Professional Documents
Culture Documents
Abstract
The sizing procedures of all the process equipment in oil and gas industry share a common assumption:
the stream flowrate measured at the inlet is always constant or stable. This principle works fine for plants
where the process conditions are controlled, but it does not apply to primary production facilities where
the streams come from multiphase flowlines or wells. In a real horizontal gas-liquid separator, the inlet
stream flowrate is not constant and the liquid fraction fluctuates as a function of time. This fact must be
considered in the design procedure applied to these units.
The sizing procedure described here allows to size horizontal gas-liquid separators, considering
non-stable flowrate at the inlet, or fluctuations in the liquid fraction on the same stream. The method looks
for the best unit design to address these variations and also gets the smallest possible horizontal gas-liquid
separator.
The proposed method consists of two parts. The first one is solved by a dynamic multiphase flow
simulator which allows modeling the multiphase flow in the pipeline and predicting flowrate and liquid
fraction fluctuations at the separator inlet. In the second part, the horizontal separator sizing is solved
following a modified Svcek and Monnery (1993) method. It is adapted to take into account a non-stable
stream at the inlet, using the surge volume calculated by dynamic multiphase simulation. Other wellknown methods are also reviewed, such as Arnold (1986). Relationships between the Svcek and Monnery
approach and other methods are depicted.
The method is illustrated sizing a gas-light oil separator located in an offshore production facility where
the feed stream is identified as non-stable. This behavior is taken into account, and the effect in the vessel
volume is numerically evaluated. This approach allows obtaining the smallest separator volume based on
dynamic simulation results; as compared to the sizing based on overdesign rules.
The approach depicted here can be applied for sizing horizontal gas-liquid separators in which the
dynamic nature of the multiphase flow must be taken into account and the smallest possible volume is
desired.
SPE-169444-MS
Background
The sizing of separators is a common task on production facilities design. There are several procedures published in the literature to size tanks [2, 3,
5, and 6]. All of them share the same basic principle: stream flowing to the separator is stable. This
assumption should be correct for equipment to be
Figure 2Forces over a liquid drop
installed in process plants, but for primary separators where the processed stream comes from wells
or multiphase flowlines, this assumption cannot be
applied. Multiphase streams exhibit a nonstable behavior due to terrain or hydrodynamic slugging. For
design purposes, the separator is split in three stages (or sections) [5]:
Primary stage. This is a mechanical operation; it uses an inlet diverter so that the momentum of
the liquid in the gas causes the largest droplets to impinge on the diverter, forming droplets which
are separated by gravity. The gas stream flows to the disengagement section.
Secondary stage. Liquid drops immersed in the gas stream are separated by gravity. This
separation is governed by the settling liquid drop velocity inside the gas phase. This velocity must
be higher than gas stream velocity to allow the drop settle to the liquid phase.
Tertiary Stage. It occurs on the mist eliminator. This is a device that allows small size droplets
coalesce to larger drops, which fall down by gravity to the liquid phase.
These design stages or sections are shown in Figure 1.
Primary stage design is based on a simple volumetric balance, following some well-known rules (to be
described below). The most important parameter to design the secondary stage is to obtain the settling
drop velocity inside the gas stream. This velocity can be calculated performing a balance around each
liquid droplet. This balance takes into account two factors, the gravity and the drag forces applied by the
gas stream. Figure 2 depicts both forces; FG and FD are gravity and drag components, respectively. Liquid
droplets settling at a constant velocity known as terminal velocity, calculated by Equation 3
Equation 1
If UV UT liquid droplets will settle. As a thumb rule, the allowable vertical velocity has a value
between 0.75 UT and UT. Equation 3 can be rewritten as Sauders and Brown suggested [5].
SPE-169444-MS
Equation 2
Where
Equation 3
K is the terminal velocity constant. For practical reasons, very small droplets cannot be separated only
by gravity. Coalescent devices are used (mist eliminators) to force this separation. This constant, K, is not
easily predicted theoretically, empirical correlations are preferred. There are several published papers
depicting procedures to obtain K [1, 3 and 6], but many of them should be applied to separators in process
plants not in primary oil-gas facilities.
Where Dp is in feet, in lb/ft3 and in cP. Usually the drop diameter is given in microns (1 micron
3.28084 10-6 ft). A well-known sizing procedure was proposed by Arnold [2]. This approach is limited
to separators with a normal level equivalent to 50% of total vessel volume. An alternative procedure to
calculate the terminal velocity constant is proposed by this author. The terminal velocity constant is
calculated using curves shown in Figure 3. Constant gas viscosity and 100-micron droplets are assumed.
To avoid this graphical step, Equation 7 is proposed to calculate this constant[4].
Equation 5
Where
Equation 6
SPE-169444-MS
Time (min)
Above 34 API
Between 20 and 30 API
Between 10 y 20 API
1
1.0 2.0
2.0 4.0
S is the relative gas density, P, the pressure in psia, API is oil density and T the temperature in Rankine.
K is calculated using Equation 7. Arnolds constant is a separator parameter, not a Sauders-Brown
constant. To convert Arnolds K to K, the following relationship is proposed [4].
Equation 7
SPE-169444-MS
P (psig)
L/D
D (ft)
LLL (in)
0.0 250.0
250.0 500.0
500.0
1.53.0
3.04.0
4.06.0
4.0
6.0
8.0
10.0
12.0
16.0
9.0
10.0
11.0
12.0
13.0
15.0
Equation 8
Where VSurge is the surge volume, , liquid accumulation measured at a fixed position (typically
flowline outlet), and Qdrain is the constant outlet separator drain rate. Surge volume can be estimated based
on simulation results using an Excel spreadsheet. Optionally, this value can be calculated directly by some
codes. Surge volume usually is reported in curves as shown in Figure 4. Surge volumes make sense for
drain flowrates higher than the average liquid flowrate measured at flowline outlet.
SPE-169444-MS
Conversionh/Da/A
Y a/A, X h/D
a 4.75593010-5
b 3.924091
c 0.174875
d 6.358805
e 5.668973
f 4.018448
g 4.916411
h 1.801705
i 0.145348
Conversion a/A h/D
Y h/D, X a/A
a 0.00153756
b 26.787101
c 3.299201
d 22.923932
e 24.353518
f 14.844824
g 36.999376
h 10.529572
i 9.892851
Heads
Thickness
Shell
Elliptical heads, 2:1
Hemispheric heads
Dished heads
Surface area
Shell
Elliptical heads, 2:1
Hemispheric heads
Dished heads
DL
1.090D2
1.571D2
0.842D2
Equation 13
5. Calculate the surge volume, based on dynamic simulation results (Equation 8).
6. Obtain an estimate of separator diameter.
Equation 14
Table 2 shows typical values for L/D relationship to horizontal separators, as a function of
operating pressure.
Round to the nearest 6 inches. Calculate the cross-sectional area.
Equation 15
7. Calculate the minimum liquid level, based on Table 3.
Alternatively, Equation 17 can be used.
Equation 16
Where D is in feet and round to the nearest inch. If D 4.0 ft, HLLL 9 in.
8. Based on HLLL/D calculateALLL/D using Table 4.
9. CalculateHV. If there is no mist eliminator, the minimum height of the vapor disengagement area
(AV) is the larger of 0.2D and 1.0 ft. If there is mist eliminator the minimum height of HV is the
larger 0.2 D and 2.0 ft. CalculateAV based on HV.
10. Calculate the minimum length to contain holdup and surge volumes.
Equation 17
11. Calculate the dropout time.
SPE-169444-MS
79
59
20
18,000
17.7
0
175
53.2
9.0
Equation 18
12. Calculate the actual gas velocity.
Equation 19
13. Calculate the minimum required length to gas-liquid disengagement section.
Equation 20
14. IfLLMIN, then L LMIN. Gas liquid separation is the controlling parameter, this result in some
extra holdup volume.
If LMINL, the increase HV and repeat from step 9.
If LLMIN, the design is acceptable.
If LLMIN, holdup is controlling the design, L can only be decreased and LMIN increased ifHV
is decreased. HV may only be decreased if it is greater than the minimum depicted in step 9.
Calculations would be repeated from the step 9 with reduced HV.
Calculate L/D. If L/D6.0, increase D and repeat from step 6. If L/D1.5, decrease D and repeat
from step 6.
15. Calculate shell and heads thickness. Select heads type according to Table 5.
Calculate wall thickness according to Table 6.
P is the design pressure, in psig (typically 10 to 15 % above the operating pressure). D is the
diameter in inches, S the material stress in psi, E weld efficiency (typically 0.85) and y tC in the
allowable corrosion, in inches. Wall thickness must be rounded to the nearest commercial
thickness. Calculate head and shell surface according to Table 7.
16. Calculate the approximate vessel weight.
SPE-169444-MS
1.0
1.2
1.4
0.00
8.56
0.90
0.66
Equation 21
Where AS and AH are shell and head areas respectively.
17. Increment and decrease the diameter in 6 inches, repeat the calculation until L/D has ranged
between 1.5 and 6.0.
18. With the optimum design (minimum weight) calculate normal and high liquid level.
SPE-169444-MS
Length
(ft)
Diameter,
(ft)
Vessel volume
(ft3)
1
2
3
4
20
28
23
22
4.5
5.5
4.5
4.5
318.1
665.2
365.8
349.9
52.2
13.0
9.1
Equation 22
Equation 23
Calculate ANLL based on HNLL.
Separator dimensions are shown in Figure 5 and Figure 6. This procedure was coded in an Excel
spreadsheet; it is available contacting the authors.
Case study
The procedure depicted here was used to size a separator for an oil field located in the Gulf of Mexico.
Table 8 shows some general input data [4].
Figure 7 shows a schematic diagram of this flowline. Separator is located at flowline outlet.
Conclusions
A procedure to size gas-liquid separators, based on Svcek and Monnery approach, is depicted in this
paper. This modified procedure is adapted to size separators handling nonstable multiphase streams. This
procedure, replaces the original Svcek and Monnerys definitions of separator holdup and surge volumes,
by other characteristic parameters related to slugging. Surge volume is calculated using a dynamic
multiphase code, standard steady state tools cannot predict nonstable. Surge volume is a function of the
separator liquid drain rate.
10
SPE-169444-MS
The procedure was applied to size a separator for a field located in Gulf of Mexico. If the slugging
effect is included in the sizing routine, an additional volume is required to catch and damp the slugs
generated in the flowline. In the studied case, if the drain rate is equal to the average total liquid flowrate,
the separator requires around of 52% extra volume. This additional volume decreases if the drain rate
increases. Vessel volume increases 13 and 9% if a drain rate 1.2 and 1.4 times the average total liquid
flowrate are used.
Nomenclature
Drag coefficient
CD
D
Diameter
Drop diameter
DP
E
Weld efficiency
F
Force
g
Gravity
G
Gas-oil relationship
GOR
H
Height
Vertical separator distance
Hv
h
Liquid level
j
Time step
K
Terminal velocity constant
K
Separator constant
L
Length
L
Liquid phase
P
Pressure
Qdrain Separator drain flowrate
S
Gas relative density
S
Gas relative density
S
Maximum allowed stress
T
Temperature
Residence time
TH
T
Time, thickness
Allowed corrosion
tc
U
Velocity
Terminal Velocity
Ut
Allowable vertical velocity
UV
V
Volume, vapor section on sizing procedure
VSurge Surge volume
W
Mass flowrate, total vessel weight
Dropout time
G
Gas viscosity
G
Gas density
V
Vapor density
References
1 API, Specification for oil gas separators, API specification 12J, October 1989.
2 Arnold, K, M. Steward, Surface production operations, Gulf Publishing Co., 1986
SPE-169444-MS
11
3 Gerunda, Arthur, How to size liquid-vapor separators, Chemical Engineering, May 1981.
4 Hernndez, Jos Luis, Dimensionamiento de separadores para lneas multifsicas con transporte
de flujo inestable empleando resultados de simulacin dinmica (in Spanish). Thesis, ESIA, IPN,
Mexico 2009.
5 Svcek, W, W, Monnery, Design two-phase separators within the right limits, Chemical Engineering Progress, October 1993.
6 Watkins, R. N., Sizing separators and accumulators, Hydrocarbon Processing, November 1967