Separator Sizing Spreadsheet

INDEX:
1
2
3
4
5
5A
5B
5C
5D
6
6A
6B
6C
6D
Discussion
Nomenclature
References
Standard Separator Sizes as per API
Separator sizing with mist extractor
Two Phase (Gas - Oil) Vertical Separator as per API 12J
Two Phase (Gas - Oil) Horizontal Separator as per API 12J
Three Phase (Gas - Oil - Water) Vertical Separator as per API 12J
Three Phase (Gas - Oil - Water) Horizontal Separator as per API 12J
Separator sizing without mist extractor
Two Phase (Gas - Oil) Vertical Separator As per Petroleum and Gas Field Processing
Two Phase (Gas - Oil) Horizontal Separator as per Petroleum and Gas Field Processing
Three Phase (Gas - Oil - Water) Vertical Separator as per Petroleum and Gas Field Processing
Three Phase (Gas - Oil - Water) Horizontal Separator as per Petroleum and Gas Field Processing
Prepared by:
Ajay S. Satpute
Sr. Process Engineer
Ramboll Consulting Engineering, Qatar
DISCUSSION
This spreadsheet provides an easy and simple approach to (2/3 phase and vertical/horizontal) separat
Formulae and references are also provided for process engineers to edit/duplicate this work (file is NO
password protected).
There is as much art as there is science to properly design a separator. Three main factors should be
considered in separator sizing:
1) vapor capacity, 2) Liquid capacity, and 3) operability.
The vapor capacity will determine the cross-sectional area necessary for gravitational forces t
the liquid from the vapor.
The liquid capacity is typically set by determining the volume required to provide adequate residence
de-gas the liquid or allow immiscible liquid phases to separate.
Operability issues includ
separators ability to deal with solids if present, unsteady flow/liquid slugs, turndown, etc. Finally, the
design will usually result in an aspect ratio that satisfies these requirements in a vessel of reasonable
These factors often result in an iterative approach to the calculations.
Two sets of calculations are carried out here.

1. Separators with Mist Extractors and
2. Separators without Mist Extractors
Several useful guidelines for separator design are provided below;
Momentum & Velocity criteria for nozzles (Source: DEP 31.22.05.12 - Gen.- 2008)
Inlet Nozzle
No Internal
Half open pipe
Schoepentoeter used as inlet device
Gas outlet Nozzle
Liquid outlet Nozzle
Selection guideline for separator types
System Characteristics
Large vapour, less liquid Load (by volume)
Large liquid, less vapour Load (by volume)
Large vapour, large liquid Load (by volume)
Liquid-liquid separation
Liquid-solid separation
Level setting in the separator
Level type
Level Alarm High High (LAHH)

Level Alarm High (LAH)
Normal Alarm Level (NAL)
Level Alarm Low (LAL)
Level Alarm Low Low (LALL)

Typical K factors for the sizing of wire mesh demisters (Source: IPS-E-PR-880, 1997)
Separator type
Horizontal (with vertical pad)
Spherical
Vertical or horizontal (with horizontal pad)
At atmospheric pressure
At 2100 kPa
At 4100 kPa
At 6200 kPa
At 10300 kPa
Wet steam
Most vapours under vacuum
Salt and caustic evaporators
INDEX
mple approach to (2/3 phase and vertical/horizontal) separator sizing.

d for process engineers to edit/duplicate this work (file is NOT
o properly design a separator. Three main factors should be
ity, and 3) operability.

e the cross-sectional area necessary for gravitational forces to remove
rmining the volume required to provide adequate residence time to

uid phases to separate.
Operability issues include the
esent, unsteady flow/liquid slugs, turndown, etc. Finally, the optimal
o that satisfies these requirements in a vessel of reasonable cost.
pproach to the calculations.
re.
nd
tractors
sign are provided below;

zzles (Source: DEP 31.22.05.12 - Gen.- 2008)
Momentum or Velocity Limit
Max. Momentum, m V2m 1400 Pa
Max. Momentum, g V2g,out 4500 Pa
Maximum velocity, 1 m/s
es
Type of Separator
Vertical
Horizontal
Horizontal
Horizontal
Vertical
Level setting
30 60 seconds or 200 mm whichever is greater

60% of horizontal separator
30 60 seconds or 200 mm whichever is greater Should be
at least 200 mm above the vessel bottom or maximum
interface level
e mesh demisters (Source: IPS-E-PR-880, 1997)

K factor (m/s)
0.122 to 0.152
0.061 to 0.107
0.055 to 0.107
0.107
0.101
0.091
0.082
0.064
0.076
0.061
0.046
NOMENCLATURE
A
Aw
total cross sectional area of the separator.
Ao
cross sectional area of the separator occupied by oil, ft 2
Ag
cross sectional area of the separator occupied by gas, ft 2
CD
D
h
hg
drag coefficient
vessel internal diameter, in.
bubble or drop diameter, m
vessel diameter, ft
liquid height, in.
gas-phase space height, in.
ho
oil pad height, in.
hw
K
Leff or L
water pad height, in.

mesh capacity factor, ft/sec
effective length of the vessel where separation occurs, ft
Lss or Ls
seam-to-seam vessel length, ft
NLL
P
Qc
normal liquid level, %

operating pressure, psia
continuous liquid-phase flow rate, bbl/day
Qg
gas flow rate, MMSCFD or ft3/s
Qo
oil flow rate, bbl/day
W or Qw
water flow rate, bbl/day

Reynolds number
operating temperature, R
liquid settling volume
max. allowable velocity through secondary separation section
d
dm
Re
T
V
Va
Vm
cross sectional area of the separator occupied by water, ft 2
Z
c
velocity of the mixture, m/s

gas compressibility
continuous phase dynamic viscosity, cp
water dynamic viscosity, cP
density, lbm/ft3
liquid density, lbm/ft3
oil density, lbm/ft3
mean density of mixture, kg/m3
water density, lbm/ft3
gas density, lbm/ft3
INDEX
REFERENCES
http://en.citizendium.org/wiki/Vapor-liquid_separator
API 12J, Specification for oil and gas separators, 1989
http://petrowiki.org/Separator_sizing
http://www.cheresources.com/invision/topic/11856-selecting-vertical-separator-ld-ratio/
Petroleum and Gas Field Processing - Hussein K. Abdel-Aal, Mohamed Aggour, 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&ots=u979BoWCxd&sig=p13fCbqS52y7bE3eGRDtfj7nGq0&hl=en&sa=X&ei=s9dMVJH
http://www.cheresources.com/invision/topic/17158-three-phase-separator-design-suggestion-needed/
wO4tIK4BQ&redir_esc=y#v=onepage&q=%22three%20phase%22%20separator%20L%2FD%20ratio
%20%22GPSA%22&f=false
http://en.citizendium.org/wiki/Vapor-liquid_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/41-sizing-a-flash-tank-or-vapor-liquid-separator/
http://www.eng-tips.com/faqs.cfm?fid=1153
http://process-designs.com/
http://www.razifar.com/cariboost_files/Design_20Two_20Phase_20Separators_20Within_20the_20Right
s.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+separator&source=bl&ots=fV8ewKHkag&sig=q70X8xfxPnk9MBMHgaEFwLhIhU&hl=en&sa=X&ei=M-NVVPepM4XWPfaLgYAI&redir_esc=y#v=onepage&q=
IPS-E-PR-880, 1997
%20%3D%201.25%20Kv%20separator&f=false
GPSA - Engineering Data Book (12th Ed)
tor-ld-ratio/
r, M. A. Fahim
7&dq=%22three+phase
&hl=en&sa=X&ei=s9dMVJHiHKvcy
esign-suggestion-needed/
rator%20L%2FD%20ratio
iquid-separator/
_20Within_20the_20Right_20Limit
9&dq=Kh+
ir_esc=y#v=onepage&q=Kh
INDEX
STANDARD SEPARATOR SIZES AS PER API INDEX

D [in] x H or L [ft]
12 in x 5 ft
12 in x 7 ft
12 in x 10 ft
16 in x 5 ft
16 in x 7 ft
16 in x 10 ft
20 in x 5 ft
20 in x 7 ft
20 in x 10 ft
24 in x 5 ft
24 in x 7 ft
24 in x 10 ft
30 in x 5 ft
30 in x 7 ft
30 in x 10 ft
36 in x 5 ft
36 in x 7 ft
36 in x 10 ft
36 in x 15 ft
42 in x 7 ft
42 in x 10 ft
42 in x 15 ft
48 in x 7 ft
48 in x 10 ft
48 in x 15 ft
54 in x 7 ft
54 in x 10 ft
54 in x 15 ft
60 in x 7 ft
60 in x 10 ft
60 in x 15 ft
Two Phase (Gas - Oil) Vertical separator: As per API 12J
Qo
'o
o
P
T'
T
MW
t
Z
g
H
K
NLL
3000 bbl/d
0.70
40 oAPI
Gas rate
Oil rate
Gas specific gravity
Oil density
0.83
814.5 psia
80 oF
Oil specific gravity

Operating pressure
Operating temperature
540
20.3
1
0.84
0.013
10
0.30
30%
Molecular weight
Retention time (Refer Table 2)
Gas compressibility
Gas viscosity
Shell height (assume)
Refer Table 1
Normal liquid level (assume)
R
lb/lbmole
minutes
o
cP
ft
ft/s
CALCULATIONS
Step 1:
Determine gas and oil properties
g
3.4 lb/ft3
Gas operating density
o
51.5 lb/ft3
Yellow boxes are input boxes.
INPUT PARAMETERS
Qg
25 mmscfd
SCHEMATIC
EQUATIONS
TABLES
Table 1
Oil operating density
Height, ft
Souders-Brown equation
5
10
Step 2:
Va
1.13 ft/s
Qg,a
4.55 ft3/s
Actual volume flow of gas
Ag,min
4.03 ft2
Minimum gas flow area
Oil Gravities
Minimum ID of separator
Above 35 oAPI
Dmin
27 in
Table 2
20 to 30 oAPI
Dselected
30 in
10 ft
4.0 unitless
Next larger and appropriate size

Shell height
Refer Note 4
2.6 bbl
Liquid volume (excluding bottom head)
3777 bpd
Liquid capacity of separator should be

more than 3000 bpd (input value)
H
H/D
10 to 20 oAPI
Step 3:
Manipulate NLL and H to get

appropriate W.
NOTES
1. The maximum allowable superficial velocity calculated from the above factors is for separators normally having a wire mesh mist extracto
rate should allow all liquid droplets larger than 10 microns to settle out of gas.
2. Additional resource for K factor from GPSA Engineering Data Book:
Pressure, barg
K factor, m/s
Adjustment of K factor for pressure
0
0.11
Pressure, psig
% of Design value
7
0.11
Atm.
100
21
0.10
150
90
42
0.09
300
85
63
0.08
600
80
105
0.07
1150
75
GPSA Notes:
1. K = 0.107 at a gauge pressure of 7 bar. Subtract 0.003 for every 7 bar above a gauge pressure of 7 bar.
2. For glycol or amine solutions, multiply above K values by 0.6 - 0.8.
3. Typically use one-half of the above K values for approximate sizing of vertical separators without mesh pads.
4. For compressor suction scrubbers and expander inlet separators, multiply K by 0.7 - 0.8.
3. Additional resource for retention times from gas Conditioning and Processing, Volume 2.
Natural gas-oil
1 to 3 minutes
Lean oil surge tanks
10 to 15 minutes
Fractionation feed surge tanks
8 to 15 minutes
Refrigerant surge tanks
4 to 7 minutes
Refrigerant econonomizers
2 to 3 minutes
4. As per GPSA, typical vertical H/D ratios are normally in the 2 to 4 range.
INDEX
1
Typical K factor
range
0.12 to 0.24
0.18 to 0.35
2
Retention time,
minutes (Typical)
1
1 to 2
2 to 4
e mesh mist extractor. This
Two Phase (Gas - Oil) Horizontal Separator: As per API 12J
Qo
'o
o
P
T'
T
MW
t
Z
g
K
NLL
L
3000 bbl/d
0.70
40 oAPI
SCHEMATIC
Gas rate
Oil rate
Oil density
0.83
814.5 psia
80 oF

Operating pressure
540
20.3
1
0.84
0.012
0.5
30%
10
Molecular weight
Gas compressibility
Gas viscosity
Refer Table 1
Shell Length (assume)
R
lb/lbmole
minutes
o
cP
ft/s
ft
CALCULATIONS
Step 1:
g
3.4 lb/ft3
o
Step 2:
Va
51.5 lb/ft3
INPUT PARAMETERS
Qg
25 mmscfd
EQUATIONS
TABLES
Table 1
Length, ft
10
Other Lengths
1.881 ft/s
Qg,a
4.55 ft3/s
Ag,min
2.42 ft2
Oil Gravities
Assume
Above 35 oAPI
Dmin
4 in
Table 2
Ag,min
2.42 ft2
20 to 30 oAPI
Error
Dselected
0.00
10 to 20 oAPI
L
L/D
30 in
10 ft
4.0 unitless
Next larger and appropriate size

Shell length
Refer Note 4
Step 3:
V
W
3 bbl
3644 bpd

Manipulate NLL and L to get

appropriate W.
NOTES
1. The maximum allowable superficial velocity calculated from the above factors is for separators normally having a wire mesh mist extracto
Pressure, barg
K factor, m/s
0
0.11
Pressure, psig
% of Design value
7
0.11
Atm.
100
21
0.10
150
90
42
0.09
300
85
63
0.08
600
80
105
0.07
1150
75
GPSA Notes:
2. For glycol or amine solutions, multiply above K values by 0.6 - 0.8.
3. For compressor suction scrubbers and expander inlet separators, multiply K by 0.7 - 0.8.
3. Additional resource for retention times from gas Conditioning and Processing, Volume2.
Natural gas-oil
1 to 3 minutes
10 to 15 minutes
8 to 15 minutes
4 to 7 minutes
2 to 3 minutes
4. As per GPSA, typical horizontal L/D ratios are normally in the 2.5 to 5 range.
INDEX
12J
1
Typical K factor
range, ft/s
0.4 to 0.5
0.4 to 0.5 x (L/10)0.56
2
Retention time,
minutes (Typical)
1
1 to 2
2 to 4
wire mesh mist extractor. This
Three Phase (Gas - Oil - Water) Horizontal Separator: As per API 12J
Gas rate
Qo
8000 bbl/d
Oil rate
Qw
3000 bbl/d
0.70
40 oAPI
Water rate
Oil density
'o
o
P
T'
0.83
250 psia
60 oF

Operating pressure
T
MW
H
to
520
20.3
18
5
Molecular weight
Shell height (assume)
Oil retention time (Refer Table 2)
tw
Z
g
K
NLL
R
lb/lbmole
ft
minutes
o
5 minutes
0.84
0.013 cP
0.35 ft/s
50%
Water retention time (Refer Table 2)

Gas compressibility
Gas viscosity
Refer Table 1
CALCULATIONS
Step 1:
g
1.1 lb/ft3
o
Step 2:
Va
51.5 lb/ft3
SCHEMATIC
INPUT PARAMETERS
Qg
8 mmscfd
EQUATIONS
TABLES
Table 1
Height, ft
5
10
2.4 ft/s
Qg,a
4.58 ft3/s
Ag,min
1.92 ft2
Oil Gravities
Table 2
Dmin
19 in
Assume
Above 35 oAPI
Dselected
96 in
Next larger (than Dmin) and

appropriate size
Below 35 oAPI
18 ft
Shell height
H/D
2.3 unitless
100+ oF
Refer Note 4
80+ oF
60+ oF
Step 3:
V
W
81 bbl
11602 bpd

Manipulate NLL, D and H to

get appropriate W.
NOTES
1. The maximum allowable superficial velocity calculated from the above factors is for separators normally having a wire mesh mist extract
Pressure, barg
K factor, m/s
0
0.11
Pressure, psig
% of Design value
7
0.11
Atm.
100
21
0.10
150
90
42
0.09
300
85
63
0.08
600
80
105
0.07
1150
75
GPSA Notes:
2. For glycol or amine solutions, multiply above K values by 0.6 - 0.8
3. Typically use one-half of the above K values for approximate sizing of vertical separators without mesh pads
4. For compressor suction scrubbers and expander inlet separators, multiply K by 0.7 - 0.8
Natural gas-oil
1 to 3 minutes
10 to 15 minutes
8 to 15 minutes

4 to 7 minutes
2 to 3 minutes
4. As per GPSA, typical horizontal H/D ratios are normally in the 2 to 4 range.
INDEX
r API 12J
1
Typical K factor
range, ft/s
0.12 to 0.24
0.18 to 0.35
2
Retention time,
minutes (Typical)
3 to 5
5 to 10
10 to 20
20 to 30
wire mesh mist extractor. This
Three Phase (Gas - Oil) Horizontal Separator: As per API 12J

Gas rate
Qo
8000 bbl/d
Oil rate
Qw
3000 bbl/d
0.70
40 oAPI
Water rate
Oil density
'o
o
P
T'
0.83
250 psia
60 oF

Operating pressure
T
MW
L
to
520
20.3
18
5
Molecular weight
Shell Length (assume)
tw
Z
g
K
NLL
R
lb/lbmole
ft
minutes
o
5 minutes
0.84
0.013 cP
0.35 ft/s
50%

Gas compressibility
Gas viscosity
Refer Table 1
CALCULATIONS
Step 1:
g
1.1 lb/ft3
o
Step 2:
Va
51.5 lb/ft3
SCHEMATIC
INPUT PARAMETERS
Qg
8 mmscfd
EQUATIONS
TABLES
Table 1
Length, ft
10
Other Lengths
2.388 ft/s
Qg,a
4.58 ft3/s
Ag,min
1.92 ft2
Oil Gravities
Dmin
2.4 in
Assume
Above 35 oAPI
Ag,min
1.92 ft2
Error
0.00
Dselected
L
L/D
78 in
Table 2
Below 35 oAPI
100+ oF
Next larger (than Dmin) and
appropriate size
80+ oF
18 ft
Shell length
2.8 unitless Refer Note 4
60+ oF
Step 3:
V
W
77 bbl
11036 bpd

Manipulate NLL, D and L to

get appropriate W.
NOTES
1. The maximum allowable superficial velocity calculated from the above factors is for separators normally having a wire mesh mist extract
Pressure, barg
K factor, m/s
0
0.11
Pressure, psig
% of Design value
7
0.11
Atm.
100
21
0.10
150
90
42
0.09
300
85
63
0.08
600
80
105
0.07
1150
75
GPSA Notes:
2. For glycol or amine solutions, multiply above K values by 0.6 - 0.8
3. For compressor suction scrubbers and expander inlet separators, multiply K by 0.7 - 0.8
Natural gas-oil
1 to 3 minutes
10 to 15 minutes

4. As per GPSA, typical horizontal L/D ratios are
8 to 15 minutes
4 to 7 minutes
2 to 3 minutes
normally in the 2.5 to 5 range.
INDEX
PI 12J
1
Typical K factor
range, ft/s
0.4 to 0.5
0.4 to 0.5 x (L/10)0.56
2
Retention time,
minutes (Typical)
3 to 5
5 to 10
10 to 20
20 to 30
a wire mesh mist extractor. This
Two Phase (Gas - Oil) Vertical Separator: As per "Petro

Processing - Hussein K. Abdel-Aal, Mohamed Aggo
INPUT PARAMETERS
Qg
15 mmscfd
Qo
3000 bbl/d
'o
o
0.6
35.0 oAPI
0.85
985 psia
T'
60 oF
T
t
Z
g
dm
520 oR
3 minutes
0.84
0.013 cP
100 Micron
Gas rate
Oil rate
Oil density
Operating pressure
Gas compressibility
Gas viscosity
Smallest oil droplet size to be removed
CALCULATIONS
Step 1:
g
3.7 lb/ft3
o
Step 2:
Cd
u
Re
Cd
Error
Step 3:
D2
Dmin
Step 4:
DH
2
53.0 lb/ft3
Determine Cd
1.13 Assume
0.41 ft/s
56
Drag coefficient
Settling velocity of oil droplet
Reynolds no.
1.16
0.00
Click me
Use goal seek to get error zero, by changing

asssumed Cd
Check for gas capacity constraint

974 in2
31.2 in
Minimum allowable vessel diameter for separation

of oil droplets down to 100 micron
Check for liquid capacity constraint

77085
Try different combinations of D.

TABLE 1
H = Height of oil column
H = Height of oil column
D, in
Ls
SR
D
Ls, ft
H, in
SR
30
36
42
48
54
60
85.7
59.5
43.7
33.5
26.4
21.4
13.5
11.3
10.5
10.1
10.0
10.1
5.4
3.8
3.0
2.5
2.2
2.0
66
17.7
10.3
1.9
72
14.9
10.6
1.8
78
84
90
12.7
10.9
9.5
10.9
11.2
11.6
1.7
1.6
1.6
11.3 ft
3.8
36.0 in
Seam to seam length (select from Table 1)

Slenderness ratio (typical value 3 to 4) (select from Table 1)
Separator diameter (select from Table 1)
NOTES
INDEX
As per "Petroleum and Gas Field

hamed Aggour, M. A. Fahim"
Yellow boxes are input

boxes.
SCHEMATIC
EQUATIONS
TABLE 2 (Ref. API 12J)

Retention time,
Oil Gravities
minutes (Typical)
Above 35 oAPI
1
e 1)
ect from Table 1)
1)
20 to 30 oAPI
1 to 2
10 to 20 oAPI
2 to 4
Two Phase (Gas - Oil) Horizontal Separator: As per "Petroleum and Gas Field Process
- Hussein K. Abdel-Aal, Mohamed Aggour, M. A. Fahim"
'o
0.6
35.0 oAPI
o
P
0.85
985 psia
T'
60 oF
T
t
Z
g
0.013 cP
100 Micron
NLL
Oil rate
Oil density
Operating pressure
520 oR
3 minutes
0.84
dm
Gas rate
INPUT PARAMETERS
Qg
15 mmscfd
Qo
3000 bbl/d
Gas compressibility
Gas viscosity
Normal Liquid Level
50%
CALCULATIONS
Step 1:
g
3.7 lb/ft3
o
SCHEMATIC
EQUATIONS
53.0 lb/ft3
Determine Cd
Step 2:
Cd
1.2 Assume
0.40 ft/s
55
1.19
u
Re
Cd
Error
0.00
Click
Click me
me
Drag coefficient
Reynolds no.
asssumed Cd
Step 3:
LD

83 in.ft
Step 4:
D2L
12852 in2.ft

TABLE 1
Lg, ft
D, in
Ls
SR
Ls, ft
(gas)
Lo, ft
Ls, ft (oil)
SR = 12
Governing ls (oil or
case
gas)/D
13.85
14.35
357.00
Liquid
476.0 Capacity
952.00
12
6.93
7.93
89.25
Liquid
119.0 Capacity
119.00
24
3.46
5.46
22.31
Liquid
29.8 Capacity
14.88
30
2.77
5.27
14.28
Liquid
19.0 Capacity
7.62
36
2.31
5.31
9.92
Liquid
12.4 Capacity
4.14
42
1.98
5.48
7.29
Liquid
9.8 Capacity
2.80
48
1.73
5.73
5.58
Liquid
8.1 Capacity
2.02
54
1.54
6.04
4.41
Liquid
6.9 Capacity
1.53
60
1.39
6.39
3.57
Gas
6.1 capacity
1.28
66
1.26
6.76
2.95
Gas
5.5 capacity
1.23
72
1.15
7.15
2.48
Gas
5.0 capacity
1.19
12.4
4.1
ft

Oil Gravities
Above 35 oAPI
20 to 30 oAPI
10 to 20 oAPI

36
in
NOTES
2. If D>30", Ls = 2.5 + Lo;
Else, Ls = (4/3)*Lo
Ref. http://process-designs.com/separators_and_scrubbers/separators_and_scrubbers.jsp
INDEX
as Field Processing
m"
I 12J)
Retention time,
minutes (Typical)
1
1 to 2
2 to 4
Three Phase (Gas - Oil - Water) Vertical Separator: As per "Petroleum and Gas Fi
Processing - Hussein K. Abdel-Aal, Mohamed Aggour, M. A. Fahim"
Gas rate
Oil rate
Water rate
'o
27.6 oAPI
Oil density
o
o
0.89
Z
P
1.04
0.65
0.89
250 psia
T'
95 oF
Oil viscosity
20 cP
T
tw
to
Water specific gravity

Gas compressibility
Operating pressure
555 oR
10 minutes
15 minutes
0.013 cP
Gas viscosity
dm,w
500 Micron
Smallest water droplet size to be removed
dm,o
100 Micron
CALCULATIONS
Step 1:
g
0.89 lb/ft3
o
SCHEMATIC
INPUT PARAMETERS
Qg
8 mmscfd
Qo
8000 bbl/d
Qw
3000 bbl/d
EQUATIONS
55.5 lb/ft3
Determine Cd
Step 2:
Cd
2.07 Assume
0.65 ft/s
22
2.09
0.00 Click me
u
Re
Cd
Error
Step 3:
D2min
Drag coefficient
Reynolds no.
asssumed Cd
Determine minimum diameter for water droplet settling

28428 in2
Dmin
168.6 in
Step 4:
D2min

1475 in2
Dmin
38.4 in
Dmin
168.6 in
Larger of Step 2 and 3 values
Step 5:
D2(Ho + Hw)
1286400 in3
TABLE 1
Ls
SR = 12 Ls
/D
Ho + Hw, in Ls, ft
D, in

Oil Gravities
Retention time, mi
(Typical)
3 to 5
16
5025
425.1
318.8
Above 35 oAPI
20
3216
274.3
164.6
Below 35 oAPI
24
2233
192.4
96.2
30
1429
125.4
50.2
80+ oF 10 to 20
36
42
48
54
60
120
132
993
729
558
441
357
89
74
89.0
67.6
53.9
44.6
38.1
20.8
20.5
29.7
19.3
13.5
9.9
7.6
2.1
1.9
60+ oF 20 to 30
20.8 ft
Seam to seam length (select from table 1)
100+ oF 5 to 10
SR
D
Qg
2.1
120.0 in
86 mmscfd
Slenderness ratio (typical value 1.5 to 3) (select from Table 1)

Calculated gas capacity for selected L & D (Should be more than 8 MMSCFD - input value)
NOTES
m and Gas Field

Fahim"
etention time, minutes

Typical)
to 5
to 10
0 to 20
0 to 30
INDEX
t value)
INPUT PARAMETERS
Qg
8 mmscfd
Gas rate
Qo
8000 bbl/d
Oil rate
Qw
3000 bbl/d
Water rate
'o
27.5 API
Oil density
0.89
20 cP
1.04
0.65
0.89
250 psia
95 oF
Z
P
T'
T
tw
to
g
555
10
15
0.013
Oil viscosity
Water specific gravity
Gas compressibility
Operating pressure
R
minutes
minutes
cP
o
Gas viscosity
dm,w
500 Micron
Smallest water droplet size to be removed
dm,o
100 Micron
NLL
Three Phase (Gas - Oil - Water) Horizontal Separator: As per "Petroleum and Gas Fie
Hussein K. Abdel-Aal, Mohamed Aggour, M. A. Fahim"
50%
Normal liquid level due to oil and water
CALCULATIONS
Step 1:
g
0.89 lb/ft3
o
55.5 lb/ft3
EQUATIONS
Determine Cd
Step 2:
Cd
2.07 Assume
0.65 ft/s
22
2.09
0.00 Click me
u
Re
Cd
Error
Step 3:
Ho,max
Drag coefficient
Reynolds no.
Use goal seek to get error zero, by changing asssumed C d
Determine minimum diameter for water droplet settling

36.0 in
Aw / A
Ao + Aw = NLL * A
0.10
Ho / D
0.315 Assume
Aw / A
0.13
0.00 Click me
114 in
Error
Dmax
Use goal seek to get error zero, by changing asssumed H o/D

Maximum allowable vessel diameter
Step 4:
DL

122 in.ft
Step 4:
D2L

214350 in2ft
Try different combinations of D (smaller than D max).

TABLE 1
Ls (gas)= L
L (gas), ft + D/12,
ft
D, in
SR = L /
Ls (liquid)= 4 L/3, Governing
ft
(D/12)
case
L, ft
12
10.2
11.2
1488.5
1984.7
Liquid
Capacity
1984.7
24
5.1
7.1
372.1
496.2
Liquid
Capacity
248.1
30
4.1
6.6
238.2
317.6
Liquid
Capacity
127.0
36
3.4
6.4
165.4
220.5
Liquid
Capacity
73.5
66
1.9
7.4
49.2
65.6
Liquid
Capacity
11.9
72
1.7
7.7
41.3
55.1
Liquid
Capacity
9.2

Oil Gravities
Above 35 oAPI
Below 35 oAPI
100+ oF
80+ oF
Ls
SR
D
L
Qg
78
1.6
8.1
35.2
47.0
Liquid
Capacity
7.2
84
1.5
8.5
30.4
40.5
Liquid
Capacity
5.8
90
1.4
8.9
26.5
35.3
Liquid
Capacity
4.7
96
1.3
9.3
23.3
31.0
Liquid
Capacity
3.9
102
1.2
9.7
20.6
27.5
Liquid
Capacity
3.2
35.3
4.7
90.0
26.5
156
ft
in
ft
mmscfd
60+ oF

Effective length of
the separator
Calculated gas capacity for selected L & D (Should be more than 8 MMSCFD - input value)
NOTES
INDEX
oleum and Gas Field Processing A. Fahim"

SCHEMATIC
QUATIONS
ABLE 2 (Ref. API 12J)

Oil Gravities
Retention time, minutes

(Typical)
Above 35 oAPI
3 to 5
Below 35 oAPI
100+ oF
5 to 10
80+ oF
10 to 20
60+ oF
FD - input value)
20 to 30

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INDEX:

Two sets of calculations are carried out here.

Level Alarm High High (LAHH)

Level Alarm Low Low (LALL)

mple approach to (2/3 phase and vertical/horizontal) separator sizing.

o properly design a separator. Three main factors should be

ity, and 3) operability.

rmining the volume required to provide adequate residence time to

sign are provided below;

30 60 seconds or 200 mm whichever is greater

e mesh demisters (Source: IPS-E-PR-880, 1997)

total cross sectional area of the separator.

cross sectional area of the separator occupied by oil, ft 2

cross sectional area of the separator occupied by gas, ft 2

oil pad height, in.

water pad height, in.

seam-to-seam vessel length, ft

normal liquid level, %

gas flow rate, MMSCFD or ft3/s

oil flow rate, bbl/day

water flow rate, bbl/day

cross sectional area of the separator occupied by water, ft 2

velocity of the mixture, m/s

water dynamic viscosity, cP

liquid density, lbm/ft3

oil density, lbm/ft3

mean density of mixture, kg/m3

water density, lbm/ft3

gas density, lbm/ft3

STANDARD SEPARATOR SIZES AS PER API INDEX

Two Phase (Gas - Oil) Vertical separator: As per API 12J

Oil specific gravity

Yellow boxes are input boxes.

Oil operating density

Actual volume flow of gas

Minimum gas flow area

Next larger and appropriate size

Liquid volume (excluding bottom head)

Liquid capacity of separator should be

Manipulate NLL and H to get

e mesh mist extractor. This

Two Phase (Gas - Oil) Horizontal Separator: As per API 12J

Oil specific gravity

Yellow boxes are input boxes.

Oil operating density

Actual volume flow of gas

Minimum gas flow area

Next larger and appropriate size

Liquid volume (excluding bottom head)

Manipulate NLL and L to get

wire mesh mist extractor. This

Oil specific gravity

Water retention time (Refer Table 2)

Yellow boxes are input boxes.

Oil operating density

Actual volume flow of gas

Minimum gas flow area

Next larger (than Dmin) and

Liquid volume (excluding bottom head)

Manipulate NLL, D and H to

Refrigerant surge tanks

wire mesh mist extractor. This

Three Phase (Gas - Oil) Horizontal Separator: As per API 12J