Vertical Separator Design Theory & Calculation Sheet

Separator Design-4
PRACTICAL GUIDELINES TO DESIGN THREE PHASE VERTICAL

SEPARATOR
Prepared By: Baber Rafique

Process Engineer
www.linkedin.com/in/baberrafique
[email protected]
Designing of Three Phase Vertical Separator
The following information are mean to give some practical guidelines that may applicable in
most of the cases but can’t replace good engineering intuitions, in addition exact design of
separator depends upon the design engineer understanding towards fluctuation in fluids flow
& properties, operating parameters & uncertainties involved.
The basic design concept of three phase separator are similar to the what described in case
of two phase separators, the only difference is when it comes to the addition of extra liquid-
liquid phases. When water and oil are mixed together as found in most of oil & gas
reservoirs and allowed to settle for a reasonable time the oil water emulsion breaks into
three distinct layers’ upper layer oil, middle emulsion and lower free water. With the
passage of time the thickness of upper & lower layer grows on while middle emulsion layer
goes on squeezing until an equilibrium state reached as depicted in figure-1. The thickness
of emulsion layer and time required to reach that equilibrium state depends upon the
properties of the liquids and operating conditions.
Figure 1:Oil-Water layer distribution
In three phase separator three separation phenomena are carried out;
 Settling of liquid droplets from gas phase (100 microns)

 Settling of water droplets from oil phase (500 microns)
 Removal of oil droplets from water phase (200 microns)
Sizing of three phase mainly governs by the settling of water droplets from oil phase this is
due to the high viscosity of oil compared to the water. Water contents in oil is very crucial
parameter for sale oil agreements & to achieve this, the selection of size of water droplets
that will settle out from oil phase in given period of retention time is the main controlling
factor. In the absence of laboratory data water droplets of 500 microns are good estimate
that will remove 80-90% of water from oil phase. Figure-2 shows the water droplets size
distribution with water percentage in oil applicable in majority of cases.
As flow of oil droplets in water phase & water droplets in oil phase is laminar so Stokes’ law
will be used to calculate the terminal velocity of moving droplets.
1.78 × 10−6 ሺ𝛥𝑆𝐺ሻ 𝑑𝑚

2
𝑉𝑡 = Eq-1a (Field Units)
𝜇
5.56 × 10−7 ሺ𝛥𝑆𝐺ሻ 𝑑𝑚

2
𝑉𝑡 = Eq-1b (SI Units)
𝜇
Vt = terminal settling velocity, ft/s (m/s), ΔSG = difference in specific gravity relative to
water between the oil and the water phases, d m = drop size, microns, μ= viscosity of
continuous phase, cp.
Figure 2:Water droplet size distribution w.r.t. oil contents in residual oil
Retention Time
Selection of optimum retention is a decisive factor so that oil & water phases may attain the
equilibrium in separator. It is common to use 3 to 30 minutes’ retention time. In the
absence of laboratory data table-1 can be used as guidance.
Oil Retention Time
°API Gravity Minutes
°API > 40 2-5
30-40 5-7.5
20-30 7.5-10
°API < 20 10+
Note: In case of persistent emulsion it’s better to use to the laboratory data or increase the
above given time by the factor of 2-4.
Table 1:Oil retention time
Vertical Separator Sizing (Half full liquid)
As described in two phase vertical separator design that for a vertical separator design a
minimum diameter is to be determined large enough to allow the liquid droplets to settle
from gas moving in opposite direction. In three phase separator addition to the above
condition the diameter should be large enough to allow the water droplets to settle down
from the moving oil phase in opposite direction and vice versa.
Sizing of a vertical three phase separator is computed for four constraints
 Gas capacity
 Water droplets settling from Oil phase
 Oil droplets rise from water phase
 Retention time
Any diameter greater than minimum required for above constraints can be used.
Gas Capacity Constraint
Equation 2 describes the gas capacity constraint;
1/2
𝑇𝑍𝑄𝑔 𝜌𝑔 𝐶𝐷
2
𝑑 = 5040 ൤ ൨ ቈቆ ቇ ቉ Eq-2a (Field Units)
𝑃 𝜌𝑙 − 𝜌𝑔 𝑑𝑚
1/2
𝑇𝑍𝑄𝑔 𝜌𝑔 𝐶𝐷
2
𝑑 = 34500 ൤ ൨ ቈቆ ቇ ቉ Eq-2b (SI Units)
𝑃 𝜌𝑙 − 𝜌𝑔 𝑑𝑚
d = vessel internal diameter, in. (mm), T = operating temperature, °R(°K), Qg = gas flow
rate, MMscfd(scm/h), P = operating pressure, psia.(kPa), Z = gas compressibility, CD = drag
coefficient, dm = liquid droplet to be separated (micron), ρg = density of gas, lb/ft3(kg/m3),
ρl = density of liquid, lb/ft3(kg/m3).
Water Droplets Settling from Oil Phase

Equation-3 describes the diameter required for settling of water droplets from oil phase.
𝑄𝑜 𝜇𝑜
𝑑 2 = 6690 2
Eq-3a (Field Units)
ሺ∆𝑆𝐺ሻ𝑑𝑚
𝑄𝑜 𝜇𝑜
𝑑2 = 6.37 × 108 2
Eq-3b (SI Units)
Qo = oil flow rate, BPD(m3/h), μo = Oil viscosity, cP(Pa s)
Oil Droplets Rise from Water Phase

Equation-4 describes the diameter required for rise of oil droplets from water phase.
𝑄𝑤 𝜇𝑤
𝑑 2 = 6690 2
Eq-4a (Field Units)
𝑄𝑤 𝜇𝑤
𝑑2 = 6.37 × 108 2
Eq-4b (SI Units)
Qw = Water flow rate, BPD(m3/h), μw = Water viscosity, cP(Pa s)
Retention Time Constraint

Eq-5 relates the diameter of the separator with oil pad thickness h o & water pad thickness
hw. Use the maximum diameter from above constraints to determine the h o+hw.
ሾሺ𝑡𝑟 ሻ𝑜 𝑄𝑜 + ሺ𝑡𝑟 ሻ𝑤 𝑄𝑤 ሿ
ℎ𝑜 + ℎ𝑤 = Eq-5a (Field Units)
0.12𝑑2
ሾሺ𝑡𝑟 ሻ𝑜 𝑄𝑜 + ሺ𝑡𝑟 ሻ𝑤 𝑄𝑤 ሿ
ℎ𝑜 + ℎ𝑤 = Eq-5b (SI Units)
4.713 × 10−8 𝑑 2
Keep in mind that ho ℎ𝑜 ≤ ሺℎ𝑜 ሻ𝑚𝑎𝑥 & ℎ𝑤 ≤ ሺℎ𝑤 ሻ𝑚𝑎𝑥
2
0.00128 ሺ𝑡𝑟 ሻ𝑜 ሺ𝛥𝑆𝐺ሻ 𝑑𝑚
ሺℎ𝑜 ሻ𝑚𝑎𝑥 = Eq-6a (Field units)
𝜇
2 Eq-6b (SI units)
0.033 ሺ𝑡𝑟 ሻ𝑜 ሺ𝛥𝑆𝐺ሻ 𝑑𝑚
ሺℎ𝑜 ሻ𝑚𝑎𝑥 =
𝜇
2
0.00128 ሺ𝑡𝑟 ሻ𝑤 ሺ𝛥𝑆𝐺ሻ 𝑑𝑚
ሺℎ𝑤 ሻ𝑚𝑎𝑥 = Eq-7a (Field units)
𝜇𝑤
2
0.033 ሺ𝑡𝑟 ሻ𝑤 ሺ𝛥𝑆𝐺ሻ 𝑑𝑚
ሺℎ𝑤 ሻ𝑚𝑎𝑥 = Eq-7b (SI units)
𝜇𝑤
Seam to Seam Length (S/S)

Seam to seam length of vertical separator includes the allowance for vessel internals such
inlet diverter, mist extractor & space below the water as depicted by figure-3.
Eq-8 & 9 describes the S/S length based on diameter.
ℎ𝑜 + ℎ𝑤 + 76
𝐿𝑠𝑠 = (for d ≤ 36 𝑖𝑛.) Eq.-8a (Field Units)
12
ℎ𝑜 + ℎ𝑤 + 1930
𝐿𝑠𝑠 = (for d ≤ 194 𝑚𝑚) Eq.-8b (SI Units)
1000
ℎ𝑜 + ℎ𝑤 + 𝑑 + 40
𝐿𝑠𝑠 = (for d > 36 𝑖𝑛.) Eq.-9a (Field Units)
12
ℎ𝑜 + ℎ𝑤 + 𝑑 + 1016
𝐿𝑠𝑠 = (for d > 194 𝑚𝑚) Eq.-9b (SI Units)
1000
Slenderness Ratio (SR)
In case of vertical separator, the SR should be less than 4, however common practice is 1.5
to 3.
Note: Standard separator vessel sizes may be obtained from API 12J. It is a good practice
to choose the near possible standard size as they are more readily available in market.
Figure 3: Vertical Separator S/S Length
References:
1-GPSA Engineering Data Book
2-API SPEC 12J, specification for Oil and Gas Separators
3-Arnold K, Stewart M, Surface Production Operations, Design of Oil-
Handling Systems and Facilities (3rd Edition)
4-https://petrowiki.spe.org/Separator_sizing

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Separator Design-4

PRACTICAL GUIDELINES TO DESIGN THREE PHASE VERTICAL

Prepared By: Baber Rafique

Figure 1:Oil-Water layer distribution

In three phase separator three separation phenomena are carried out;

 Settling of liquid droplets from gas phase (100 microns)

1.78 × 10−6 ሺ𝛥𝑆𝐺ሻ 𝑑𝑚

5.56 × 10−7 ሺ𝛥𝑆𝐺ሻ 𝑑𝑚

Oil Retention Time

°API Gravity Minutes

°API > 40 2-5

°API < 20 10+

Vertical Separator Sizing (Half full liquid)

Sizing of a vertical three phase separator is computed for four constraints

Gas Capacity Constraint

Equation 2 describes the gas capacity constraint;

Water Droplets Settling from Oil Phase

Qo = oil flow rate, BPD(m3/h), μo = Oil viscosity, cP(Pa s)

Oil Droplets Rise from Water Phase

Qw = Water flow rate, BPD(m3/h), μw = Water viscosity, cP(Pa s)

Retention Time Constraint

Seam to Seam Length (S/S)

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