourLoad(byvolume)
Largevapour,largeliquidLoad(byvolume)
Liquidliquidseparation
Liquidsolidseparation

TypeofSeparator
Vertical
Horizontal
Horizontal
Horizontal
Vertical

Levelsettingintheseparator
Leveltype
LevelAlarmHighHigh(LAHH)
LevelAlarmHigh(LAH)

Levelsetting
3060secondsor200mmwhicheverisgreater
3060secondsor200mmwhicheverisgreater

NormalAlarmLevel(NAL)
LevelAlarmLow(LAL)

60%ofhorizontalseparator
3060secondsor200mmwhicheverisgreater

LevelAlarmLowLow(LALL)

3060secondsor200mmwhicheverisgreaterShouldbe
atleast200mmabovethevesselbottomormaximum
interfacelevel

TypicalKfactorsforthesizingofwiremeshdemisters(Source:IPSEPR880,1997)
Separatortype
Kfactor(m/s)
Horizontal(withverticalpad)
0.122to0.152
Spherical
0.061to0.107
Verticalorhorizontal(withhorizontalpad)
0.055to0.107
Atatmosphericpressure
0.107
At2100kPa
0.101
At4100kPa
0.091
At6200kPa
0.082
At10300kPa
0.064
Wetsteam
0.076
Mostvapoursundervacuum
0.061
Saltandcausticevaporators
0.046

NOMENCLATURE

INDEX

A
Aw

totalcrosssectionalareaoftheseparator.
2
crosssectionalareaoftheseparatoroccupiedbywater,ft

Ao

crosssectionalareaoftheseparatoroccupiedbyoil,ft2

Ag

crosssectionalareaoftheseparatoroccupiedbygas,ft2

CD
d
dm
D
h
hg

dragcoefficient
vesselinternaldiameter,in.
bubbleordropdiameter,m
vesseldiameter,ft
liquidheight,in.
gasphasespaceheight,in.

ho

oilpadheight,in.

hw
K
LefforL

waterpadheight,in.
meshcapacityfactor,ft/sec
effectivelengthofthevesselwhereseparationoccurs,ft

LssorLs

seamtoseamvessellength,ft

NLL
P
Qc

normalliquidlevel,%
operatingpressure,psia
continuousliquidphaseflowrate,bbl/day

Qg
Qo

gasflowrate,MMSCFDorft3/s
oilflowrate,bbl/day

WorQw
Re
T
V
Va

waterflowrate,bbl/day
Reynoldsnumber
operatingtemperature,R
liquidsettlingvolume
max.allowablevelocitythroughsecondaryseparationsection

Vm
Z
c

velocityofthemixture,m/s
gascompressibility
continuousphasedynamicviscosity,cp

waterdynamicviscosity,cP

density,lbm/ft3
gasdensity,lbm/ft3

liquiddensity,lbm/ft

oildensity,lbm/ft

meandensityofmixture,kg/m3

waterdensity,lbm/ft3

REFERENCES
http://en.citizendium.org/wiki/Vaporliquid_separator
API12J,Specificationforoilandgasseparators,1989
http://petrowiki.org/Separator_sizing
http://www.cheresources.com/invision/topic/11856selectingverticalseparatorldratio/
PetroleumandGasFieldProcessingHusseinK.AbdelAal,MohamedAggour,M.A.Fahim
http://books.google.com.qa/books?id=BZOPlA
SmMUC&pg=PA97&lpg=PA97&dq=%22three+phase%22+separator+L/D+ratio+%22GPSA%22&source=bl&ot
http://www.cheresources.com/invision/topic/17158threephaseseparatordesignsuggestionneeded/
http://en.citizendium.org/wiki/Vaporliquid_separator
http://www.chemicalforums.com/index.php?topic=8913.0
http://www.chemicalforums.com/index.php?topic=9252.0
http://www.cheresources.com/invision/topic/41sizingaflashtankorvaporliquidseparator/
http://www.engtips.com/faqs.cfm?fid=1153
http://processdesigns.com/
http://www.razifar.com/cariboost_files/Design_20Two_20Phase_20Separators_20Within_20the_20Right_2
0Limits.pdf
http://en.wikipedia.org/wiki/Souders%E2%80%93Brown_equation
http://books.google.com.qa/books?id=lpA83iVcaGYC&pg=PA159&lpg=PA159&dq=Kh+%3D+1.25+Kv+separa
tor&source=bl&ots=fV8ewKHkag&sig=q70X8xfxPnk9MBMHgaEFwLhIhU&hl=en&sa=X&ei=M
IPSEPR880,1997
GPSAEngineeringDataBook(12thEd)

STANDARDSEPARATORSIZESASPERAPI
D[in]xHorL[ft]
12inx5ft
12inx7ft
12inx10ft
16inx5ft
16inx7ft
16inx10ft
20inx5ft
20inx7ft
20inx10ft
24inx5ft
24inx7ft
24inx10ft
30inx5ft
30inx7ft
30inx10ft
36inx5ft
36inx7ft
36inx10ft
36inx15ft
42inx7ft
42inx10ft
42inx15ft
48inx7ft
48inx10ft
48inx15ft
54inx7ft
54inx10ft
54inx15ft
60inx7ft
60inx10ft
60inx15ft

INDEX

TwoPhase(GasOil)Verticalseparator:AsperAPI12J
Gasrate

Qo

'o

Oilrate
Gasspecificgravity
Oildensity

o
P
T'
T
MW
t
Z
g
H
K
NLL

3000 bbl/d
0.70
40 oAPI
0.83
814.5 psia
80 oF
540
20.3
1
0.84
0.013
10
0.30
30%

R
lb/lbmole
minutes
cP
ft
ft/s

Oilspecificgravity
Operatingpressure
Operatingtemperature
Operatingtemperature
Molecularweight
Retentiontime(ReferTable2)
Gascompressibility
Gasviscosity
Shellheight(assume)
ReferTable1
Normalliquidlevel(assume)

CALCULATIONS
Step1:
Determinegasandoilproperties
g
Gasoperatingdensity
3.4 lb/ft3
o

51.5 lb/ft3

Oiloperatingdensity

SCHEMATIC

Yellowboxesareinputboxes.

INPUTPARAMETERS
Qg
25 mmscfd

EQUATIONS

TABLES
Table1
Height,ft
5
10

Step2:
Va

1.13 ft/s

Qg,a

4.55 ft3/s

Actualvolumeflowofgas

Ag,min

4.03 ft2

Minimumgasflowarea

Dmin

27 in

MinimumIDofseparator

Table2
OilGravities

Retentiontime,
minutes(Typical)

o
Above35 API

1to2

2to4

20to30 API
Dselected
H
H/D

30 in
10 ft
4.0 unitless

Nextlargerandappropriatesize
Shellheight
ReferNote4

2.6 bbl

Liquidvolume(excludingbottomhead)

3777 bpd

Liquidcapacityofseparatorshouldbe
morethan3000bpd(inputvalue)

TypicalKfactor
range
0.12to0.24
0.18to0.35

10to20 API

Step3:

NOTES
1.Themaximumallowablesuperficialvelocitycalculatedfromtheabovefactorsisforseparatorsnormallyhavingawiremeshmistextractor.This
rateshouldallowallliquiddropletslargerthan10micronstosettleoutofgas.
2.AdditionalresourceforKfactorfromGPSAEngineeringDataBook:
Pressure,barg
AdjustmentofKfactorforpressure
Kfactor,m/s
0
Pressure,psig
%ofDesignvalue
0.11
Atm.
100
7
0.11
150
90
21
0.10
42
300
85
0.09
63
600
80
0.08
105
1150
75
0.07
GPSANotes:
1.K=0.107atagaugepressureof7bar.Subtract0.003forevery7baraboveagaugepressureof7bar.
2.Forglycoloraminesolutions,multiplyaboveKvaluesby0.60.8.
3.TypicallyuseonehalfoftheaboveKvaluesforapproximatesizingofverticalseparatorswithoutmeshpads.
4.Forcompressorsuctionscrubbersandexpanderinletseparators,multiplyKby0.70.8.
3.AdditionalresourceforretentiontimesfromgasConditioningandProcessing,Volume2.
Naturalgasoil
1to3minutes
Leanoilsurgetanks
10to15minutes
Fractionationfeedsurgetanks
8to15minutes
Refrigerantsurgetanks
4to7minutes
Refrigerantecononomizers
2to3minutes
4.AsperGPSA,typicalverticalH/Dratiosarenormallyinthe2to4range.

TwoPhase(GasOil)HorizontalSeparator:AsperAPI12J
Gasrate

Qo

'o

Oilrate
Gasspecificgravity
Oildensity

o
P
T'
T
MW
t
Z
g
K
NLL
L

3000 bbl/d
0.70
40 oAPI
0.83
814.5 psia
80 oF
540
20.3
1
0.84
0.012
0.5
30%
10

R
lb/lbmole
minutes
cP
ft/s
ft

SCHEMATIC

Oilspecificgravity
Operatingpressure
Operatingtemperature
Operatingtemperature
Molecularweight
Retentiontime(ReferTable2)
Gascompressibility
Gasviscosity
ReferTable1
Normalliquidlevel(assume)
ShellLength(assume)

CALCULATIONS
Step1:
Determinegasandoilproperties
g
Gasoperatingdensity
3.4 lb/ft3
o
Step2:
Va

51.5 lb/ft3

Oiloperatingdensity

4.55 ft3/s

Actualvolumeflowofgas

Ag,min

2.42 ft2

Minimumgasflowarea

Ag,min
Error
Dselected
L
L/D

EQUATIONS

TABLES
Table1
TypicalKfactorrange,
ft/s
10
0.4to0.5
OtherLengths 0.4to0.5x(L/10)0.56
Length,ft

1.881 ft/s

Qg,a

Dmin

Yellowboxesareinputboxes.

INPUTPARAMETERS
Qg
25 mmscfd

4 in
2.42 ft
0.00

Assume

30 in
10 ft
4.0 unitless

Table2
OilGravities

Retentiontime,
minutes(Typical)

o
Above35 API

1to2

2to4

20to30 API
10to20 API
Nextlargerandappropriatesize
Shelllength
ReferNote4

Step3:
V
W

3 bbl

Liquidvolume(excludingbottomhead)

3644 bpd

Liquidcapacityofseparatorshouldbe
morethan3000bpd(inputvalue)

NOTES
1.Themaximumallowablesuperficialvelocitycalculatedfromtheabovefactorsisforseparatorsnormallyhavingawiremeshmistextractor.This
rateshouldallowallliquiddropletslargerthan10micronstosettleoutofgas.
2.AdditionalresourceforKfactorfromGPSAEngineeringDataBook:
Pressure,barg
AdjustmentofKfactorforpressure
Kfactor,m/s
0
Pressure,psig
%ofDesignvalue
0.11
7
Atm.
100
0.11
21
150
90
0.10
42
300
85
0.09
63
600
80
0.08
105
1150
75
0.07
GPSANotes:
1.K=0.107atagaugepressureof7bar.Subtract0.003forevery7baraboveagaugepressureof7bar.
2.Forglycoloraminesolutions,multiplyaboveKvaluesby0.60.8.
3.Forcompressorsuctionscrubbersandexpanderinletseparators,multiplyKby0.70.8.
3.AdditionalresourceforretentiontimesfromgasConditioningandProcessing,Volume2.
Naturalgasoil
1to3minutes
Leanoilsurgetanks
10to15minutes
Fractionationfeedsurgetanks
8to15minutes
Refrigerantsurgetanks
4to7minutes
Refrigerantecononomizers
2to3minutes
4.AsperGPSA,typicalhorizontalL/Dratiosarenormallyinthe2.5to5range.

INDEX

ThreePhase(GasOilWater)HorizontalSeparator:AsperAPI12J
Gasrate

Qo

8000 bbl/d

Oilrate

Qw

Waterrate
Gasspecificgravity
Oildensity

o
P
T'

3000 bbl/d
0.70
40 oAPI
0.83
250 psia
60 oF

T
MW
H
to

520
20.3
18
5

'o

tw
Z
g
K
NLL

R
lb/lbmole
ft
minutes

5 minutes
0.84
0.013 cP
0.35 ft/s
50%

Oilspecificgravity
Operatingpressure
Operatingtemperature
Operatingtemperature
Molecularweight
Shellheight(assume)
Oilretentiontime(ReferTable2)
Waterretentiontime(ReferTable2)
Gascompressibility
Gasviscosity
ReferTable1
Normalliquidlevel(assume)

CALCULATIONS
Step1:
Determinegasandoilproperties
g
Gasoperatingdensity
1.1 lb/ft3
o
Step2:
Va

51.5 lb/ft3

Oiloperatingdensity

SCHEMATIC

Yellowboxesareinputboxes.

INPUTPARAMETERS
Qg
8 mmscfd

EQUATIONS

TABLES
Table1
TypicalKfactorrange,
ft/s
0.12to0.24
0.18to0.35

Height,ft
5
10

2.4 ft/s

Qg,a

4.58 ft3/s

Actualvolumeflowofgas

Ag,min

1.92 ft2

Minimumgasflowarea

Dmin

19 in

Assume

Above35 API

Dselected

96 in

Nextlarger(thanDmin)andappropriate
size

o
Below35 API

18 ft

Shellheight

H/D

2.3 unitless

ReferNote4

Table2
OilGravities
o

o
100+ F

Retentiontime,
minutes(Typical)
3to5

5to10

10to20

20to30

80+ F
60+ F

Step3:
V
W

81 bbl

Liquidvolume(excludingbottomhead)

11602 bpd

Liquidcapacityofseparatorshouldbe
morethan11000bpd(inputvalue)

NOTES
1.Themaximumallowablesuperficialvelocitycalculatedfromtheabovefactorsisforseparatorsnormallyhavingawiremeshmistextractor.This
rateshouldallowallliquiddropletslargerthan10micronstosettleoutofgas.
2.AdditionalresourceforKfactorfromGPSAEngineeringDataBook:
AdjustmentofKfactorforpressure
Pressure,barg
Kfactor,m/s
Pressure,psig
%ofDesignvalue
0
0.11
Atm.
100
7
0.11
21
150
90
0.10
42
300
85
0.09
63
600
80
0.08
105
1150
75
0.07
GPSANotes:
1.K=0.107atagaugepressureof7bar.Subtract0.003forevery7baraboveagaugepressureof7bar.
2.Forglycoloraminesolutions,multiplyaboveKvaluesby0.60.8
3.TypicallyuseonehalfoftheaboveKvaluesforapproximatesizingofverticalseparatorswithoutmeshpads
4.Forcompressorsuctionscrubbersandexpanderinletseparators,multiplyKby0.70.8
3.AdditionalresourceforretentiontimesfromgasConditioningandProcessing,Volume2.
Naturalgasoil
1to3minutes
Leanoilsurgetanks
10to15minutes
Fractionationfeedsurgetanks
8to15minutes
Refrigerantsurgetanks
4to7minutes
Refrigerantecononomizers
2to3minutes

4.AsperGPSA,typicalhorizontalH/Dratiosarenormallyinthe2to4range.