Outlines

• Introduction
• Theory
• Calculation
• Conclusion
• References

1
Introduction
• There are two common types of three horizontal separators are
free-water knockout and three-phase separator
• Most theory and calculation are based on the two-phase
separator design
• Drag force, constant terminal velocity and level controller are
include in this design.

2
Theory

3
Process Pressure control valve

Inlet diverter
Mist extractor Gas out

Weir
Inlet Gravity setting section

s
Oil & emulsion LCC
Downcomer LCC

Water-washing Water

Oil pad
Water out Oil out

Level control valves

4
Free water knockout

Pressure control valve

Inlet diverter
Gas out

Inlet Gravity setting section

Oil & emulsion

Water

Water out Oil out

Level control valves

- Volume gas<Volume liquid
- An interface controller and a weir

5
Three-phase separator (Bucket and weir design)
Pressure control valve

Inlet diverter Gas out

Inlet Gravity setting section

Oil weir
Oil & emulsion Water weir

Water

Oil out Water out

Level control valves

- Volume gas>Volume liquid

- Eliminates an interface controller 6
• Free-water knockout and three-phase separator are

Same Similar in Shape and components

Same design and procedures

Different Controlling the levels of oil and water

phases
Additional –control devices, internal
components
7
 Constant terminal velocity
𝐹𝑑
𝑑𝑚
𝜌, 𝛾, 𝜇
𝐹𝑔

𝐹𝑑
The settling terminal velocity, u, is reached when
𝜌, 𝛾, 𝜇
𝐹𝑑 = 𝐹𝑔 .
𝐹𝑔

𝐹𝑑
OR
𝜌, 𝛾, 𝜇
𝐹𝑔 8

Where:
Drag Force

9
Oil pad
Gravity settling section

Oil pad

Water oil
Water interface

In operation, Oil pad thickness is much greater than the water thickness

- Much slower velocity of water droplets

- Time needed for separation of water form oil longer than the time needed 10
for separation of oil from water.
 𝐻𝑜ൗ
1 12
𝑡𝑤𝑑 = 2
60 1.787 × 10−6 ∆𝛾 𝑑𝑚 ൗ𝜇
𝑜

1.28 × 10−3 𝑡0 ∆𝛾 𝑑𝑚
2
𝐻𝑜,𝑚𝑎𝑥 =
𝜇𝑜

Oil
pad
𝐻𝑜

11
Water
12
Retention Time
• Laboratory test
• From field experience, the following liquid retention times
have been suggested by Sivalls (s1977)

Oil- gas separation 1 min

High pressure oil-water-gas
separation
Low pressure oil-water-gas
separation
2 to 5 min
5 to 10 min at > 100℉
10 to 15 min at 90℉
15 to 20 min at 80℉
20 to 25 min at 70℉
25 to 30 min at 60℉

13
Water droplet settling constraint

Dmax

𝐴𝑜,
A
𝐴𝑤,
Aw 0.5Q w t w
=
A Qoto + Qwtw
to determine the maximum vessel diameter associated with the maximum oil
pad height according to Eq

Ho,max
Dmax =
Hoൗ
D
14
Gas Capacity constraint
• Same with two-phase separator
1Τ
Qg TZ ρg cd 2
DL = 422 P ρo −ρg dm

15
Retention time constraint
Assume ½ of the separator volume, like 2-phase
2
π D
Vl = 0.5 L
4 12
toQo
V0 =
24 × 60
twQw Vo, t o
Vw =
24 × 60 Vl Vw,t o
Vl =V0 +Vw

D2 L = 1.429(Q o t o + Q w t w )

16
Three-phase separator level control

LAHH
LAH
IAHH
IAH NLL
NIL LAL
IAL
LALL
IALL

Table 1: Summary of level abbreviation definitions

LAHH Level Alarm High High
LAH Level Alarm High
NLL Normal Liquid Level
LAL Level Alarm Low
LALL Level Alarm Low Low

IAHH Interface Alarm High High

IAH Interface Alarm High
NIL Normal Interface Level 17
IAL Interface Alarm Low
IALL Interface Alarm Low Low
Common problems, Mistakens and pitfalls
Level instrumentation 51.56%
Level control valves 20.31%
Pressure sensors 8.33%
Unknown 5.21%
Vessel mechanical error 4.17%
(Multiple) remaining failure modes ≤2.08%

“Level instruments”

- Density-based level instruments

- Instruments based on other principles

18
Calculation

19
Procedure for determining the diameter and length for 3-phase
separator

1) Determine the value of 𝐴𝑤ൗ𝐴

2) Use fig (1) to determine the value of 𝐻𝑜ൗ𝐷 using 𝐴𝑤ൗ𝐴
3) Determine 𝐻𝑜,𝑚𝑎𝑥
4) Determine 𝐷𝑚𝑎𝑥:
5) Gas capacity constraint
6) Retention time constraint
7) Compare the results obtained in steps 5 and 6 to determine
whether gas capacity or retention time (liquid capacity)
governs the design

20
8)
If gas capacity governs the If liquid retention time governs
design the design
𝐷 4
𝐿𝑠 = 𝐿 + 𝐿𝑠 = 𝐿𝑜
12 3

9) Recommend a reasonable D and L with SR (3-5)

10) Final selection (cost and availability will be important)

21
Example
Given: Gas production rate : 8MMSCFD
Oil production rate : 8000 BPD
Water production rate : 3000 BPD
Gas-oil ratio : 1000 SCF/bbl
Oil viscosity : 20cp
Oil specific gravity : 0.89
Water specific gravity : 1.04
Gas specific gravity : 0.65
Gas compressibility : 0.89
Operating pressure: 250 psia
Operating temperature : 95 ℉
Oil retention time : 15 min
Water retention time : 10 min
To find :
Diameter and seam to seam length : ?
Actual gas and liquid capacity :? 22
 Solution :

Aw 0.5Qw tw
1) =
A Qo to +Qw tw
Aw 0.5× 3000×10
= = 0.1
A 8000×15 + 3000×10

Ho
2) From fig (1) = 0.338
D
1.28×10−3 to γo −γo d2m
3) Ho,max =
μo
1.28×10−3 ×15× 0.89−1.04 500 2
=
20
= 36 in

0.338 Figure (1) Ho/D as a

function of Aw/A.
Ho/D

23

Aw/A
24
 Ho,max 36
4) Dmax = Ho = 0.338 = 106.5 in
ൗD
This is the max: allowable vessel diameter.

5) Gas capacity constraint

1Τ
Qg TZ ρg cd 2
DL = 422 P ρo −ρg dm
1ൗ
8 × 555 × 0.89 0.888 0.65 2
DL = 422
250 55.54 − 0.888 100
DL = 68.22
6) Liquid capacity constraint
D2 L = 1.429(Q o t o + Q w t w )
D2 L = 10429 8000 × 15 + 3000 × 10
D2 L = 214350

7) The gas capacity doesn’t govern the design;

The liquid capacity constraints , the results are tabulated as follows.
25
 D (in) L (ft) Ls = 4/3L (ft) SR
8) 66 49.21 65.61 11.93
72 41.35 55.13 9.19
78 35.23 46.98 7.23
9) 84 30.38 40.50 5.79
90 26.46 35.28 4.70
96 23.26 31.01 3.88
102 20.60 27.47 3.23

10) Normally, smaller D and longer L is less expensive than the longer D and
shorter L separator.

70.00
SR
60.00
Ls = 4/3L (ft)
50.00
L (ft)
40.00
30.00
20.00
10.00 26
0.00
60 70 80 Diameter 90 100 110
Actual gas constraint : Q g

D
Ls = Lg +
12
D
Lg = Ls −
12
96
Lg = 31 − 13 = 23 ft

1ൗ
Q g TZ ρg cd 2
DL = 422
P ρo − ρg dm
1ൗ
P ρo − ρg dm 2
Q g = 0.00237Lg D ( )
TZ ρg cd
1ൗ
550 55.54 − 0.888 100 2
Q g = 0.00237 × 23 × 96
555 × 0.89 0.888 0.65
Q g = 257.72 MMSCFD
27
This is much larger than the gas production rate of 8MMSCFD
Actual liquid constraint : Q o

4
Ls = Lo
3
3 3
Lo = Ls = × 31 = 23.25 ft
4 4

D2 L = 1.429(Q o t o + Q w t w )
D2 L
− Qwtw
Qo = 1.429
to
2
96 × 23.25
− 3000 × 10
Qo = 1.429 = 7996.36 BPD
15

28
Summary of the problem

8 MMSCFD

8000 BPD
3000 BPD

275.72 MMSCFD
96 in 23 ft
7996.36 BPD
3000 BPD

29
31 ft
Conclusion
• The equation developed for separation of liquid droplets from
the gas phase, which determined the gas capacity constraint,
are exactly the same for three-phase separators.
• Retention time constraint doesn’t same with water and oil

30
Assignment 4
Given: Gas production rate : 9MMSCFD
Oil production rate : 9000 BPD
Water production rate : 4000 BPD
Gas-oil ratio : 1000 SCF/bbl
Oil viscosity : 20cp
Oil specific gravity : 0.89
Water specific gravity : 1.04
Gas specific gravity : 0.75
Gas compressibility : 0.8
Operating pressure: : 250 psia
Operating temperature : 95 ℉
Oil retention time : 15 min
Water retention time : 10 min
To find :
Diameter and seam to seam length :?
Actual gas and liquid capacity :? 31