Facilities Engineering

Transportation and Storage

EMB 5443
Mohd Shiraz Aris
Department of Mechanical Engineering,
Universiti Teknology PEtronas.
Separators and Filters
Acknowledgement:
Pn. Putri Nazirah, Dpt of Chemcial Engineering, UTP
Separators
Week Date Topics Lecturer Assessment
1& 2 24/01-04/01 Introduction:
E&P business, PSC, Project Life Cycle Concept
MSA/AL
3 & 4 07/02-18/02 Field Development Concept:
Fixed Platform, Manned and Unmanned Platform,
Minimum manning, Jackets, Tripod & Monopod,
Subsea Facilities Concept, Guyed Tower System,
Light Weight and Concrete Gravity Structures,
FPSO and FSO System, Integrated Development
Systems
MSA/AL
Group Project
Start (MSA)
&
Lab Work
(MSA)
5 21/02-25/02 Oil and Gas Production Processes:
Oil Production Process, Gas and Production
Process
MSA/AL
Lab Work
(MSA)
11 21/3-1/04 Process Equipment and Facilities:
Separator Design & Stages Required, Knockout
Drums & Flare System Design, Instrumentation &
Electrical Power Requirement & Design, Flowline
System design, Pump/Compressor Requirement,
Water Injection & Gas Injection Facilities
MSA Lab Work
(MSA)
Introduction
Main Offshore Production Facilities (key components):
Wellhead Equipment
Separation
Waster Handling Pump/Compressor Gas utilities, flaring
Introduction
Wellhead equipment
Wellhead and Christmas tree used to maintain surface control
of well
Contain key components (valves) for the safe production of
crude/gas from the wells:
manual master gate valve, manual wing gate valve, manual
swab gate valve, automatic shutdown valve, choke valve
Flowline and production manifolds send the well fluids to the
production and test separators
Introduction
Wellhead equipment
Introduction
Wellhead equipment
Introduction
Flowlines and production header
Introduction
Separation System
Introduction
Crude Separation and Export System-Overview
Introduction
Crude/Gas Separation System-Overview
Introduction
Gas Separation and Export System-Overview
Introduction
Gas Separation System-Overview
Introduction
Separation System-Focus
Separators
Separators
SEPARATORS form the HEART of the
production process
SEPARATION MODULE
reservoir
well
wellhead
Wellhead
manifold
FIRST STAGE
SECOND STAGE
To
export
Disposal
Storage tank
final oil
treatment
Water
treatment
Water
Gas to gas
scrubber and
gas
compression
module
Oil
What is a separator?
A SEPARATOR is a pressure VESSEL designed to DIVIDE a
combined liquid-gas system into individual COMPONENTS that
are relatively free of each other for SUBSEQUENT
PROCESSING or disposition
Why separator is needed?
Downstream equipment cannot handle gas-liquid
mixtures
Pumps require gas-free liquid
Compressor/ dehydration equipment require liquid-free
gas
Product specifications has limits on impurities
Oil should not contain > 1% impurities
Gas sales contract no free liquids in gas
Measurement devices (metering) for gases/liquids
highly inaccurate when the other phase is present
Principles of Separators
Principals of separation: momentum, gravity and
coalescing
Momentum
Fluid phases at different densities have different momentum
Changes in fluid direction will separate fluids at different momentum
Gravity
Liquid phase separated from gas due to difference in weight of
droplets
Coalescence
Small droplets coalesced when combined together
Coalescing devices force small droplets flowing through it to
collide, form larger droplets and then settling out of the gas
phase by gravity
Principles of Separators
Equipment and components involved in a separation process:
Filter separators: typically with 2 compartments (filter coalescing
elements and wire mesh)
Flash tank: Separation as a result of high AP
Line drip: Removal of free liquids in a dominant gas stream (high
gas/liq)
Liquid-liquid separators: Similar in design to gas/liquid separators
except at much lower velocities
Scrubber/knockout: Handling of high gas/liquid stream. Liquid typically
entrained as mist or free flowing along pipe walls
Principles of Separators
Separator: separation of mixed phase streams into gas
and liquid phases that are relatively free from each
other
Slug catcher: ability to absorb sustained in-flow of large
liquid volumes at irregular intervals
3 phase separator: separation of gas and two
immiscible liquids of different densities
What properties affect separation?
Gas and liquid flow rates
Operating & design pressures and temperatures
Surging or slugging tendencies of the feed streams
Fluid physical properties density, compressibility
Desired phase separation - gas-liquid or liquid-liquid
Desired degree of separation - e.g. remove 100% particles
>10 micron in size
Presence of impurities paraffin, sand, scale
Foaming tendencies
Corrosive tendencies
Must know and
understand the
characteristics of
the flow stream in
order to design
separators!
Separator Design Checklist
A primary separation section to remove the bulk of the liquid
from the gas
Sufficient liquid capacity to handle surges of liquid from the line
Sufficient length of height to allow small droplets to settle out
by gravity
A means of reducing turbulence in the main body to ensure
proper settling
A mist extractor to capture entrained droplets
Back pressure and liquid level controls
Separator classification and types
Classification
Two-phase separation (gas-liquid)
Three-phase separation (liquid-liquid i.e. water/oil/gas separation)
Types
Gravity separators
Horizontal
Vertical
Spherical
Centrifugal separators
(effect of gravity is enhanced by spinning the fluids at a high velocity)
Selection of
separators is
based on
obtaining the
desired results at
the lowest cost
Governing Laws
Momentum
Fluid phases at different densities will have different momentum
Change in fluid flow direction will separate fluids at different momentum
Momentum separation method applied for bulk separation of 2 phases in a
stream
Gravity settling
Liquid phase separated due to difference in
weight of droplets
The drag coefficient C is found to be a function of the
particle shape and Re of the flowing gas
drag
'
) ( 2
C A
gm
Vt
p g l
g l p


=
'
3
) ( 4
C A
gD
p g
g l p

=
gravity
Gas velocity
Liquid /solid
droplet
Governing Laws
Particles are assumed to be a solid sphere
Solving the equation requires the elimination of either
variables, V
t
or D
p
. The use of specific drag
coefficient charts together with CRe
2
, enables the
particle diameter and eventually the terminal velocity
to be solved:

g t pV D 1488
Re =
2
3 8
2 '
) ( ) 10 )( 95 . 0 (
Re

g l p gD
C

=
Estimation of Particle Size
Estimation of Particle Distribution in a
Separator
Governing Laws
Gravity settling for larger particles
for particles 1000 microns or larger, Newtons Law with a limiting
drag coefficient of 0.44 (Re >500). Substituting for C = 0.44
and for the upper limit of the Newtons law, the maximum droplet size is
estimated from,
where for,
Re = 200,000
K
cr
= 18.13
g
g l p
t
gD
V

) (
74 . 1

=
33 . 0
2
) (
(
(

=
g l g
cr p
g
K D


Governing Laws
Stokes Law
for low Re (less than 2), a linear relationship exists between Drag and Re
D
p
for Re less than 2 is found using K
cr
= 0.008 in,
The lower limit of Stokes Law is for a droplet diameter of approx. 3
microns.

18
) ( 1488
2
g l p
t
gD
V

=
33 . 0
2
) (
(
(

=
g l g
cr p
g
K D


Alternative Generic Terminal Velocity Formulae
Particles falling through a fluid by the pull of gravity:
Where,
A and N are constants related to the flow regime and the drag coefficient as
determined by
3 / 1
2
) (
(

l p l
p
g
D K
)
2
1
(
) 1 (
1
3
) ( 4
N
N
t
A
gD
V
N
l
l p
N
p

(

=

+


Law K A N
Stokes K<3.3 24 1
Intermediate 3.3 K 43.6 18.5 0.6
Newtons K > 43.6 0.44 0
Governing Laws
Coalescing
Small droplets coalesced and separated by gravity.
Coalescing devices like wire mesh screens, vane
elements, and filter cartridges force small particles
flowing through it to collide, forming larger droplets
and then settling out of the gas phase through gravity
Other Separation Techniques
Cyclone Separator
concept of inertia separation is employed where the different
speeds of gas and solid particles would cause separation to
occur. Baffles are use to recover/capture the solid particles
Floating Separators
Removal of solid objects in a solid-liquid phase through the
use of bubbles. Horizontal vessels are used and fluid directed
through the chamber would be fed by bubbles from
underneath. The bubbles would tend to float the solid particles
and this would captured at the upper portion of the vessel with
the aid of baffles. Utilized in a Deinking process in the pulp and
paper industry.
Separator Design and Construction
Usually characterized as vertical, horizontal or spherical
Parts of a separator
4 major sections: primary separation, gravity (secondary),
coalescing, sump
Primary section separates main portion of free liquid through
inertial effects or abrupt change in direction.
Gravity section utilizes gravitational force for enhanced
separation and entrainment of droplets
Coalescing section uses a mist extractor to remove very
small droplets of liquid from gas.
The sump section is basically a collector of all liquid from the
gas stream
Separator Design and Construction
Separator Sections:
A primary
B secondary
C coalescing
D sump
Separator Design and Construction
Separator Configurations:
Factors to consider in separator selection:
handling of extraneous material
available floor space
transportation and handling issues
spacing for interfacing
room for additional features, ie heat coils
surface area for degassing of separated liquid
handling of surge liquid
necessary for large liquid retention volume?
Separator Design and Construction
Vertical Separators
high gas-liquid ratios
low total gas volume
handling capacity increases with
increase in height
level controls not critical
use of mist extractors to reduce vessel diameter
example: compressor suction scrubber
Separator Design and Construction
Horizontal Separators
high total fluid volume
large amounts of dissolved
gas
provides for larger liquid
surface area
increased capacities through shorter retention time and increased liquid
levels
example: rich amine flash tank
Separator Design and Construction
Spherical Separators
high pressure service
compactness
low liquid volumes
Specifying Separators
Basic parameters: temperature, pressure, flow rates, physical
properties of the fluids as well as degree of separation
Define time frame of separation occurrence
For known fluids, specify type and amount, also state ie. mist,
free liquid or sludge
Select worst case scenario and apply safety factors: safer to be
wrong on the right side
A compressor suction scrubber desgined for 70-150 MMscfd gas at 400-600
psig and 65-105
o
F would require the seprator manufacturer to offer a unit
sized for the worst conditions, ie. 150 MMscfd at 600 psig and 105
o
F
Specifying Separators
Basic design equations for
separators with mist
extractors (vertical):
critical velocity (max)
correlation
by Sounders and Brown
G
m
maximum allowable gas mass-velocity
necessary for particles of size D
p
to drop or
settle out of gas
sec) / (
) (
ft K V
g
g l
t

=
) . / ( ) (
2
ft hr lb C G g l g m =
Separator Type
K factor
(ft/sec)
C factor
(ft/hr)
Horizontal (w/vertical pad) 0.4 50 0.5 1440 to
1800
Spherical 0.2 to 0.35 720 to 1260
Vertical or Horizontal
(w/horiz. Pad)
@atm pressure
@300 psig
@600 psig
@900 psig
@1500 psig
0.18 to 0.36
0.36
0.33
0.30
0.27
0.21
648 to 1260
1260
1188
1080
972
756
Wet Steam 0.25 900
Most Vapor under vacuum 0.20 720
Salt and Caustic Evaporators 0.15 540
Note:
(1) K = 0.35 @100 psig subtract 0.01 for every 100
psi above 100 psig
(2) For glycol and amine solutions, multiply K by 0.6
0.8
(3) Typically use one half of the above K or C values for
approximate sizing of vertical separators without
woven demisters
(4) For compressor suction scrubbers and expander
inlet separators multiply K by 0.7-0.8
Specifying Separators
Horizontal separators with mist extractors are sized using similar
equations + additional factors for length, L.
Gas capacity is calculated by subtracting the cross sectional
area occupied by the liquid from the vessel cross section
Common for horizontal separators to maintain its seam-seam
length to its diameter ratio of between 2:1 to 4:1
56 . 0
10
) (
(

=
L
K V
g
g l
t

56 . 0
10
) (
(

=
L
C G g l g m
Gas
Specifying Separators
Important note:
The separator sizing equations given are used in the sizing of
the separation elements. It is common for the separation
elements to be placed in a larger vessel ie. For surging
purposes.
Specifying Separators
Mass flow rates:
In most instances it is convenient to use mass flow rate for
sizing purposes. When handling gas flows, the flow is given in
volume flow rate (MMSCFD)
The fraction of the total area available for gas flow
can be found using the following table
g t V M 3600 =
F Md m
2
785 . 0 =
-
h/D F
0 1
0.05 0.981
0.1 0.948
0.15 0.906
0.2 0.858
0.25 0.804
h/D F
0.30 0.748
0.35 0.688
0.40 0.626
0.45 0.564
0.50 0.5
0.55 0.436
D
h
Specifying Separators
Horizontal separators without mist extractors are dependent of
gravity as its sole mechanism for separation.
Important to set minimum droplet diameter to be removed
Typical range of droplet diameters 150 2000 microns
Vessel length can be calculated using,
Assuming the time taken for the gas to flow from inlet to outlet is the same as the
time for the liquid droplet of size D
m
to fall from the to pof the vessel to the liquid
surface v t
a
D V
Q
L
t
4
=
Example 1
A horizontal gravity separator ( without mist extractor) is required to
handle 60 MMscfd (39.8 Ib/s) of 0.75 specific gravity gas (MW =
21.72) at a pressure of 500 psig and a temperature of 100 F.
compressibility is 0.9, viscosity is 0.012 cp and liquid specific
gravity is 0.50. It is desired to remove all entrainment greater than
150 microns in diameter. No liquid surge is required.
Note:
1 micron = 0.00003937 in
MMscfd = 1000000 ft
3
/day
Example 1
Solution
Gas Density
g
= P (MW) / RTZ
= (514.7)(21.72) / ( 10.73)(560)(0.90)
= 2.07 Ib/ft
3
Liquid Density
l
= 0.5 (62.4)
= 31.2 Ib/ft
3
Mass flow rate m = 60 x 10
6
( 21.72) / ( 379)(24)(3600)
= 39.8 Ib/sec
Particle Diameter D
p
= (150)(0.00003937) / (12)
= 0.000492 ft
CRe
2
= (0.95)x10
8

g
D
p
3
(
l
-
g
) /
2
= 4738
Drag Coefficient, C = 1.40
Terminal Velocity =
= 0.46 ft/sec
Gas Flow rate = m/
g
= 19.2 ft
3
/sec
' 3
) ( 4
C
gD
V
g
g l p
t

=
Example 1
Solution
Assume a diameter, D
v
= 3.5 ft
Vessel Length, L = 4Q
a
/ tV
t
D
v
= (4)(19.2)/(3.14)(0.46)(3.5)
= 15.2 ft
Varying diameters, appropriate lengths = Diameter, ft Length, ft
3.5 15.2
4 13.3
4.5 11.8
5 10.6
Example 2
What size vertical separator without mist extractor is required
to meet
the conditions in example 1
Solution
Area = Q / V
t
= 19.2/0.46
= 41.7 ft
2
D
v
= 7.29 ft (minimum)
= 90 ID selected
Separators with Wire Mesh Mist Extractors
Frequently used as entrainment separators for the removal of very
small liquid droplets ( less then 10 microns)
Horizontally located and perpendicular to gas flow
Should be within 0-30
o
flat
Sizing is conducted using the previous terminal velocity equations
for horizontal and vertical vessels ( K value also obtained from
same table)

Separators with Wire Mesh Mist Extractors

Separators with Wire Mesh Mist Extractors

Example 3
What size of vertical separator equipped with a wire mesh mist
extractor is required for conditions used in the previous examples
From table for K values: K = 0.31 ft/sec
07 . 2
) 07 . 2 2 . 31 (
31 . 0

= t V
sec
16 . 1
ft
Vt =
t V
Q
A =
16 . 1
2 . 19
= A
Separators with Wire Mesh Mist Extractors
A = 16.5 ft
2
Vessel ID = 60 in
ft Dv 59 . 4 =
Separators with Vane Type Mist Extractors
No draining back through rising gas stream
A downcomer is used to routes
liquid out to drain
Inertia forces liquid droplets
against the vane walls
Offer similar separation performance to wire mesh with the added
advantage of higher resistance to plugging and cane be easily
installed in smaller vessels
The dependence on inertial forces can be a disadvantage at reduced
production rates
Retention Time in Separators
Liquid retention time
Retention time is average time a liquid molecule is
retained in vessel
To ensure liquid and gas reach equilibrium so that gas
molecule can evolve from liquid phase
Retention time = Volume of liquid storage in vessel
Liquid flow rate
Usually 1 to 3 minutes
Retention Time in Separators
Oil/water retention time
Need certain amount of oil storage so that oil reaches
equilibrium, entrained gas liberated, and free water
coalesced to fall into water storage
Need certain amount of water storage for entrained large
droplets of oil have time to coalesce and rise to oil-water
interface
Retention time 3 30 minutes
Separators with Centrifugal Elements
Separation of solids and liquids from a gas stream
Advantage over filter separators is lesser maintenance
The disadvantage include :
Lower efficiency compared to other
separator designs
Higher pressure drops compared to mist
extractors
Narrow operating flow range to achieve
higher efficiencies
Filter Separators
Higher separation efficiency compared to centrifugal
separator
Periodic replacement of filter can be seen as a
disadvantage
Solid particles are filtered out and the liquid phase is
separated through coalecing small droplets
Body size estimates for a horizontal filter separator
uses a K value of 1.3
Units designed for water will be smaller than units sized
to remove light hydrocarbons
Filter Separators
Separators with Centrifugal Elements
Example 4
A filter separator is required to handle a flow of 60 MMscfd at the similar conditions
found in previous examples. Estimate the diameter of a filter separator
and
A = Q
A
/V
t
= 19.2/4.88
= 3.93 ft
2
D
v
= 2.2 ft
= 26.9 in. min.
Select a 30 ID separator
07 . 2
) 07 . 2 2 . 31 (
3 . 1

= t V
Liquid-Liquid Separators
Divided into 2 broad separation categories: gravity and coalescing
Horizontal and vertical separators share the same principles of
separation; horizontal separators have the advantage of a larger
surface area
2 factors affecting gravity separation in the liquid phase:
extra fine particles with random movement
electric charge from dissolved ions (repelling instead of
coalescing)
Separator sizing is based on Stokes Law
Liquid-Liquid Separators
Vertical vessels
Wcl flowrate of light condensate liquid (bbl/day)
Shl specific gravity of heavy liquid
Sll specific gravity of light liquid
Horizontal vessels
Ll - length of liquid interface area, ft
Hl width of liquid interface area, ft
For unknown droplet sizes liquid-liquid separator sizing
can be done through retention time,
U volume of settling section, bbl
W total liquid flow rate, bbl/day
2 *
) 785 . 0 (
) (
v
ll hl
cl D
S S
C W

=
l l
ll hl
cl H L
S S
C W ) 785 . 0 (
) (
*

=
1440
) (t W
U =
Liquid-Liquid Separators
Values of C*
Emulsion
Charactersitics
Droplet diameter
(microns)
C*
Free liquids 200 1100
Loose emulsion 150 619
Moderate emulsion 100 275
Tight emulsion 60 99
Liquid-Liquid Separators
Typical retention time for liquid-liquid separation
Type of Separation Retention time (min)
Hydrocarbon/water Separators
Above 35
o
API HC
Below 35
o
API HC
100
o
F and above
80
o
F
60
o
F
3-5
5-10
10-20
20-30
Ethylene Glycol/HC separators 20-60
Amine/HC separators 20-30
Coalescers, HC/Water separators
100
o
F and above
80
o
F
60
o
F
5-10
10-20
20-30
Caustic/Propane 30-40
Caustic/Heavy Gasoline 30-90
Separators with Centrifugal Elements
Example 5
Determine the size of a vertical separator to handle 600 bpd of 55
o
API condensate
and 50 bpd of produced water. Assume the water particle size is 200 microns.
Other operating conditions are as follows:
Operating temperature = 80 F
Operating pressure = 1000 psig
Water specific gravity = 1.01
Condensate viscosity = 0.55 cp @ 80 F
Condensate specific gravity for 55
o
API = 0.76
For 200 microns, C* = 1100
2 *
) 785 . 0 (
) (
v
ll hl
cl D
S S
C W

=
Separators with Centrifugal Elements
Example 5
Using manufacturers std size vessels might result in specifying a 20 OD
separator
2
) 785 . 0 (
55 . 0
) 76 . 0 01 . 1 (
1100 / 600 v D day bbl

=
ft Dv 24 . 1 =
Separators: Construction Aspects
Fabrication specifications:
governed by specific codes and standards
ASME pressure vessel code ( the most widely used: Div 1 and 2)
BS/EC
JIS
DIN
Separators: Construction Aspects
Vessel Shell Thickness
as specified by ASME VIII, Div 1 (sect UT-27)
P SE
PR
t
i
6 . 0
=
t - thickness
R
i
- internal radius of shell (exc. Corrosion allowance)
R
o
- external radius of shell
P - working pressure
S - maximum allowable stress
E - joint efficiency
Double Welded Butt Joint
Fully radiographed 1.0
Spot radiographed 0.85
No radiographed 0.70
Single Welded Butt Joint
Fully radiographed 0.9
Spot radiographed 0.80
No radiographed 0.65
P SE
PR
t
o
4 . 0 +
=
P SE
PR
t
i
2 . 0
=
Spheres:
Separators: Construction Aspects
Weight and Deck Area calculations
The weight of the internals (Wi) may be estimated from the following table:
dt Wb 15 =
Wb - mass per unit length (Ibm/ft)
d - internal diameter, in
t - wall thickness (inc. corrosion allowance), in
For skidded equipment the following factors have been
found satisfactory for preliminary estimates:
Piping, W
p
40% of W
v
Electrical and Instumentation, W
e
8% of W
v
Skid Steel, W
s
10% of W
v
Wskid = W
v
+ W
p
+ W
e
+ W
s
Separators: Construction Aspects
The total weight of the vessel can now be estimated using:
W
v
= W
b
L + W
I
+ W
N
Separators: Instrumentation and Controls
Split range level control
Level control with for pumping
Separators: Instrumentation and Controls
Liquid residence time and control