Chapter 4 Separators
-
Upload
dineshhsenid -
Category
Documents
-
view
124 -
download
28
description
Transcript of Chapter 4 Separators
-
Production Engineering II
Separation Process
-
Learning Outcomes
At the end of this lecture, students should be able to :
1. Describe the different types of separator and their functions.
2. Understand the basic theory of separation process.
3. Describe the two phase separation process.
4. Describe the three phase separation process.
5. Perform separator sizing calculations.
-
Introduction
Crude/Gas Separation System-Overview
-
Introduction
Main Offshore Production Facilities (key components):
Wellhead Equipment
Separation
Waste Handling Pump/Compressor Gas utilities, flaring
-
Introduction The oil production system begins at the
wellhead, which includes at the least one
choke valve (percentage opening
determines the flowrate from the wells).
Most of the pressure drop between the well flowing tubing head pressure (FTHP) and
the separator operating pressure occur
across the choke valve.
Whenever there are two or more producing wells, a production manifold (as well as a
test manifold) is installed to gather fluids
prior to be processed.
The test manifold is provided to allow an individual well to be tested via a test
separator or a multiphase flowmeter.
Simple wellhead assembly including
casing spools and Christmas tree
-
Introduction
Manifold / Gathering Station
-
The Production Process
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
-
Introduction
Produced wellhead fluids are complex mixtures of different compounds of hydrogen and carbon, all with different densities, vapor pressures, and other
physical characteristics.
As a well stream flows from the reservoir, it experiences pressure and temperature reductions.
Gases evolve from the liquids and the well stream changes in character. The velocity of the gas carries liquid droplets, and the liquid carries gas bubbles.
The physical separation of these phases is one of the basic operations in the production, processing, and treatment of oil and gas.
In oil and gas separator design, we mechanically separate from a hydrocarbon stream the liquid and gas components that exist at a specific temperature and
pressure.
-
Introduction
Phase Diagram of a typical production system
-
Introduction
Proper separator design is important because a separation vessel is normally the initial processing vessel in any facility, and improper design
of this process component can bottleneck and reduce the capacity of the entire facility.
Separators are classified as the following
Two Phase if they separate gas from the total liquid stream
Three Phase if they also separate liquid stream into its crude oil and water components.
-
Introduction
What is a separator?
A separator is a pressure vessel designed to separate a combined
liquid-gas system into individual components that are relatively free of
each other for subsequent processing or disposition
Why separators are 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
Measurement devices (metering) for gases/liquids highly
inaccurate when the other phase is present.
-
Basic Separator Construction
Regardless of the size/shape of a separator, each gas-liquid
separator contains four major
sections :
I. Inlet Diverter Section
II. Liquid Collection Section
III. Gravity Settling Section
IV. Mist Extractor Section
Vertical
Separator
Schematic
Horizontal
Separator
Schematic
-
Basic Separator ConstructionI. Inlet Diverter Section
The inlet stream to the separator is typically a high-velocity turbulent mixture of gas and liquid.
Due to the high velocity, the fluids enter the separator with a high momentum.
Fluid phase at different densities have different momentum.
The Inlet Diverter abruptly changes the direction of flow by absorbing the momentum of the liquid and allowing the liquid and gas to separate.
Results in the initial gross separation of liquid and gas. Initial separation of gas phase from the free liquid phase.
-
Basic Separator ConstructionII. Liquid Collection Section
Located at the bottom of the vessel.
Provides the required retention time necessary for any entrained gas in the liquid to escape to the gravity settling section.
Also provide a surge volume to handle intermittent slugs.
After a certain period of retention time, phases become equilibrium with each other and separated naturally due to density differences
Degree of separation is dependent on the retention time available.
Retention time is affected by the amount of liquid the separator can hold, the rate at which the fluids enter the vessel, and the differential density of
the fluids.
-
Basic Separator ConstructionIII. Gravity Settling Section
As the gas stream enters the gravity settling section, its velocity drops.
Small liquid droplets that were entrained in the gas and not separated by the inlet diverter are separated out by gravity and fall to the gas liquid
interface.
The gravity settling section is sized so that liquid droplets greater than 100 to 140 microns fall to the gas-liquid interface while smaller liquid droplets
remain with the gas.
Liquid droplets greater than 100 to140 microns are undesirable as they can overload the mist extractor at the separator outlet.
-
Basic Separator ConstructionIV. Mist Extractor Section
Gas leaving the gravity settling section contains small liquid droplets, 100-140 microns.
This section uses coalescing elements that provide a large amount of surface area used to coalesce and remove the small droplets of liquid.
As the gas flows through the coalescing elements, it must make numerous directional changes.
Due to their greater mass, the liquid droplets cannot follow the rapid changes in direction of flow. These droplets impinge and collect on the
coalescing elements, where they fall to the liquid collection section.
-
Video
-
Factors Affecting SeparationThe following factors must be determined before separator design :
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
Presence of impurities (paraffin, sand, scale)
Foaming tendencies of the crude oil
Corrosive tendencies of the liquids or gas
-
Separator Design Checklist (2P)
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. Also 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
Separators are designed and manufactured in horizontal, vertical, spherical and various other configurations.
Each configuration has specific advantages and limitations.
Selection is based on obtaining the desired results at lowest life-cycle cost
-
Separator Types (2P)
Gravity separators
Horizontal Vertical Spherical
Centrifugal separators
Venturi Separators
Double-Barrel Horizontal Separators
Horizontal Separator with Water Pot
Filter Separators
Scrubbers
Selection of separators is based on obtaining the desired results at the lowest cost
-
Horizontal Separators (2P)
Illustration of a Horizontal Separator
-
Horizontal Separators (2P)
The fluid enters the separator and hits an inlet diverter, causing a
sudden change in momentum.
The initial gross separation of liquid and vapor occurs at the inlet diverter.
The force of gravity causes the liquid to fall to the bottom of the vessel and
gas to rise to the vapor space.
The liquid collection section provides retention time to let entrained gas evolve out of the oil and reach a state of equilibrium.
It also provides a surge volume, to handle intermittent slugs of liquid.
The level controller senses changes in liquid levels and controls the dump valve accordingly.
-
Horizontal Separators (2P)
Gas flows over the inlet diverter and then horizontally through the gravity settling
section above the liquid.
Small drops of liquid, which were entrained in the gas and not separated by
the inlet diverter, are separated by
gravity-settling; they fall to the gas-liquid
interface.
Some small diameter droplets are not easily separated in the gravity-settling section.
Before the gas leaves the vessel, it passes through a coalescing section, or mist extractor.
This section uses elements of vanes, wire mesh, or plates to coalesce and remove the very small droplets of liquid in one final separation step.
-
Horizontal Separators (2P)
The pressure in the separator is maintained by a pressure
controller.
The pressure controller senses changes in the pressure within
the separator and sends a
signal to the pressure control
valve accordingly.
By controlling the rate at which gas leaves the vapor space of the vessel, this system maintains the pressure in the vessel.
Normally horizontal separators are operated half full of liquid to maximize the surface area of the gas-liquid interface.
-
Vertical Separators
Illustration of a Vertical Separator
-
Vertical Separators
Inlet flow enters the vessel through the side.
The inlet diverter does the initial gross separation.
The liquid flows down to the liquid collection section of the vessel and continues to the liquid
outlet.
As the liquid reaches equilibrium, gas bubbles flow counter to the direction of the liquid flow and
eventually migrate to the vapor space.
The level controller and liquid dump valve operate in the same manner as in a horizontal separator.
The gas flows over the inlet diverter and then vertically upward toward the gas outlet.
-
Vertical Separators
In the gravity settling section, the liquid drops fall vertically downward counter-current to the upward
gas flow.
Gas goes through the mist extractor section before it leaves the vessel to capture smaller liquid
droplets.
Pressure and level are maintained as in a horizontal separators using pressure and level
controllers respectively.
-
Spherical Separators
Illustration of a Spherical Separator
-
Spherical Separators
The same four sections can be found in this separator too. (Inlet Diverter, Liquid
Collection, Gravity Settling and Mist
Extractor)
Fluid enters through the inlet diverter where flow stream is split into two.
Liquid falls to the liquid collection section.
Gases rising out of the liquids pass through the mist extractor and out of the separator through the gas outlet.
Liquid level and pressure are maintained by liquid dump valve and back pressure control valve respectively.
Not widely used because they have limited liquid surge capability and exhibit fabrication difficulties.
-
Centrifugal Separators
Illustration of a Centrifugal Separator
-
Centrifugal Separators Work on the principle that droplet separation can be
enhanced by the imposition of a radial or centrifugal force.
Consists of three sections ( inclined tangential inlet, tangential liquid outlet and axial gas outlet).
Fluids are introduced tangentially into the separator via inclined feed pipe.
The high-velocity swirling flow creates a radial acceleration field that causes the gas to flow to the axial core region due to differences in gas and liquid density.
The gas exits through an axial outlet located at the top of the separator, and the liquid leaves through a tangential outlet at the bottom.
Control can be achieved by a control valve on either liquid or the gas outlet lines.
Not suitable for widely varying flow rates since separation efficiency decreases as velocity decreases.
-
Centrifugal Separators The major benefits of using centrifugal separators are :
(i) No moving parts
(ii) Low maintenance
(iii) Compact (space and weight)
(iv) Insensitive to motion
(v) Lower cost
Not commonly used in production operations because :
(i) Too sensitive to flowrates
(ii) Require greater pressure drop than other conventional separators.
-
Venturi Separators
Like the centrifugal separator, the venturi separator increases droplet coalescence
by introducing additional forces into the
system.
Instead of centrifugal force, the venturi acts on the principle of accelerating the
gas linearly through a restricted flow path
with a motive fluid to promote the
coalescence of droplets.
Best suited for applications that contain a mixture of solids and liquids.
Not cost-effective for removing liquid entrainment alone, because of the high-
pressure drop and need for a motive fluid.
Motive Fluid
The venturi principle involves sending a motive stream horizontally
through a constricting nozzle.
This movement creates an area of low pressure at the expanding side of the
nozzle which pulls gas molecules into
the flow from an attached inlet.
-
Double-Barrel Separators
Illustration of a Double-Barrel Separator
-
Double-Barrel Separators The flow-stream strikes the inlet diverter and the free
liquids fall to the lower barrel through a flow pipe.
The gas flows through the gravity settling section and encounters a mist extractor en route to the gas
outlet.
Small amounts of gas entrained in the liquid are liberated in the liquid collection barrel and flow up
through the flow pipes.
Commonly used in applications where high gas flowrate and/or large liquid slugs are encountered
Single barrel horizontal separators can handle large flowrates but offer poor liquid surge capabilities compared to the double barrel separators.
Two-barrel separators are typically used as gas scrubbers on the inlet to compressors, glycol contact towers and gas treating systems in which the liquid flow rate is extremely
low relative to the gas flow rate.
-
Horizontal Separator with a Water Pot
Single barrel separator with a liquid water pot at the outlet end.
Small amounts of liquid in the bottom flow to the boot end
which serves as a liquid
collection section.
Less expensive than double barrel separators but has less
liquid handling capacity.
Used for productions with very low liquid flowrates
When liquid flowrates are minimal, the boot section can serve as a liquid-liquid separator as well.
Illustration of a Horizontal Separator with a Water Pot
-
Filter Separators
Illustration of a Horizontal Double Barrel Filter Separator
-
Filter Separators
Commonly used in high-gas/low liquid flow streams. Can be either horizontal or vertical in configuration.
Designed to remove small liquid and solid particles from the gas stream.
Typically used when conventional separators employing gravitational or centrifugal force are ineffective.
Filter tubes in the initial separation section cause coalescence of any liquid mist into larger droplets as the gas passes through the tubes.
A secondary section of vanes or other mist extractor elements removes these coalesced droplets.
The design of filter separators is dependent on the type of filter element employed. Some filter elements can remove 100% of 1-micron particles and
99% of 1/2-micron particles when they are operated at rated capacity and
recommended filter-change intervals.
-
Scrubbers
Is a two-phase separator that is designed to recover liquids carried over from the gas outlets of production separators or to catch liquids condensed due to
cooling or pressure drops.
Lower liquid loading compared to a conventional separator.
Typical applications :
Mechanical equipment (such as compressors) that could be damaged by free liquid
Equipment (such as coolers) that can cause liquids to condense from a gas stream.
Gas dehydration equipment that would lose efficiency if contaminated with liquid hydrocarbons
-
Selection Criteria
The geometry, physical and operating attributes give each separator type its own advantages and disadvantages.
Horizontal separators are normally more efficient at handling large volumes of gas than vertical separators ; less expensive compared to vertical separator for
a given gas capacity.
Since the interface area is larger in a horizontal separator than a vertical separator, it is easier for the gas bubbles, which come out of solution as the
liquid approaches equilibrium, to reach the vapor space.
Thus, from a pure gas/liquid separation viewpoint, horizontal separators would be preferred.
-
Selection Criteria
The following are the limitations of a horizontal separator which would require the usage of a vertical separator :
(i) Horizontal separators cannot handle solids as good as vertical separators.
The liquid dump of a vertical separator can be placed at the center of the bottom head so that, solids will not build up in the separator but continue to
the next vessel in the process.
(ii) Necessary to place several drains along the length of the horizontal separator.
In a horizontal vessel, it is necessary to place several drains along the length of the vessel.
The distance between the drains can be increased by using sand jets but is not cost effective.
-
Selection Criteria
(iii) Horizontal separators require more area to perform the same separation as
vertical separators.
Not critical for onshore development but very critical consideration for offshore development due to space constraint.
(iv) Lower liquid surge capacity compared to vertical separators.
Surge capacity of a separator is defined as the ability to absorb a slug of liquid.
The liquid level change is larger in liquid volume for horizontal separator compared to the vertical separator which is sized for the same flowrate.
Surges in horizontal vessels could create internal waves which can activate the high level sensor prematurely.
-
Selection Criteria Vertical separators also have some drawbacks which are not process-related
and must be considered in making a selection :
The location of the relief valves and other controls which would be difficult to access without scaffolding for maintenance activities.
More expensive than an equally sized horizontal separator.
Taller vertical separators are subjected to larger wind loads which
requires the wall thickness to be
increased
Vertical Separators are supported by bottom skirt, which requires the
walls of the vertical separator to be
much thicker than a horizontal
separator which is supported by
support saddles. Illustration of a the support structures of
vertical and horizontal separators.
-
Selection Criteria
Overall, horizontal separators are most economical for normal oil-gas separation, particularly where there may be problems with emulsions, foam, or
high gas-oil ratios (GOR).
Vertical separators work most effectively in low-GOR applications.
Vertical separators are used in some very high-GOR applications, such as scrubbers in which only fluid mists is removed from the gas and where extra
surge capacity is needed (particularly for compressor suction scrubbers)
-
Comparison Summary of Different Gravity Separators
Horizontal Vertical Spherical
1.Can handle much higher gas-
oil ratio well streams because
the design permits much higher
gas velocities
2.Cheaper than the vertical
separator
3.Easier and cheaper to ship
and assemble
4.Requires less piping for field
connections
5.Reduces turbulence and
reduces foaming (thus, it can
handle foaming crude)
6.Several separators may be
stacked, minimizing space
requirements
1.Easier to clean
2.Saves space
3.Provides better surge control
4.Liquid level control is not
critical
5.Less tendency for re-
evaporation of liquid into the
gas phase due to the relatively
greater vertical distance
between liquid level and gas
outlet
1.Good for low or
intermediate gas-oil ratio
2.Very compact and easy
to ship and install
3.Better clean-out.
Comparison of different
gravity separator types
Advantages
-
Comparison Summary of Different Gravity Separators
Horizontal Vertical Spherical
1.Greater space requirements
generally
2.Liquid level control more
critical
3.Surge space is somewhat
limited
4.Much harder to clean (hence
a bad choice in any sand
producing area
1.It takes a longer diameter
separator for a given gas
capacity as compared to
horizontal separator
2.More expensive to
fabricate
3.Difficult and more
expensive to ship
(transport)
1.Very limited liquid
settling section and rather
difficult to use for three
phase separation
2.Liquid level control is
very critical
3.Very limited surge space
Disadvantages
-
Vessel Internals
Vessel Internals
Inlet Diverter
Wave Breaker
DefoamingPlates
Vortex Breaker
Mist Extractor
Sand Jets and Drain
-
Vessel Internals
-
Inlet Diverter
Functions to :
(i) To impart flow direction of the entering stream
(ii) To provide primary separation of liquid and vapor
There are many types of inlet diverters. The three main types are
(i) Baffle Plates
(ii) Centrifugal Diverters
(iii) Elbows.
-
Inlet Diverter
(i) Baffle Plates
Can be a spherical dish, flat plate, angle iron, cone or any shape that will accomplish a rapid change in direction and velocity of the fluids which will disengage the gas and
liquid.
Liquid strikes the diverter and falls to the bottom of the vessel
Gas tends to flow around the diverter.
-
Inlet Diverter
(ii) Centrifugal Diverters
Uses centrifugal force to disengage oil and gas rather than mechanical agitation.
Can be designed to efficiently separate the liquid while minimizing the possibilities of
foaming or emulsification of oil
Design is rate sensitive. They dont work properly at low velocities. Hence not
recommended for normal operations since
the rates are not expected to be steady.
-
Inlet Diverter
(ii) Elbows
Similar theory as the baffle plates ; instead of plates, an inlet in the shape of an elbow pipe is used
-
Wave Breakers Function of wave breakers are to dampen any wave action that is caused by incoming
fluids.
Wave breakers are perforated baffles or plates that are placed perpendicular to the flow which is located in the liquid collection section.
Waves are resulted from surges of liquids entering the vessel.
Why eliminate wave?
To ensure liquid level controllers, level safety switches, and weirs
perform properly.
Waves results in reduced separation
-
Defoaming Plates
Function is to aid in coalescence of the foam bubbles.
Foam at the interface may occur when gas bubbles are liberated from the liquid.
Foam can degrade the performance of a separator but can be stabilized with the
addition of chemicals.
However, the most effective way would be to force the foam to pass through a series of
inclined parallel plates or tubes.
This will break up the foam and allow the foam to collapse into the liquid layer.
-
Vortex Breaker
Liquid leaving the separator may form vortices which can pull gas down into theliquid outlet. This may result in re-entrainment of gas in the liquid outlet.
Separators are equipped with vortex breakers to prevent the formation of vortexwhen the liquid line is open.
A vortex breaker is a covered cylinder with radially directed flat plates.
When a liquid stream passes through the vortex breaker, the circular motion isprevented by the flat plates.
-
Sand Jets and Drains Accumulation of sand and solids
at the bottom of the vessel is a
common operational problem.
If build up of solids is not controlled, the separator
operations will not be efficient as
there is less volume available.
To remove the accumulated solids, the sand drains are
opened in a controlled manner
and then high pressure fluid
(usually water) is pumped
through the jets to agitate the
solids an flush them down the
drains.
-
Mist Extractor
Designed to remove the liquid droplets and solid particles from the gas stream.
The impingement-type of mist extractor is the most widely used type as it offers good balance between efficiency, operating range, pressure drop requirement
and installation cost.
There are three main types of impingement-type of mist extractors :
i. Baffles
ii. Wire Meshes
iii. Micro Fiber Pads.
-
Mist Extractor
i. Baffles
This type of impingement mist extractor consists of a series of baffles, vanes or plates between which gas must flow.
The most common is the vane shaped mist extractor.
The vane forces the gas flow to be laminar between parallel plates coupled with directional changes.
The surface of the plates serves as target for droplet impingement and collection.
As gas flows through the plates, droplets impinge on the plate surface.
The droplets coalesce, fall and is routed to the liquid collection section of the vessel.
-
Mist Extractor
i. Baffles (cont)
-
Mist Extractor
ii. Wire Meshes
The most common type of mist extractor found in production operations is the knitted-wire-mesh type
Has high surface area and void volume.
Effectiveness depends on the gas being in the proper velocity range. If the velocity is too high, the liquids knocked out will be re-entrained. If the velocity is
too low, the vapor will just drift pass the wire mesh without the droplets
impinging or coalescing.
Although it is not expensive compared to the other types, they are more easily plugged that the others. Not the best choice if solids can accumulate and plug
the mesh.
-
Mist Extractor
ii. Wire Meshes (cont)
-
Mist Extractor
iii. Micro Fiber Pads
Use very small diameter fibers to capture very small droplets (>0.02mm).
Since it is manufactured from densely packed fiber, the drainage by gravity inside the unit is limited.
Most of the liquid is eventually pushed through the micro-fiber and drains on the downstream face.
The surface area can be 3 to 150 times that of a wire mesh unit of equal volume.
-
Mist Extractor
The table below illustrates the major parameters which should be considered when selecting a mist extractor.
-
Potential Operational Problems
The following are the potential operating problems which
can apply to two-phase and three-phase separators
(i) Foamy Crude
(ii) Paraffin
(iii) Sand
(iv) Liquid Carryover
(v) Gas Blowby
(vi) Liquid Slugs
-
Potential Operational Problems
i. Foamy Crude
Foam is caused by the impurities in the crude oil which is not possible to removed before the stream reaches the separator.
Foaming in a separator results in :
Aggravated mechanical control of liquid level because the control device must deal with essentially three phases instead of two.
Reduced space for liquid collection or gravity settling as foam has a large volume-to-weight ratio (it occupies a large amount of the vessel
space)
Difficulties in removing separated gas or degassed oil from the vessel without entraining some of the foamy material in either the liquid or gas
outlets.
-
Potential Operational Problems
Foaming tendencies of an incoming stream can be determined via laboratory tests.
Foaming cannot be predicted ahead of time without laboratory tests.
By comparing the foaming tendencies of a known oil to a new one, the operational problems which may be expected with the new oil can be analyzed.
Foaming can be expected where CO2 is present, even in small quantities. (one percent to two percent).
The amount of foam is dependent on :
(i) Pressure drop to which the inlet liquid is subjected.
(ii) Characteristics of the liquid at the separator conditions.
-
Potential Operational Problems
Changing the temperature at which a foamy oil is separated has two effects on the foam.
a) Change in viscosity
b) Change in oil-gas equilibrium
It is difficult to predict the effects of temperature on foaming tendencies, but some general trends can be identified.
For heavy oils with a low GOR, an increase in temperature will typically decrease foaming tendencies.
Similarly, for light oils with a high GOR, temperature increases typically decrease foaming tendencies.
However, for light oils with a low GOR, a temperature increase may increase foaming tendencies. (because it is rich in intermediates which
have tendency to evolve to the gas phase as temperature is increased)
-
Potential Operational Problems
Foam-depressant chemicals can be utilized to increase the capacity of a given separator.
In sizing a separator to handle a specific crude, the use of an effective depressant may not be of the same type as characteristics of the crude and of
the foam may change during the life of the field.
The cost of foam depressants for high-rate production may not be cost economical.
During the design phase, sufficient capacity should be provided in the separator to handle the anticipated production without use of a foam depressant or
inhibitor.
Once the foam depressants are used in the operation, it may allow more throughput than the design capacity.
-
Potential Operational Problemsii. Paraffin Wax
The accumulation of paraffin wax in the separator can adversely affects its operation.
Coalescing plates in the liquid section and mesh-pad mist extractors in the gas section are particularly prone to plugging by accumulations of paraffin wax.
Vane-type or centrifugal mist extractors should be used in events where it is determined that paraffin is an actual or potential problem.
Manways and nozzles should be provided to allow steam, solvent or other types of cleaning of the separator internals.
In general, paraffinic oils are not a problem when the operating temperature is above the cloud point of crude oil (temperature at which paraffin crystals begin to form).
-
Potential Operational Problemsiii. Sand
Sand causes plugging of separator internals and accumulation in the bottom of the separator.
Accumulations of sand can be minimized by periodically injecting water/steam in the bottom of the vessel to suspend the sand during
draining.
Plugging of the separator internals is a problem that must be considered during the design stages of the separator.
A design that will promote good separation and have minimum traps for sand accumulation may be difficult to attain.
This is because the design that provides the best mechanism for separating the gas, oil, and water phases probably will also provide areas for sand
accumulation. A practical balance for these factors is the best solution.
-
Potential Operational Problems
iv. Liquid Carryover
Occurs when free liquid escapes the gas phase which results in :
Indication of high liquid level Damage to vessel internals Foam Plugged liquid outlets Flowrates which exceeds the vessels design rate
Can usually be prevented by installing a level safety high (LSH) sensor that shuts in the inlet flow to the separator when liquid level exceeds the normal
maximum liquid level by 10-15% (usually).
-
Potential Operational Problemsv. Gas Blowby
Gas Blowby occurs when free gas escapes with the liquid phase which can be an indication of :
Low liquid level Vortexing Level control failure
If there is a level control failure and the level dump valve is open, the gas will exit the liquid line and will have to be handled by the next equipment in the process.
Unless the next equipment is designed for gas blowby conditions, it can be over pressured.
Can be prevented by installing a level safety sensor (LSL) tat shuts the inflow when the liquid level drops 10-15% below the lowest operating level.
Downstream equipment should be equipped with PSH sensor/ PSVs sized for gas blowby
-
Potential Operational Problems
vi. Liquid Slugs
Two phase flow lines tend to accumulate liquids in low spots in the lines.
When the level of liquid in these low spots rises high enough to block the gas flow then the gas will push the liquid along the line as a slug.
Depending on the flow rates, flow properties, length and diameter of the flow line, and the elevation change involved, these liquid slugs may contain large
liquid volumes.
Situations in which liquid slugs may occur should be identified prior to the design of a separator.
The normal operating level and the high-level shutdown on the vessel must be spaced far enough apart to accommodate the anticipated slug volume.
-
Potential Operational Problems
If sufficient vessel volume is not provided, then the liquid slugs will trip the high-level shutdown.
The separator size must then be checked to ensure that sufficient gas capacity is provided even when the liquid is at the high-level set point.
This check of gas capacity is particularly important for horizontal separators because, as the liquid level rises, the gas capacity is decreased.
For vertical separators, sizing is easier as sufficient height for the slug volume may be added to the vessel seam-to-seam length.
-
Two Phase Separation Theory
i. Liquid Droplet Settling
ii. Droplet Size
iii. Liquid Retention Time
iv. Liquid Re-Entrainment
-
Separation Theory
i. Liquid Droplet Settling
In the gravity settling section of a separator, liquid droplets are removed using the force of gravity. Liquid droplets, contained in the gas, settle at a terminal or settling velocity.
At this velocity, the force of gravity (or negative buoyant force) on the droplet equals the drag force exerted on the droplet due to its movement through the continuous gas phase.
The drag force on a droplet is determined using the following equation:
=
2
2Where, FD = drag force, lb
CD = drag coefficient, dimensionless
Ad = cross sectional area of droplet, ft2
Dm = oil droplet diameter, ft
= density of continuous (gas) phase, lb/ft3
Vt = settling velocity of the oil droplet, ft/s
g = gravitational constant, 32.17 ft/s2
(1) =
4
2 2
2
-
Separation Theory
The buoyant force, FB, on a spherical oil droplet from Archimedes principle is :
Where, FB = gravitational or buoyant force, lb
V = volume of spherical oil droplet, ft3
Dm = oil droplet diameter, ft
= density of continuous (gas) phase, lb/ft3
= density of oil, lb/ft3
Vt = settling velocity of the oil droplet, ft/s
(2)
=
=
6
3
-
Separation Theory
=
4
2
2
2=
6
3
The oil droplet will accelerate until the frictional resistance of the fluid (gas) drag force, FD, approaches and balance the buoyancy force FB. Under this condition, the oil
droplets acceleration is zero so that it falls at a constant velocity known as the terminal or settling velocity (Vt). Therefore,
The oil droplet diameter Dm is normally expressed in microns (1 m is equal to 3.280810-6 ft). Let dm be the droplet diameter in m. Now, the above equation can be reduced for the settling velocity as:
2 =
4
3
= 0.01186
1/2
(4)
(3)
FD
FB
-
Separation Theory
(7)
The CD is a function of Reynolds number. For low Reynoldss number flow, i.e. NRe < 1,
Unfortunately, Stokes Law (creeping flow) doesnt govern for production facilities design. Hence the following drag coefficient formula can be used for practical application:
=24
=24
+
3
+ 0.34
Here, Reynolds number,
Where = density of gas, lb/ft3
dm = oil droplet diameter, m Vt = terminal velocity, ft/s
= viscosity of gas, cP
= 0.0049
(6)
(5)
-
Separation Theory
Determining CD
1. Determine oil-gas properties (o, g, ) and gas compressibility, Z if required 2. Assume CD = 0.34 considering high Reynolds number 3. Evaluate Vt using equation (4)
4. Calculate NRe using equation (7)
5. Calculate CD using equation (6)
6. Go to step 3 and iterate until convergence is obtained
= 0.01186
1/2
= 0.0049
=24
+
3
+ 0.34
(4)
(7)
(6)
-
Separation Theory
Example 1
Determine drag coefficient using the following operating conditions:
- Gas specific gravity: 0.6
- Oil gravity: 35 oAPI
- Operating pressure: 1000 psia
- Operating temperature: 60 oF
- Gas compressibility: 0.84
- Viscosity of gas: 0.013 cP
- Diameter of oil droplet: 100 m
-
Separation Theory
Tabulate the Values
Iteration Step
CD Vt NRe CD % error Remarks
1.
2.
3.
4.
5.
6.
7.
8. Convergence
-
Separation Theory
Tabulate the Values
Iteration Step
CD Vt NRe CD % error Remarks
1. 0.3400 0.7419 103.7142 0.8660 154.7013
2. 0.8660 0.4649 64.9864 1.0815 24.8811
3. 1.0815 0.4160 58.1533 1.1461 5.9782
4. 1.1461 0.4041 56.4893 1.1640 1.5626
5. 1.1640 0.4010 56.0530 1.1689 0.4173
6. 1.1689 0.4001 55.9364 1.1702 0.1120
7. 1.1702 0.3999 55.9051 1.1705 0.0301
8. 1.1705 0.3999 55.8967 1.1706 0.0081 Convergence
-
Separation Theory
ii. Droplet Size
The purpose of the gravity settling section is to condition the gas for final polishing by the mist extractor.
In the designing phase of a separator, the liquid droplet sized to be removed must be selected.
From field experience, if 140 micron sized droplets are removed, the mist extractor will not be flooded and is able to removed droplets of sized between 10 to 140 micron
diameters.
The design calculation for separators in this module is based on 140 micron sized droplets removal.
-
Separation Theory
iii. Liquid Retention Time
The average time a molecule of liquid is retained in the vessel is termed as retention time.
Sufficient retention time would ensure that the liquid and gas reach equilibrium at separator pressure.
The retention time is represented by the volume of the liquid storage in the separator divided by the liquid flow rate.
In normal operations a retention time of 30s to 3 mins is sufficient for separation operations. However, retention times of 4 times the normal amount is required in cases
where foaming crude is present.
-
Separation Theory
iii. Liquid Retention Time (cont)
The table below illustrates the typical retention times required for two phase separators from field data.
-
Separation Theory
iv. Liquid Re-Entrainment
Caused by high gas velocity at the gas-liquid interface in a separator.
The momentum which is transferred from the gas to the liquid causes waves and ripples in the liquid which results in droplets being broken away from the liquid phase.
The general rule of thumb to minimize the liquid re-entrainment is to limit the slenderness ratio to a maximum of 4 or 5 for half full horizontal separators.
Is more prominent for high pressure separators sized on gas-capacity constraints and also for applications with higher oil viscosities (
-
Separator Design - Horizontal
Separator Design Horizontal Separators Sizing (Half Full)
i. Gas Capacity Constraint
ii. Liquid Capacity Constraint
iii. Seam-To-Seam Length
iv. Slenderness Ratio
When sizing a horizontal separator, it is necessary to choose a seam
to seam vessel length and a diameter that satisfies all the conditions
for gas capacity that allows the liquid droplets to fall from the gas to
the liquid volume.
It must also provide sufficient retention time to allow the liquid to
reach equilibrium.
-
Separator Design - Horizontal
HORIZONTAL SEPARATOR
Liquid capacity (50%)
Gas capacity (50%)
Seam-to-seam Length Lss
Effective Length LeffInlet Liquid Outlet
Gas molecule flowing at average gas velocity, Vg
Liquid droplet dropping at settling velocity Vt relative to gas phase
Gas-oil interface
Diameter d
Gas outlet
-
Separator Design - Horizontali. Gas Capacity Constraint
Based on setting the gas retention time equal to the time required for a droplet to settle to the liquid interface.
For a separator 50% full of liquid and separation of 100 micron liquid droplets from the gas, the following equation can be derived :
Where
d = vessel internal diameter, in.
Leff = effective length of the vessel, ft
T = operating temperature, oR,
Qg = gas flow rate, MMscfd,
P = operating pressure, psia ,
z = gas compressibility,
CD = drag coefficient,
dm = liquid droplet to be separated,
g = density of gas, lb/ft3
l = density of liquid, lb/ft3
= 420
1/2
(8)
-
Separator Design - HorizontalEquation 8 is derived as the following :
=
=1
2
42
=1
2
4
2
144
=2
367
= 106
24
1
3600 14.7
520
= 0.327
=(0.327
(367)
2
=120
2 (9)
-
Separator Design - HorizontalSetting the residence time (tg) equal to time required for droplet to fall to the gas liquid
interface (td) :
=
=
2=
24
=
1202
(10) (11)
Combining 9 and 10 Combining 4 and 11
=
(24)(0.0119)
1/2
Equating tg to td :
1202
=
(24)(0.0119)
1/2
= 420
1/2
(8)
-
Separator Design - Horizontal
ii. Liquid Capacity Constraint
Separators must be sized to provide some liquid retention time so the liquid can reach phase equilibrium with the gas
For a separator 50% full of liquid, with a specified flow rate and retention time, the following equation is used to determine the vessel size :
Where
tr = desired retention time for the liquid, min,
Ql = liquid flow rate, bpd
2 =0.7 (12)
-
Separator Design - HorizontalEquation 12 is derived as the following :
=
=1
2
24
= 2.73 1032
= 5.62 3
24
1
3600
= 6.5 105
(12)
=21152
= 422
2 =0.7
*t = 60 tr (Assuming retention time of 60 seconds)
Retention time of between 30 seconds and 3 minutes
have been found to be sufficient for most applications.
-
Separator Design - Horizontal
iii. Seam-To-Seam Length
From the effective length calculated from equations 8 and 9 the vessels seam to seam length can be determined.
For vessels sized on a gas capacity basis, some section of the vessel length is
required to distribute the flow evenly near
the inlet diverter.
Another portion is required to place the mist extractor.
The length of separator between the inlet diverter and the mist extractor with evenly
distributed flow is the Leff (calculated from
Equation 8).
-
Separator Design - Horizontal
iii. Seam-To-Seam Length (cont)
As the diameter increases, more length is required to evenly distribute the gas flow.
The seam to seam length of a separator can be calculated using the following formula (from whichever is larger) :
= +
12
For separators sized on liquid capacity basis, the seam to seam length of a separator should not exceed the following :
(13)* For gas capacity
=4
3
(14)* For liquid capacity(or)
(15)
= + 2.5
If d < 36 ft If d 36 ft
-
Separator Design - Horizontaliv. Slenderness Ratio
Equation 8 and 12 allows for various options of diameter and length.
The smaller the diameter, the less the vessel will weigh and therefore lower cost.
However, there is an equilibrium point where further decrease in diameter increases the possibility that high velocity in the gas flow which will create waves and/or re-entrainment
of liquids.
Slenderness ratio is the ratio between length and diameter. Its calculated using the formula : 12Lss/d
Generally, most two phase separators are designed for slenderness ratios between 3-4.
Field data indicates that slenderness ratio greater than 4 or 5 will result in liquid re-entrainment.
For designs of slenderness ratios outside the range of 4, the designs should ensure that liquid re-entrainment does not take place.
-
General Horizontal Separators Sizing Procedure Half Full
1. Firstly the design basis has to be established. The maximum and minimum flow
rates, operating pressure and temperature, droplet size to be removed, etc has
to be specified.
2. A table with calculated values of Leff for selected values of d that satisfy
Equation 8, and the gas capacity constraint. Lss is calculated using Equation 13.
3. Using the same values of d, the values of Leff is calculate using Equation 12 for
liquid capacity and is listed in the same table. Lss is calculated using Equation
14 or 15.
4. For each d, the larger Leff should be used.
5. The seam to seam length (Lss) is calculated using the equation (12Leff/do or
1000Leff/do) and is listed for each d. A combination of d and Lss that has a
slenderness ratio between 3 and 4 is selected.
-
Sizing Horizontal Gas-Oil Separator
Horizontal separator sizing procedure
1. Determine CD using iterative procedure
2. Calculate dLeff for gas capacity constraint
3. Calculate d2Leff for liquid capacity constraint
7.0
2 lreff
QtLd
2/1
P420
m
d
CTZQdL D
gg
eff
gl
-
Sizing Horizontal Gas-Oil Separator
Horizontal separator sizing procedure (cont)
4. Set retention time tr to be 1, 2 and/or 3 minutes (usual case)
5. For each tr , calculate and tabulate values of
a) d
b) Leff for
Gas capacity from equation Step 2
Liquid capacity from equation Step 3
-
Sizing Horizontal Gas-Oil Separator
Horizontal separator sizing procedure (cont)
c) Lss for
Gas Capacity
Liquid capacity
d) Slenderness ratio (SR), (12)Lss/d
12
dLL effss
effss LL3
4 (or) = + 2.5
-
Sizing Horizontal Gas-Oil Separator
Horizontal separator sizing procedure (cont)
From table, compare the values of Leff for each gas and liquid capacity that governs the design of the separator
The one with larger required length governs
Then, select possible choices of separator size (d x Lss) based on the values of SR
Select SR values range 3 5
Lss values selected are the one that governs the design
-
Sizing Horizontal Gas-Oil Separator
Example of Separator Selection
tr
d Gas Leff
Liquid
Leff
Gas Lss
Liquid
Lss
SR
16 2.5 33.5 44.7 33.5
20 2 21.4 28.5 17.1
24 1.7 14.9 19.9 9.9
3 30 1.3 9.5 12.7 5.1
36 1.1 6.6 9.1 3
42 0.9 4.9 7.4 2.1
48 0.8 3.7 6.2 1.6
Horizontal Separator Example
Diameter vs. Length
Liquid capacity constraint governs since it has the largest required length
Use the liquid Lss values
to select separator size
Possible size
36 X 10
-
Example - Sizing Horizontal Gas-Oil Separator
Example 1
Given
Gas flow rate: 10 MMscfd (0.6 specific gravity)
Oil flow rate: 2,000 bopd (40API)
Operating pressure: 1,000 psia
Operating temperature: 60F
Droplet size removal: 140 microns
Retention time: 3 minutes
Gas Compressibility Factor = 0.84
Viscosity of gas = 0.013cP
-
Example - Sizing Horizontal Gas-Oil Separator
Solution
1) Calculate CD
CD = 0.851
2) Gas Capacity Constraint
= 420
1/2
= 420(520)(0.84)(10)
1000
3.71
51.5 3.71
0.851
140
1/2
= 39.852
-
Example - Sizing Horizontal Gas-Oil Separator
3) Liquid Capacity Constraint
4) Compute combinations of d and Lss for gas and liquid capacity.
5) Compute seam-to-seam length for various d . Use liquid separator capacity
basis since its greater than the gas capacity basis.
2 =0.7
2 =(3)(2000)
0.7
2 = 8571.43
=4
3 = + 2.5
If d < 36 ft If d 36 ft
or
-
Example - Sizing Horizontal Gas-Oil Separator
6) Compute slenderness ratios, 12Lss/d. Choices in the range of 3 to 4 are
common.
7) Choose a reasonable size with a diameter and length combination above both
the gas capacity and the liquid capacity constraint lines. A 36-in10-ft separator provides about 3 minutes retention time.
d (ft) Gas Leff (ft) Liquid Leff (ft) Lss (ft) 12Lss/d16 2.5 33.5 44.6 33.520 2.0 21.4 28.6 17.124 1.7 14.9 19.8 9.930 1.3 9.5 12.7 5.136 1.1 6.6 9.1 3.042 0.9 4.9 7.4 2.148 0.8 3.7 6.2 1.6
-
THANK YOU 2013 INSTITUTE OF TECHNOLOGY PETRONAS SDN BHD
All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic,
mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
-
Q & A Session