Unit – 1:

Separation of well fluid

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Separation: Gathering, Collector and Trunk pipeline system. Principle and mechanism of separation.
Classification of separators, Type of separators, namely, Vertical, Horizontal and Spherical, their
selection criterion, advantages and disadvantages of horizontal and vertical separators. Two phase and
Three Phase separation. Separation in stages and stage wise pressure evaluation method.

1. Overview of Oil and gas field production and Processes:

For oil and gas field production, various types of facilities exist, including surface and subsea production
systems. The surface production system typically is made up of a fixed offshore platform generally in
shallow water depths (up to 200m). Oil, gas, or both are transported to shore via submarine pipeline. In
subsea production system wells are completed on seabed and are connected to and supported by a subsea
template. The hydrocarbons are then transported by a submarine pipeline to an offshore terminal where
crude oil can be loaded into storage and a transportation facility (tanker or submarine pipeline to shore). If
gas is associated with oil production, it must be flared (usually illegal in large quantities), used for process
power, re-injected or piped to shore. The system is useful in deep and very deep waters. The system is
also desirable in remote areas and for marginal field development.
1.1 Different types of gathering systems:
 Wellhead separation system
 Group gathering system
 Centralized gathering system.

a. Wellhead separation system:

 Main gathering lines are laid in the form of a loop around the field. Individual wells have
their own separation and testing facility and the oil and gas lines are connected to the main
collector lines.
 Highest recovery from the field, by maintaining lowest wellhead pressure, is possible in this
system.
 This system is generally adopted in isolated small pools along with tanker based
transportation,

b. Group gathering system:

 Main collector lines are laid from a central processing facility to group gathering facility or
process platform facility. Group gathering stations receive the produced fluid thru separate
flow lines and the fluids are collected in collecting header then opens to the assigned
separator based on the pressure rating of the separator. Separated liquids, after partially water
removal, are dispatched to the central processing facility thru the collector lines.

 This type of system is generally applicable when moderate to large amounts of liquid is
produced. Two phase flow of liquid and gas causes more pressure drop in the individual flow

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 lines and consequently high back pressure on the wells. However this is an economical and
flexible system for most of the fields.

c. Centralised gathering system

 Main gathering multiphase lines run through the field and wells are produced directly into the
main line from either side. A test line is run parallel to the mainline to carry out periodic
testing of wells.
 The system is generally used in oil and gas fields where getting ROU is normally difficult
and the wells are densely located in the field.
 Use of clustered well location system, in both offshore and onshore, necessitated well
platforms with separation and test facility in offshore or underwater manifold centre (UMC)
in subsea locations and group and test gathering lines in onshore locations.
 A header in a gathering or distribution system provides a means of joining several flow lines
into a single gathering line. Valves are provided on each pipeline entering or leaving the
header so that lines can be isolated during operation and maintenance.
 Regulations and good operational production practices require oil, gas and water production
rates to be measured for individual wells at regular intervals. In offshore, the measurement
and separation facility is provided at the well platform whereas in onshore the wells are tested
in the group gathering station (GGS).

1.2 Types of Onshore /Offshore - Subsea pipelines

There are four general classifications of pipelines, depending on the line function. Certain pipe sizes and
operating pressure may also be associated with each line classification. These classifications are flow
lines, collector / gathering lines or inter-field lines, trunk lines and loading (Unloading) lines.

a. Intra field Flow lines

A flow line connects a wells to a GGS/ platform or subsea manifold. Usually the line has a small
diameter. Flow inside of it may be at high pressure. Flow lines include well fluid; water injection
and gas lift lines. A well fluid line carries reservoir fluids before separation. Water injection lines
are used for injecting treated water in the reservoir for reservoir pressure (secondary recovery)
maintenance. Gas lift lines are used to inject gas in the tubing string for lifting of well fluid on
decline of reservoir pressure.

The pipeline and other equipment used to transport crude oil from individual wells and other
production units to a central location, is called a gathering system.
The transportation system from well to the gathering station is referred to as well fluid
transportation. The fluid in this transportation system is normally multiphase fluid. Single phase
well fluid is rarely observed in oil fields.

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 b. Collector / Gathering lines (Inter-field lines)
A collector line connects from one (multi-well) platform/GGS to another Central Processing
platform/Facility and is usually a small to medium-diameter line but can be large diameter too.
They generally carry process fluids. The range of operating pressure is usually 1,000 – 1,400 psi.
Flow in the line is done by booster pumps or compressors, which are often installed on the
Central Processing Platform/ Facility.

c. Loading (Unloading lines)

These lines are used in offshore operations and usually connect a production platform or a subsea
manifold to a loading facility (Single Buoy Mooring, SBM). The lines can be small or large
diameter and carry liquid only i.e. Oil can be loaded to tankers at SBM. These lines are generally
short. The loading facility may be temporary, such as an early production facility, to provide
limited production shipment until a gathering or a trunk line can be completed or use in
emergencies.

d. Trunk lines/ Cross-country lines

Trunk/ Cross country lines transport oil and gas from one or many platforms to shore terminal for
quality maintenance in case of offshore operation whereas to refining/ process plant in case of
onshore operations..
1.3 Types of Pipeline System

A. Oil systems are commonly divided into crude oil and refined product systems. Both system collect
and deliver hydrocarbon mixture that normally exist as liquid at ambient conditions. However,
liquefied petroleum gas (LPG) is considered also a refined product though it is stored and handled
under pressure or at reduced temperature.
B. Gas systems can be divided into dry gas systems and condensate gas system. Dry gas pipeline
systems gather and transport hydrocarbon fluids all in the gaseous state. Dry gas is comprised
mainly of methane and ethane with a small percentage of heavier components. Dry gas often
contains small quantities of non-hydrocarbon components like N2, CO2 and H2S. Condensate gas
normally comprised of methane and ethane along-with heavier hydrocarbon like propane, butane,
pentane, hexane etc. This type gas may be in the gaseous state at the dispatch point but it tends to
liquefy due to condensation of heavier hydrocarbon while transportation due to fall in temperature or
pressure (Retrograde condensation). The system becomes as multiphase fluid flow system. Special
care has to be taken in course of transportation of such type of gas.

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2.0 Separation:
SEPARATOR:
1. INTRODUCTION

A. Technical Information
Separators are mechanical devices for removing and collecting liquids from natural gas. A properly
designed separator will also provide for the release of entrained gases from the accumulated
hydrocarbon liquids. A wellstream separator must perform the following:
1. Cause a primary-phase separation of the mostly liquid hydrocarbons from those that are mostly gas.
2. Refine the primary separation by removing most of the entrained liquid mist from the gas.
3. Further refine the separation by removing the entrained gas from the accumulated liquid.
4. Discharge the separated gas and liquid from the vessel and insure that no re-entrainment of one into
the other takes place.
B. DESIGN CONSIDERATIONS:
If these functions are to be accomplished, the separator design must:
1. Control and dissipate the energy of the wellstream as it enters separator;
2. Insure that the gas and liquid flow rates are low enough so that gravity segregation and vapor-liquid
equilibrium can occur;
3. Minimize turbulence in the gas section of the separator and reduce velocity;
4. Eliminate re-entrainment of the separated liquid into the gas;
5. Accumulate and control froths and foams in the vessel;
6. Provide outlets for gases and liquids with suitable controls to maintain pre-set operating pressure
and liquid levels;
7. Provide relief for excessive pressure in case the gas or liquid outlets should become plugged or
valves malfunction;
8. Provide equipment (pressure gauges, thermometers, and liquid-level gauge assemblies) to visually
check the separator for proper operation;
9. Provide cleanout opening at points where solids will accumulate when solids are present in the inlet
stream.
C. Design Conditions Require:
 Gas Flow Rate MMSCF / Day
 Sales Line Pressure
 Oil Rate BBL / Day
 Water Rate BBL / Day
 Flowing Temperature
 Specific Gravity
 Sour Gas
 CO2

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 D. Separator Construction
All separators and scrubbers are stamped and fabricated in accordance with the latest edition of the
ASME Code Section VIII Division I. Design pressures normally start at 125 PSI. Lower design
pressures may be designed and fabricated upon request. Larger sizes of separators and scrubbers than
those shown in the individual sections may be designed and fabricated to meet special applications.
Wire mesh mist extractors for separators are usually of 304SS wire mesh. Mesh densities varies from
application to application. Pads may be formed by spooling pad layers in concentric fashion. In larger
diameter separators the wire mesh pad may be made up of smaller pre-formed rectangular pads. Wire
mesh mist extractors may be made removable if necessary. The internal parts of separators and
scrubbers, such as inlet deflector, vortex breakers, and mist extractor supports are fabricated of carbon
steel.
Vaned mist extractors made of carbon steel in vertical scrubbers. These mist extractors are the most
efficient units used. This ensures that gas streams processed through vertical scrubbers will be
essentially free of entrained liquid droplets larger than 10 microns in diameter.
E. Control Systems and Accessories
Separators are equipped with properly engineered controls. The various controls used are. Properly
sized liquid valves, coupled with the selection of the correct level controller, are a must. KW
International's Engineering will size and select liquid and gas valves, level controllers, and safety relief
devices on each application. Level gauges are selected and positioned with care. Pressure gauges are
selected with an eye toward dependability as well as durability.

2. Function of Separators

A. Primary Functions
 The Primary functions of separators are –
 Removal of oil from gas
 Removal of gas from oil
 Removal of water from oil
 Separation of oil from gas may begin as the fluid flows through the producing formation into the
well-bore and may progressively increase through the tubing, flow-lines, and surface handling
equipment.
 Under certain conditions, the fluid may be completely separated into liquid and gas before it
reaches the oil and gas separator.
 In such cases, the separator vessel affords only an "enlargement" to permit gas to ascend to one
outlet and liquid to descend to another.

B. Secondary functions

 To maintain Optimum Pressure

 For an oil and gas separator to accomplish its primary functions, pressure must be maintained
in the separator so that the liquid and gas can be discharged into their respective processing or
gathering systems.

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  Pressure is maintained on the separator by use of a gas back-pressure valve on each separator
or with one master back-pressure valve that controls the pressure on a battery of two or more
separators.
 The optimum pressure to maintain on a separator is the pressure that will result in the highest
economic yield from the sale of the liquid and gaseous hydrocarbons.
 This optimum pressure can be calculated theoretically or determined by field tests.

 To maintain Liquid Seal

 To maintain pressure on a separator, a liquid seal must be affected in the lower portion of the
vessel. This liquid seal prevents loss of gas with the oil and requires the use of a liquid-level
controller and a valve.
 A lever-operated valve can be used to maintain the liquid seal in a separator when the valve is
operated by a float that is actuated by the oil level in the separator.

3. Classification of Separation
Separators can be broadly classified as:
1. Two phase separators
2. Three phase separators

Two phase separators is the most common type and are used to separate gas from oil Three phase
separators is used to separate gas from the liquid and water from oil

2-PHASE & 3-PHASE SEPARATION

The produced well fluid is generally a mixture of oil, salt water and natural gas. Separation of gas and
liquid is therefore the first processing step. The separated liquid is further subjected to dehydration and
desalting to remove water and salt. The pure oil is metered and dispatched to the refinery. The water
removed from oil, known as effluent water, is treated to meet the environmental system disposal
requirements and is then disposed off. The gas separated from oil is further treated for dehydration, liquid
recovery/LPG production and sweetening and is then compressed and transported to the consumers.

Two-phase separator

This is the most common type and is used to separate gas from liquid. Two-phase separators may
be oriented either vertically or horizontally. In some cases, it may be necessary to compare both
designs to determine which is more economic.

Three-phase separator
This is used to separate gas from the liquid and water from oil. It is often necessary to separate
two immiscible liquids, the light and heavy phases, and a vapor. Typical examples of three-phase
separation are separation of water, and hydrocarbon liquid and vapor; and separation of gas,
condensate and glycol in gas dehydration units. As with two-phase designs, three phase units can
be either vertical or horizontal.

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 4. PRINCIPLES OF SEPARATION

The separation of well fluid containing oil, water and gas, depends on various factors
such as:
 Pressure
 Temperature
 Gas oil ratio (GOR)
 Flow rate etc.

The physical separation of gas and liquids (oil and water) is based on three
principles:
 Momentum change
 Gravity settling
 Coalescing
Any separator may employ one or more of these principles, but the underlying factor is the phases
must be “immiscible” or have different densities for separation to occur.

A. Momentum change:

Fluid phases with different densities will have different momentum. If a two-phase stream
changes direction sharply, greater momentum will not allow the particles of the heavier phase to
turn as rapidly as the lighter fluid, so separation occurs. Momentum is usually employed for bulk
separation of the two phases in a stream.

B. Gravity Settling:

Liquid droplets will settle out of a gas phase if the gravitational force acting on the droplet is
greater than the force of the gas flowing around the droplet (Fig. 1). These forces can be
described using the concept of terminal or free settling velocity. The free settling velocity of the
droplet through the vapor determines the maximum allowable gas velocity. This terminal velocity
is computed by equating the downward gravity settling force and the resisting drag force.

Vt =  [2 g Mp (l-g) / l g Ap C’] = [4 g Dp (l-g) / 3 g C’] -----------------------------Eq. 1

The drag coefficient has been found to be a function of the shape of the particle and the Reynolds
No. of the flowing gas. For the purpose of the equation, particle shape is considered to be solid
rigid sphere.

Reynolds’s No. in this case is defined as:

Re = 1488 D p V t g /  ------------------------------------------------------Eq. 2

The solution requires a trial and error calculation, since two unknowns, particle size Dp and
terminal velocity Vt are involved. To avoid trial and error, values of the drag coefficient are used,
as a function of drag coefficient C’ times the Reynold’s No Squired.

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 C’ (Re) 2 = 0.95 (108) g Dp3 (l-g) / 2 ---------------------------------------- Eq. 3

Liquid-Liquid Separations
Liquid-Liquid separations are generally based upon adequate retention or settling time to allow
for gravity separation. The process is very similar to that of gas-liquid separation; however, the
difference in densities and viscosities of each phase exert a more important influence in
determining how rapidly a particle will rise or fall to become a part of each continuous phase.
Settling time is determined by using Stokes law and the distance the selected particle travels to
reach a surface for coalescence into a continuous phase.
Stokes law is as follows:
U t= K (Ps -Pe) g (Dp) 2 18gM
Where:
Ut = terminal settling velocity in ft/sec.
g= acceleration due to gravity, normally 32.17 ft/(sec.) (sec.)
M= viscosity of the continuous phase in (lb mass)/ft (sec.)
Dp = particle diameter of dispersed phase in ft.
As = density of the heavier liquid (lb/ft.3)
pi = density of the lighter liquid (lb/ft.3)
K= 3.3 proportionality factor

Settling velocity and total volume of liquid to be separated are used to determine the retention
time and vessel dimensions. The final vessel size is determined by trial and error method; but in
any case, the final length to diameter ratio should not be less than 4 to 1 in order to minimize
turbulence.
Special internals can be used to shorten the liquid particles' path in getting away from the bulk
of the continuous phase. This increases the efficiency of the separation and increases the
capacity.
C. Coalescing:

Very small droplets such as fog or mist cannot be separated practically by gravity. These droplets
can be coalesced to form larger droplets that will settle by gravity. Coalescing devices in
separators force gas to follow a tortuous path. The momentum of the droplets causes them to
collide with other droplets or the coalescing device, forming large droplets. These large droplets
can then settle out of the gas phase by gravity. Wire mesh screens, vane elements, and filter
cartridges are typical examples of coalescing devices.

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5. COMPONENTS/ SECTIONS OF A SEPARATOR

Regardless of shape and configuration, separation vessels usually contain four major sections,
plus the necessary controls.

 Primary separation section

 Secondary or gravity section
 Coalescing section
 Sump or liquid collection section

A. Primary separation section

The primary separation section, A, is used to separate the bulk portion of free liquid in the inlet
stream. It contains the inlet nozzle, which may be tangential, or a diverter baffle, to take
advantage of the inertial effects of centrifugal force or an abrupt change of direction or
momentum, with the hop of half sphere or baffle plates, to separate the major portion of the liquid
from the gas stream. In some cases, this is also called inlet diverter or impingement baffle. The
inlet diverter is used to disengage the gas and liquid.

B. Secondary or gravity section

The secondary or gravity section, B, is designed to utilize the force of gravity to enhance
separation of entrained droplets. It consists of a portion of the vessel through which the gas
moves at a relatively low velocity with little turbulence. In some designs, straightening vanes are
used to reduce turbulence. The vanes also act as droplet collectors, and reduce the distance a
droplet must fall to be removed from the gas stream.

C. Coalescing section
The coalescing section, C, utilizes a coalescers or mist extractor which can consist of a series of
vanes, a knitted wire mesh pad, or cyclonic passages. Very small droplets cannot be separated by
gravity alone. This section removes the very small droplets of liquid from the gas by
impingement on a surface where they coalesce to form larger droplets, which settle, by gravity. A
typical liquid carryover from the mist extractor is less than 0.1 gallon per MMscf.
Mist eliminators or extractors, or demister pads, act as coalescing devices in separators which
force the gas to follow a tortuous path the momentum of the droplets causes them to collide with
other droplets or the coalescing devices, forming larger droplets. These devices consist of a
series of vanes/ woven wire mesh pad/labyrinth type. Although wire mesh type mist extractors
are claimed to be cheaper and more efficient, they are not used very often because they get
plugged with oil droplets and require frequent cleaning, thus causing more downtime. In case of
vane type / labyrinth type, no maintenance is required.

D. Sump or liquid collection section

The sump or liquid collection section, D, acts as a receiver for all liquid removed from the gas in
the primary, secondary, and coalescing sections. Depending on requirements, the liquid section

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 should have a certain amount of surge volume, for degassing or slug catching, over a minimum
liquid level necessary for controls to function properly. Degassing may require a horizontal
separator with a shallow liquid level while emulsion separation may also require higher
temperature, higher liquid level, and/or the addition of a surfactant.

6. Other components of a separator

i. Inlet diverter
The inlet diverter is used to disengage the gas and liquid. The momentum of the inlet
stream is reduced either by creating centrifugal force with the help of cyclone inlet
diverter or abrupt change in direction and velocity with the help of half sphere or baffle
plates.

ii. Defoaming plates

In secondary separation section the gas velocity is reduced such that the entrained liquid
droplets can settle by gravity. Internal inclined parallel baffles are used to dissipate
foams, reduce turbulence and for coalescence of droplets.
iii. Mist extractor
This consists of a series of vanes/woven wire mesh pad/labyrinth type. Although wire
mesh type mist extractors are claimed to be cheaper and more efficient, they are not in
Bombay high platforms because they get plugged with oil droplets and require frequent
cleaning, thus causing more downtime. In case of vane type/labyrinth type, no
maintenance is required.
iv. Vortex breaker

At the outlet, a vortex breaker is used to prevent the development of a vortex when
control valve is open. The vortex can suck more gas out of vapor space and re-entrain it
in flow at outlet

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7. Types of Separators
a. Vertical separator
b. Horizontal separator
c. Spherical separator
d. Cyclone separator
e. Centrifugal Separator

a. Vertical Separators
Vertical separators, are usually selected when gas to liquid ratio (GLR) is high or total gas
volumes are low. In the vertical separator, the fluids enter the vessel striking a diverter baffle,
which initiates primary separation. Liquid removed by the inlet baffle falls to the bottom of the
vessel. The gas moves upward, usually passing through a mist extractor to remove suspended
mist, and then the “dry” gas flows out.
Liquid removed by the mist extractor is coalesced into larger droplets, which then fall through the
gas to the liquid reservoir at the bottom. The ability to handle liquid slugs is typically obtained by
increasing height. Level control is not critical and liquid level can fluctuate several inches without
affecting operating efficiency. Mist extractors can significantly reduce the required diameter of
vertical separators.
The vertical orientation is used for three-phase, only if there is a large amount of vapor to be
separated from a small amount of the light and heavy liquid (< 10–20% by weight)

o Basic selection criteria

 For low GOR streams
 When relatively large liquid slugs are expected
 When sand, paraffin or wax are produced
 When plot space is limited
 When ease of level control is desired
o Advantages
 More versatile than horizontal
 Greater liquid surge capacity
 Liquid level control is not so critical
 Has good bottom - drain and clean-out facilities
 Can handle wax more sand, mud, paraffin, wax without plugging.
 Fewer tendencies for re-entrainment.
 Has full diameter for gas flow at top and oil flow at bottom
 Occupies smaller area
o Disadvantages
 Requires larger diameter for a given gas capacity, therefore, most
competitive for low GOR,
 More expensive than horizontal
 More difficult to skid mount and ship,
 More difficult to reach and service top mounted safety devices

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 Typical arrangement of three phase vertical separator:

 Advantages
 Greater liquid surge capacity
 Liquid level control is not so critical
 Has good bottom drain and clean out facilities
 Can handle more sand, mud, paraffin without plugging
 Less tendency for re-entrainment
 More versatile than horizontal
 Has full diameter for gas flow at top and oil flow at bottom
 Occupies smaller area
 Disadvantages
 Requires larger diameter for a given gas capacity, therefore, most competitive for low
GOR
 More expensive than horizontal
 More difficult to skid mount and ship
 More difficult to reach and service top mounted safety devices.

Vertical Separator with vane type ME

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 Optimization of separation stages for liquid recovery

b.

Two-Phase Vertical Separator Three-Phase Vertical Separator

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 b. Horizontal separator
Horizontal separators are most efficient where large volumes of total fluids and large amounts of
total gas are present with the liquid. The greater liquid surface area in this configuration provides
optimum conditions for releasing entrapped gas. In the horizontal separator, Fig. 4, the liquid,
which has been separate from the gas, moves along the bottom of the vessel to the liquid outlet.
The gas and liquid occupy their proportionate shares of the shell cross-section. Increased slug
capacity is obtained through shortened retention time and increased liquid level.

For three-phase separation, different variation of construction is used depending upon the specific
application. In a three-phase separator, the liquid separation section is usually a variation of a
device to provide interface level control, which may include a boot or a weir. A boot typically is
specified when the volume of heavy liquid is not substantial (< 15-20% of total liquid by weight),
while a weir is used when the volume is substantial. The bucket and weir type design is used
when interface level control may be difficult, such as with heavy oils or when large amounts of an
emulsion or paraffin are present.

The horizontal separator also comes in double barrel configuration. In this type, the liquid falls
through connecting flow pipes into the external liquid reservoir below. Slightly smaller vessels
may be possible with the double barrel horizontal separator where surge capacity establishes the
size of the lower liquid collection chamber.

Basic arrangement of various types of three-phase separators

Fig-a

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Fig-b

Fig-c

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Fig-d

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 Advantages
 Requires a smaller diameter for a given gas capacity
 Cheaper than vertical
 Lend themselves to skid mounting and shipping
 No counter flow, gas flow does not drainage from mist extractor
 Larger liquid surface area for foam dispersion
 Generally reduces turbulence.

 Disadvantages
 Only part of shell available for passage of gas
 Occupies more area unless “stack” mounted
 Liquid – level control is more critical
 More difficult to clean produced sand, mud, paraffin, etc.

o Basic selection criteria

 For high to medium GOR streams
 For higher volumes of gas and or liquids
 For foaming crudes
 For three phase separation.

c. Spherical separator
This is most commonly used for the separation of large volumes of gas from extremely small
volumes of liquid. It is mainly used as a scrubber and seldom used at well site as oil and gas
separator. These separators are occasionally used for high-pressure service where compact size is
desired and liquid volumes small. Fig. 7 is a schematic of a typical spherical separator. Factors
considered for a spherical separator are:
 Compactness
 Limited liquid surge capacity
 Minimum steel for a given pressure

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 Advantages:
 Compact & easy to maintain and can be stacked
 Good separation capacity & better liquid handling
 Most economical for HP single well installations
 Owing to easier mountings suitable for testing wells
Disadvantages:
 Limited surge capacity
 Uneconomical for large gas capacity
 Liquid level control is critical

d. Cyclone separator

This is relatively new type of separator and is not commonly used in gas processing industry.

e. Centrifugal Separators / Compact Separators

This is relatively new type of separator and is not commonly used in oil and gas processing
industry. These devices are proprietary in nature. Care should be taken in selecting these units, as
some styles are not suitable for some applications. The main advantage of a centrifugal separator
is that much less maintenance is involved. Disadvantages of centrifugal separators are:
 Some designs do not handle liquid slugs
 Efficiency is not as good as other types of separators
 They have a narrow operating flow range for highest efficiency.

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8. FACTORS TO BE CONSIDERED FOR SEPARATOR CONFIGURATION

The following major factors have to be considered for the configuration of a separator:
 Plot space available
 Presence of extraneous materials e.g. sand, mud, corrosion products etc.
 Available surface area for degassing of separated liquid
 Problem of transporting the separator
 Availability of enough interface surface for three phase separation
 Requirement of heating coils or sand jets
 The amount and duration of surges in liquid flow and effect on liquid level
 Necessity of large liquid retention volume

Basic Selection Criteria for vertical and horizontal separators

Design Conditions Require:
 Gas Flow Rate MMSCF / Day
 Sales Line Pressure
 Oil Rate BBL / Day
 Water Rate BBL / Day
 Flowing Temperature
 Specific Gravity
 Sour Gas
 CO2

Table 1: Comparison of Vertical and Horizontal Separator

VERTICAL SEPARATOR HORIZONTAL SEPARATOR

 For low to medium GOR streams  For high to medium GOR

 When relatively large liquid slugs are expected streams
 When sand, paraffin or wax are produced  For larger volumes of gas
 When plot space is limited  For foaming crudes
 When ease of level control is desired  For three phase separation

9. DETERMINATION OF SEPARATION STAGES

The separation is usually carried out in more than one stage (Fig. 11). By separating the mixture
of hydrocarbons into vapor and liquid phases in two or more equilibrium flashes at successively
lower pressures (i.e. in stages), more stable stock tank liquid is obtained. In addition, liquid
recovery is enhanced.

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In equilibrium or flash vaporization, the vapor is kept in intimate physical contact with the
remaining liquid for certain retention time.
The storage tank is usually considered as one stage of separation.

In differential vaporization, the vapor is removed from the contact of liquid as soon as it is
formed. In this process, the pressure is decreased in infinitesimally small pressure steps and gas
liberated at each stage is instantaneously removed. This results in maximum liquid recovery.
However, this needs infinite number of separators connected in series and is uneconomical.

In actual field practice, two or three stages are considered to be optimal.

A detailed techno-economic analysis is carried out for selection of number of separation stages
for a field.

The total GOR is the ratio of total cumulative gas recovered from all separation stages per barrel
of stock tank oil produced. Combined theoretical gas HP is equivalent to total compressor HP
necessary to compress gas recovered at each separation stage from atmospheric pressure to
separator pressure. Upon analysis of these studies it is noticed that:
 The total produced GOR varies with number of stages for given crude and is lower for more
number of stages.
 When the total GOR is lower, more of lighter fractions remain in oil and thus oil API gravity
increases (i.e. density is reduced). This yields higher income.

10. SEPARATOR SPECIFICATIONS

10.1 Separator efficiency

Liquid carryover in gas

 The amount of liquid carryover of droplets larger than 10 microns in size is generally less
than 0.1 Gal / MMSCF.
 Wire mesh type mist extractor can eliminate droplets smaller than 100, a typical efficiency
of 98-99% can be achieved. Vane type mist extractor commonly used in oil and gas
separators is less efficient than wire mesh type mist extractor. This is especially true for
droplets smaller than 5 microns.

Gas content in Oil

 Gas carried through oil is generally 2 to 5% by volume.

Oil content in Water

 The oil content of the residual water drained should not exceed 300 to 500 mg/l due to
environmental restrictions.

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Retention time for liquid-liquid separation

Retention time determines the liquid capacity of a separator.

If problems such as foaming, wax deposition, slug flows are not encountered, the following
specifications 12 J recommendations for two-phase vapor liquid separation, and three-phase
separation are used:

Table 2: API recommendations for 2-phase flow

Oil oAPI Gravity Retention time (min.)

Above 35 1

20 – 30 1 to 2

10 – 20 2 to 4

Table 3: API recommendations for 3-phase flow

Oil oAPI Gravity Retention time (min.)

Above 35 3 to 5

Below 35, Separation temp. 100+ oF 5 to 10

Below 35, Separation temp. 80+ oF 10 to 20

Below 35, Separation temp. 60+ oF 20 to 30

API specification 12-J allows equal retention times for both oil and water phases.

Liquid Level

Max. Oil level < 0.65 x I.D.

Normal oil level: 0.5 x I.D.

OR

1 min. retention time between maximum and normal liquid level

Low oil level: 0.1 x I.D.; OR 12” from bottom or safe height from normal water level to prevent
water carry through, whichever is greater.

Water level: Height corresponding to water retention time (which is 1 to 2 min. normally); OR
12”, whichever is greater.

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 10.2 Important Sizing Criteria
Holdup:

 The time it takes to reduce the liquid level from normal liquid level (NLL) to low liquid level
(LLL) while maintaining a normal outlet flow without feed make up.
 Holdup time is based on the reserve required to maintain good control and safe operation of
downstream facilities.
Surge time:

 The time it takes for the liquid level to rise from normal (NLL) to maximum or high liquid
level (HLL) while maintaining a normal feed without any outlet flow.
 Surge time is usually based on requirements to accumulate liquid as a result of upstream or
downstream variations or upsets, for example, slugs. In the absence of specific requirements, surge
time may be taken as one half of holdup time.

Fig. 11 Typical separation stages

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