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Datasheet No:
Rev :
A
Date: 23-Aug-10
By:
K
Chk'd:
App'd:
Item No: 5V - 100
Location:
Vertica
1 Type
Units
Number Required: 1
Horizontal
l
2 Internals Feed Inlet
2 1
Vapour
Outlet
Half
Vanes/
None.
Mesh
3
3
None
Vane
Pipe
Others
KOD
Pad
4
`
2 1
5
Process Design Conditions
6 Inlet Pressure
psia =
130.0
* Inlet Temperature
F =
100.0
7 Pressure Drop Allowed psi =
5.0
* Pressure Drop Calculated
psi =
8 Operating & Design Cases
Case 1
Case 2
Case 3
Design
9 Vapour
Nat Gas
10
Flow Rate
MMSCFD =
75.0
11
Flow Rate
lb/h =
186,160
12
Flow Surge Factor
%
=
0%
13
Density
lb/ft =
0.49
14
Viscosity
cP =
0.012
15 Light Liquid
=
Oil
16
Flow Rate
BFPD =
50,000
17
Flow Rate
lb/h =
657,898
18
Flow Surge Factor
%
=
0%
19
Density
lb/ft =
56.2
20
Viscosity
cP =
2
21 Heavy Liquid
=
Water
22
Flow Rate
BFPD =
50,000
23
Flow Rate
lb/h =
735,160
24
Flow Surge Factor
%
=
0%
25
Density
lb/ft =
62.8
26
Viscosity
cP =
1.1
27
28 Contaminants/ Solids
Specify
Wellmud Sand Proppant Coke
29 Short term operating requirements
30
31
Design Considerations
32
Default
33 Allowable Droplet Size
=
200
300
34 In horizontal separator, maximum vapour velocity / min area is calculated at
35 Liquid Residence Time at NLL
min =
3
36 Liquid Control Time between LAL and LAH
min =
5
37 Liquid Slug Hold up (NLL to LAHH)
ft =
38 Inflow Slug duration - all liquid flow at total volume flow rate
sec =
2
39 Operator Response Time Reqd between Alarm & Trip
min =
0.5
outlet SDV closing
40 LALL to consider:
Outlet
siphon effect
time
41
mVm lb/ft.s =
42 Nozzle sizing: Inlet Device:
Vane Distributor
4,032
gVg lb/ft.s =
43
Vapour Outlet
2,688
44 Horizontal Separator: Inlet Nozzle
Outlet Nozzle:
45
46
Design Notes
47
48
49
50
51
Client: E3 OGPE
Project: E3 Field Development
Plant: Gas - Liquid Inlet Separation
Unit:
Inlet
Service:Production Separator
Datasheet No:
Rev :
A
Date: 23-Aug-10
By:
K
Chk'd:
App'd:
Item No: 5V - 100
Location:
Orientation
Vertica
52
l
53
1
Vessel Design Conditions
2 Design Pressure
psig =
Design Temp
F =
3 Vacuum Criteria
Min Design Metal Temp
F =
4 Limitations
Plot Limitations
5 Shell Diameter, OD/ID
ft =
10.5
Length (Tan-Tan)
ft =
33.0
6 Design Code
=
Corrosion Allowance
in =
7 Wall thickness
=
Hydrostatic Test Pressure
psig =
8 Material of Construction
Shell
=
9
Vane Distributor
Mesh Pad
=
10
Sandjet Nozzles
=
Coalescer/Calming Baffl =
11
Heat
Personnel
Fire
12
External Insulation
1
None
Conservation
Protection
Protection
13
Insulation Thick in
=
Type/ Material
=
14
Anchor
=
Type/ Material
=
15 Post Weld Heat Treatment Yes/ No
% Welds fully radiographed
16 Painting Requirements
17 Heating Coil
18 Sand Wash Facility
No and Size of Nozzles
19 Water demand
=
Effluent sand + water flow
=
20 Mesh pad/Internal cleaning solvent injection nozzles?
21
Vessel Nozzles
22
23 Mark No Service
Dia, in Flange Remarks
24 Inlets & Outlets
Minimum Elevation of Bottom of Vessel
25 N1
1 Feed
28
Inlet: No valve or expansion/contraction within 10d
26 N2
1 Vapour Outlet
16
Vapour Outlet: Reducer if any should be 2d away.
27 N3
1 Liquid Outlet
20
Liquid Outlet: SDV if any should at min distance.
28 N4
29 N5
1 Vent
2
N
30 N6
1 Drain
3
Suggested Levels
2 N
31 N7
1 Relief Valve
Level
in
5
32 N8
1 Utility Connection
2
LAHH
100
33 N9
LAH
92
34
NLL
52
N
35 Instrumentation
LAL
28
1
36 K1
PG
LALL
20
37 K2
TG
38 K3A/B
LT
39 K4A/B
Not used
N
N
40 K5A/B
LG
3
8
41 K6A/B
Not used
42 K7A/B
Not used
N
43 K8A/B
LAHH
5
N2
44 K9A/B
LALL
N1
N7
N5
45 K10A/B
Not used
K8A
K3
46 K10A/B
Not used
K1
K5
A
A
47
N7
N1
48
K8B K9
M1
B
49 Manholes
K2
K3
B
K5
B
Client: E3 OGPE
Project: E3 Field Development
Plant: Gas - Liquid Inlet Separation
Unit:
Inlet
Service:Production Separator
50 M1
51 H1
52
53
Orientation
Vertica
Datasheet No:
Rev :
A
Date: 23-Aug-10
By:
K
Chk'd:
App'd:
Item No: 5V - 100
Location:
18
K2
N8
N6
K3
B
N6 K9
B
N3
K5
B
Client: E3 OGPE
Calculation No:
Rev : A
Service:Production Separator
5V - 100
By: K
Chk'd:
App'd:
Vapour
Light Liq
Heavy Liq
Total
lb/s
51.7
182.7
204.2
438.7
ft/s
105.5
3.3
3.3
112.0
Mixture Density
lb/ft
3.92
Nozzle Sizing
Size nozzles first, as they decide 'net' travel distance in
horizontal KODs
Number Diameter, in
Velocity
Location
off
Min Select ID
Criteria
ft
Feed Inlet
1 25
28
Vapour Outlet
1 16
16
Liquid Outlet
1 19
20
1.58
Size, in No
Miscellaneous
3,624
2,688 High
3.3
3.3 High
Vent
Manholes
18
Drain
Hand holes
Size, in No
Utility
Vapour Separation
Allowable Droplet Size
200.0
CRe
5,088
Log CRe
3.7
1.28
ft/s
1.58
ft/s
4.25
ft/s
105.5
0.001 ft
User K =
Default K =
0.40
Horizontal Separator. Trial & Error. Dia Vs Length and Levels. In 2-3 tries you'd get it
Vessel Diameter - Selected
Liquid Level
ft
10.5
LAHH
in
100
ft
= 2.1667
ft
12.89
ft/s
8.19
OK
High
Liquid Separation
Vessel Length
Ag
ft
ft
ft
ft/s
>
= 341.18
= 6.5035 Liquid Downward Velocity
ft/s
= 0.0191
ft/s
= 0.0319
Client: E3 OGPE
Calculation No:
Rev : A
5V - 100
By: K
Chk'd:
App'd:
Liquid Levels
Level
Settings
in
ft
Mud Level
51.7
LALL
20
28
511
NLL
52
1,225
LAH
92
2,484
100
260.53
40
20 sec OK
198.86
0.51
0.5 OK
3.1
3.0 OK
217.43
0.56
0.5 OK
1,973
5.1
5.0 OK
1,477
0.0 OK
13.2 sec
2 sec OK
2,702
ft
ft
Required
312.2
LAL
LAHH
ft Available
Remarks
ft/s
112.04
= Later
Sand Accumulation, %
Sand Accumulation per day
Vessel Diameter
Inlet to Demister
Demister
0 Demister to Outlet Nozzle
Outlet nozzle to Tan Line
Vessel Size
ft =
10.5
ft =
17.5
ft =
0.5
ft =
8.0
ft =
4.0
=
30.00
=
=
33.00
3.14 OK
=
ft
Default
11.67
0.50
6.17
2.22
0.00
20.55
Remarks
Space to explain design features, add comments on caution messages
Client: E3 OGPE
Calculation No:
Rev : A
5V - 100
By: K
App'd:
Client: E3 OGPE
Project: E3 Field Development
Service:Production Separator
Rev :
By:
5V - 100
ft/s
ft/s
ft
=
=
=
Calculation No:
Date:
Chk'd:
App'd:
105.5
6.5
1,951.1
Separator Sizing
Vertical
Allowable Vap Velocity ft/s
Vapour Flow Area
ft
=
=
3.2
33.0
Vessel Diameter, D
Vessel X Area
Liquid LAHH
For Liquid Hold up
For Level Gaps
Vapour Space
Suggested Height, L
L/D
=
=
6.5
33.18
ft
ft
ft
ft
ft
ft
=
=
=
=
=
58.8
1.8
9.0
67.7
10.4
11.0
95.03
20.5
1.8
9.0
29.5
2.7
ft
ft
12.5
19.4
1.5
Horizontal
=
4.8
=
22.0
=
5.9
=
12.0
13.0
17.6
1.4
13.5
16.1
1.2
0.5
14.0
14.8
1.1
12.0
21.4
1.8
ft/s
ft
ft
ft
ft
=
2.8
=
1.00
Calculated Liquid X Secn % =
0.17
Ratio: assumed/ calculated
=
1.0
Note 1: Goal seek on W24 to make W32 as 1
Length - Liquid Holdup
ft =
99.9
Suggested Length, L
ft =
99.9
L/D
=
8.3
gpm
Volume
gallon
ft/s
MMGPD AcreFt/d l/s
BPD
m/h
m/d
1 0.002223 0.001439 0.004405 0.063091 34.28571 0.227129 5.451104
ft
1
Pressure psi
14.7
TemperatuF
0.1337
HP
Ft
Ft
880
GPM
53
273.15
m
120.0
Sp.Gr
55
psi
880
491.67
Mile
in
10 0.001894
GPM
3.785
bbl
m
0.02381 0.003785
ft Water in Hg
ft Liquid m Water m Liquid kg/cm
bar
kPa
33.957
29.988
15.435 10.35009 4.704588 1.03341 1.013793 101.3793
of Sp Gra
2.2
32
Length
2.2
cm
3.05
304.80
Eff, %
BHP
70.0% 38.4127
Eff, %
BHP
70.0% 38.85048
atm
1
Separator Sizing
Service
Gravity
The intermediate law is usually valid for many of the gas liquid and liquid-liquid
Separation separation applications encountered in the oil & gas plants.
KOD
No internals. For waxy, coking and dirty service. High liquid loads where vapour
separation is not an issue. In flare KODs where internals are avoided.
Note: In long horizontal drum, allowable vapour velocity based on gravity separation
may be higher than that based on mesh pad or vane pack.
Go for 150 in continuous service requiring fine separation and no internals like vanes
or mesh pad are allowed. Go for 400 in Flare KODs for continuous (dumping) loads;
600 in low probability loads like design blocked outlet flow or intermittent one like
blowdown. Droplets formed as a result of chilling/condensation caused via high
pressure PSV or BDV are too fine (0.1 to 50 ) to be trapped in a KOD.
Impingement Impingement type mesh pad and vane pack are sized based on Souders and Brown
Separation Equation, Vallowed = K.sqrt((l - g)/g). Lower the K, lower is gas velocity and higher
is the removal efficiency. Use lower K in Compressor, Glycol and Amine Unit service.
Wire mesh
Vane
Several sources give different values for K. For instance API 12J gives lower or
conservative values for vertical separators. But its K value for longer horizontal drum is
high and unrealistic. The program recommends an average value as a default and
allows the user to input a desire value. K is decided by difficulty or ease of separation.
Best is go by successful previous experience.
Caution: No point in under sizing a separator based on what the project or client or supplier says.
During start-up/ commissioning, you will be left holding the baby and others would have vanished. If a
compressor is damaged, blamed on droplet carried over and deposited on blades + causing
unbalanced loads, 1 day production loss is hefty, compared to the 200 mm you saved on dia. No one
remembers a good design. A poor design is remembered and is talk of the town.
K Factor, GPSA
ft/s Vertical
Horizontal
Mesh pad
0.22
0.39
Vane Pack
0.45
0.90
K Factor, Mesh pad API 12J, based on vessel height or length
ft/s Vertical
Horizontal
5' (1.5m)
0.24
10' (3 m)
0.35
0.45
L'
0.45*(L/10)^0.56
Some vendors consider higher Ks based on vapour space (between LAHH and Mesh pad bottom) as
below. Suggest that you take 0.3 fps (0.1 m/s) in all new applications. You may consider higher values
in revamp jobs, if operational feedbacks favour it; less likely as Mesh pads usually get fouled up in
service, reducing their effectiveness
K Factor Vendor 1
Vapour Space
K
Vapour Space
K
in
ft/s
in
ft/s
3
0.12
9
0.32
4
0.15
10
0.35
5
0.19
11
0.38
6
0.22
12
0.40
7
0.25
13
0.42
8
0.29
14
0.43
Note: K is for velocity thru the Mesh pad or vanes; not necessarily for velocity in the drum.
Ideally K should be based on the desired separation needed. For instance a Compressor KOD can not
tolerate liquid droplets (droplets may damage the blades rotating at high speed, evaporate, leaving
residue or coke up) leading to unbalanced load on shaft.
But a separator feeding a column or a cooler/ condenser may allow higher liquid loading. Thus
selection of K should be based on service and should not be a magic number for all applications.
K Factor Vendor - Based on Service
Service
Compress
K
ft/s
0.25
K Correction for Op Pressure, GPSA
psig
150
300
%
90
85
Column Condenser
0.35
0.45
600
80
1,150
75
Fuel Gas
0.30
It is common in Oil & Gas applications to have flow surges into the first or Inlet (Production) Separator
and suitable margins are added to flow. Ignore the margins, if design rate includes a higher margin.
Natural
10%
20%
30%
10%
20%
Gaslift
20%
30%
40%
30%
40%
Most of the sources provide guidance on finding vapour flow area but are silent on
Section sizing the liquid section, holdup volume or time between various level settings.
Vessel may have to accommodate pigging or random slug from incoming pipelines
between NLL and LAHH. Slug volume decided by pipeline transit analysis. Assume 2
riser volumes, if unknown. In addition, inflow slug viz when the entire inlet volume flow
is 100% liquid for 1 - 2 seconds, may have to be accommodated.
Minimum gap between liquid levels are 4" (100 mm). Long horizontal vessels require a
longer gap, to avoid wave action resulting in spurious trips and alarms. Perforated
calming baffles (plates) may help.
d2
z
t
d1
D
y
d
x
d3
d3 alternative
A side liquid outlet is preferred as it can avoid vortex effect and let sand and mud accumulate inside
the separator to be drained.
d1 alternative
Horizontal Drum Spacing
x'
t
d2 y'
There is no guideline for Horizontal drum lengths. In case
l
of KOD, clear distance between inlet and outlet vapour
d1
x
y
nozzle should match the travel time of a liquid droplet
from top of the drum to reach the liquid level. Min L =
0 - L
2.5D. Looking at Sep Sizing calculations at cells AK38:
d3
AN44, you may realize that required length is longer for
Coalescer, if any
liquids at LALL. Usual design is based at LAHH.
For a mesh pad/ vane pack horizontal separator, it is usual to locate the pad 5d1 distance from inlet
and have minimum distance = vapour space at NLL vapour outlet.
On large horizontal drums, a lower LALL level may result in its bottom tapping
getting located too low. For ease of fabrication, a min angle of 40 is desired.
D/2
This will also help minimize the ovality of the shell opening c.f. one at 90 .
In horizontal sep, if sandjet or sand sucking nozzles are provided, their size
needs to be taken while fixing LALL.
LALL may have to provide enough head to handle vortex at liquid outlets.
Drum Sizes
Dia?
Standard plate sizes 2,500 - 3,000 x 6,500 mm;
796
1,114
While drums can be rolled to any ID/OD, standard sizes are as below
300 to 1,200 mm in steps of 100 mm
1,200 to 4,000 mm in steps of 200 mm
4,000 and above in steps of 250 mm
Nozzle Location from Tangent Lines
Size, in
2
4
Distance, mm
150
260
8
400
12
500
20
850
2,069
28
1,100
LG are usually available at 14", 32" and 48" span. Check with your Instrument Dept
Inlet Devices
Inlet devices may be simple, a nozzle flowing against an
impingement plate or box; half pipe (bottom of pipe cut open) or vane
distributor. Simple devices are used in smaller vessels and designed
proprietary devices are used in large flow large vessels.
Nozzle
Half-Pipe Vane
Inlet and outlets are sized based on V criteria given below, though
some may go by the external line sizes.
Inlet devices help reduce nozzle size. Use a simple nozzle + impingement
for smaller vessels, say 2.5 - 3' (0.75 - 0.9 m) dia; then half-pipe. If nozzle size is 2 sizes more than
external piping, it is OK. If bigger, use vane type distributor.
Nozzle
Half-Pipe VaneDistr
As mentioned in Norsok P-100, A good
Feed inlet, mVm
672
1,008
4,032
inlet device reduces inlet momentum
bulk separates minimizing liquid shearing into droplets and creates good vapour distribution.
Nosok P-100
Performance factor
Nozzle
Half pipe Baffle
Vane
Momentum reduction
Poor
Good
Good
Good
Bulk separation
Good
Average Poor
Good
Prevent re-entrainment
Good
Average Average Good
Prevent liquid shearing
Good
Average Poor
Good
Good gas distribution
Poor
Poor
Poor
Good
Heating Coil
Heating Coils are usually provided at the bottom of vessels, while handling light emulsions.
How to use the Sep Sizing spreadsheet
It is easy on vertical separators as the full cross-sectional area is available for flow. Diameter is fixed on
vapour flow; liquid levels and height fixed by liquid. In Horizontal separator, liquid takes away part of the
cross section and hence a number of diameter and length configuration is possible. Smaller diameter
vessels require thinner metal plates, weigh and cost less. Experienced users would converge on the
right diameter x length usually 3 attempts. Inexperienced users like me may adopt the "shrinking
envelope" method as below.
1 Start with a generous size. Have a look at the Quicksize page to decide a diameter and select a length
3 times that. Fix LAHH at 50% dia. Keep 4" (100 mm) - 8" (200 mm in longer vessels) between levels.
Check if assumed diameter is OK to meet all levels - that is minimum dia is (6"+4"+6"+4"+4") x 2 = 48"
(1,200 mm) L = 12' (3,600 mm).
2 Now check if vapour flow area is OK. Adjust dia x LAHH to get it right. Have a look at liquid levels times
slugs etc. Slowly reduce length in steps of 6" (100 mm) and diameter in steps of 2" (50 mm) with
changes in level to converge on the smallest size.
3 It is easy on a 2 Phase Seperator but gets difficult in a 3 Phase Separator. Nightmare on a bucket type.
Luckily there are not many 3 Phase Sep specially bucket types.
Good hunting or number crunching!!
Abbreviations: LALL - Very Low Liquid Level (Level Alarm Low Low); LAL - Low Liquid Level; LAH - High
Liquid Level; LAHH - Very High Liquid Level NLL - Normal Liquid Level; SDV - shutdown valve
SMKumar
Revision AA Changes
Sheet
Cell
All
Datsheet
AA91
Ref! AD26
Decimal place
Fill colour
L44 L38
I20 K20
Decimal place
AH28 AI28
AH28 AI28
AH28 AI28
I17 K17
"L68" L66
I19 K19
v AA Oct 2010
ow selection
Error correction
Nozzle sizing part moved up, to do it first
Cells combined and decimal places increased to allow bigger no
Fill colour changes if previous and erroneuous values are 'retained'
Ref changed from M30 to L34. Error correction
Error correction
Now that nozzles are sized first, actual values are used!
Cells combined and decimal places increased to allow bigger no
Error correction. Plus 5" added. Additional correction for SI
Round off added. Additional correction for SI
Error correction. "in" changed to applicable units.
Error correction. Additional correction for SI
Error correction
Now that nozzles are sized first, actual values are used!
Error correction
Now that nozzles are sized first, actual values are used!
Provision added to find sand accumulation
Formula simplified
Added: How to use the Sep Sizing spreadsheet