Appendix P.

Separator Vessel and Filter Design Guide

Abstract
This appendix gives guidelines for designing and selecting knockout pots and high efficiency filters for compressor suction systems. Contents P1.0 P2.0 P3.0 Vertical Separator Vessels Horizontal Separator Vessels High Efficiency Filters Page P-2 P-13 P-17

Chevron Corporation

P-1

February 1998

Appendix P

Compressor Manual

P1.0

Vertical Separator Vessels

P1.1 Determining Vessel Length (Height)
Vessel dimensions are determined by the liquid and gas flowrates and densities during normal maximum operating conditions. This includes potential upset conditions that can jeopardize the downstream equipment.

Liquid Storage Capacity

Vessel length is determined by the requirements for accommodating vessel internals, in addition to the amount of liquid surge volume required to ensure sufficient level control. The design basis must take into account the potential volume of liquid that might slug into the vessel during a process upset. This amount is determined by evaluating the upstream process for its potential to entrain liquids in the gas stream in the event of logical operating scenarios, such as a pump or valve failure. This is a judgment requiring careful operations/engineering review.

Surge Volume
Surge volume is defined as the liquid capacity below the maximum allowable liquid level. The designer must factor into this vessel dimension any additional capacity necessary to control potential liquid loading. Figure P-1 illustrates surge volume and other design features of a basic vertical knockout drum. For compressor suction knockout service, a minimum recommended fill time of five minutes, based on maximum potential liquid loading, should be provided between the high level alarm (LAH) and the automatic compressor shutdown (LSH). This time period is based on the amount of time necessary for operating personnel to respond to the high level, and should be adjusted to suit the operating circumstances. Discussions with experienced operating personnel is recommended.

Liquid Drainage
Liquid drainage capacity must be addressed in a similar manner. Failure to adequately size drain lines and level control valves for the above conditions can result in uncontrollable high levels and consequential shutdowns. Part of this judgment comes from understanding the location of the vessel and relative availability of operating personnel during upset conditions. A two-inch outlet provision is recommended as a minimum.

February 1998

P-2

Chevron Corporation

Compressor Manual

Appendix P

Fig. P-1

Basic Vertical Knockout Drum Configuration

Chevron Corporation

P-3

February 1998

Appendix P

Compressor Manual

P1.2

Determining Vessel Diameter

The vessel diameter is dictated by the desired mass velocity through the vessel. The recommended allowable mass velocity takes into account the terminal, or free settling velocity of aerosol particles at predetermined operating conditions. A K factor is used to modify the velocity calculation for such factors as extreme pressures (high or vacuum), suspended solids content, reduced surface tension, entrainment loading and viscosity. The value of K in the formula for calculating maximum allowable velocity depends on the nature of the gas contaminants and whether mist elimination devices are to be used. Optimum velocity factored by K value is calculated using the following Souders Brown equation: V = K [ ( L G ) G ] where: V = Optimum gas velocity, ft./sec. K = Factor used for optimum liquid/gas separation G = Gas Density L = Liquid Density Empirical data suggests that when sizing the minimum inside diameter of a basic vertical gravity separator (no impingement device), the following K values should be used: K = 0.11 or less K = 0.15 - 0.17 Gas streams containing high liquid loading with no impingement device Gas streams containing low liquid loading with no impingement device
0.5

These values were largely determined through experiments with a perforated plate column where tray spacing and liquid seal depths were varied to observe the effect on K value. The K value was observed to level off between 0.17 to 0.19 at a disengaging space of 28 inches, suggesting a reasonable value for simple gravity separation without the aid of impingement devices. These values are consistent with the Scrubber Services Classes 'A', 'B', and 'C' as described in API Specification 11P - Specification for Packaged Reciprocating Compressors for Oil and Gas Production Services, however, slightly more conservative. In the interest of maximizing compressor reliability, it is preferred to design on the conservative side to provide a degree of process capacity contingency. For further guidance regarding allowable mass velocities for system pressures above and below 800 psi at given vapor/liquid densities, refer to Chevron Research chart RE 690433-1. Charts RD 663794-1, and RD 663795-1 are also reference tools for required vessel diameter as a function of gas rate and system properties.

February 1998

P-4

Chevron Corporation

Compressor Manual

Appendix P

Note Inside diameter of the annular support ring is the dimension to use in the vessel area calculation when the vessel is equipped with a demister pad or vane mist eliminator. This represents the velocity for the inlet surface area of the impingement device.

P1.3

Mist Elimination Internals

The reliability and service life of all compressors is directly related to the inlet gas cleanliness. To ensure optimum knockout drum performance, mist elimination devices are necessary to increase impingement surface area in the gas flow path. Reciprocating compressors are most sensitive to gas quality. It is highly desirable to reduce the amount of aerosol contaminants to the lowest practical concentration. Liquid and solid aerosols entrained in the inlet gas are the prime contributors to premature valve failure, cylinder wear and corrosion damage. Although centrifugal compressors are more forgiving to entrained aerosols, they are still susceptible to efficiency losses due to particle induced fouling, erosion, and corrosion. There are several methods commonly used in compressor suction service, each one capable of achieving a certain degree of removal efficiency. They are: 1. 2. 3. 4. Vane mist eliminators Wire mesh pads (demister pads) High efficiency coalescer filters Brownian diffusion mist eliminators

Figure P-2 illustrates the approximate capture efficiency for these impingement devices for a given range of particle sizes. Although most installations use only one mist elimination device, a combination of two or more of the above devices will provide additional protection for almost all services. Selecting the combination depends primarily on the nature and volume of the liquids to be removed. Generally, as the viscosity of the liquid increases, the larger the entrained droplet size. Similarly, as liquid surface tension decreases, so does the droplet size.

Selecting a Mist Eliminator

Figure P-3 will be useful as a guide in selecting a satisfactory type of mist eliminator or combination of devices best suited for the application. Figure P-4 illustrates the relative operating range for each media type. This represents the approximate particle size and concentration of water aerosols under controlled test conditions.

Vane Mist Eliminators

Vane Mist eliminators (sometimes referred as chevron design mist eliminators) are best used when liquid loading is high and/or the liquid is viscous or has fouling characteristics (such as paraffins, hydrates). They are not recommended for use as the sole mist elimination device for compressor suction service due to their high

Chevron Corporation

P-5

February 1998

Appendix P

Compressor Manual

Fig. P-2

Approximate removal efficiency of conventional mist elimination devices for given particle sizes. Note that the effectiveness of vane mist eliminators is marginal at the point where woven mesh efficiency is near its peak.

Fig. P-3

Mist Eliminator Types Wire Mesh Pad Vane (Chevron) High Efficiency Media X X X X X X X X X X X X X X X

Ultra Fine Droplets Fine Droplets Coarse Droplets High Liquid Loads Fouling Contaminants Corrosive Service Maximum Efficiency Widest Range of Materials Lowest Differential Pressure High Pressure

(< 5 micron) (5-15 micron) (> 15 micron)

February 1998

P-6

Chevron Corporation

Compressor Manual

Appendix P

Fig. P-4

The approximate range of water aerosols entrained in air is plotted in this graph to illustrate the aerosol concentration versus particle size and type of media effective to use for control. Note that as the aerosol particle size declines, higher efficiency media is required to achieve efficient particle contact.

particle size cut-off point. The expected particle size cutoff (98% efficiency) is about 15 micron, resulting in a considerable amount of aerosols carried through with the gas. The ability of the vane mist eliminator to handle large volumes of liquid at relatively high vapor velocity is one of its key benefits. As long as the actual vapor velocity is restricted to proper design K values, reasonable liquid scrubbing efficiency is achieved with minimum pressure drop and fouling. When determining a vessel diameter for vane mist eliminators, the actual velocity is calculated using the same Souders Brown equation previously discussed in Section P1.2, Determining Vessel Diameter. The recommended K values for vane mist eliminators in vertical vessels are: Minimum K value = 0.12 Maximum K value = 0.54 K value 0.60 and above = Re-entrainment

A maximum K value of 0.54 is recommended for vertical vessels. This is approximately 120% of design rate to protect against carryover during upsets and unusual operating conditions. A minimum K value of 0.12 is a turndown limitation to prevent an insufficient velocity condition such that aerosols tend to flow around the vanes in laminar gas flows, as opposed to impinging on the vane surfaces.

Chevron Corporation

P-7

February 1998

Appendix P

Compressor Manual

Another benefit of the vane mist eliminator is its stout physical structure. In corrosive services, a wire mesh pad can be relatively short lived compared to a vane mist eliminator. In this circumstance, a combination of wire mesh and vanes can be of further benefit. In either case, a conservative corrosion allowance is recommended when separating corrosive liquid/gas vapors.

Combination Installations
Vane mist eliminators can be used in tandem with wire mesh pads to control the amount of liquid pooling within the pad. Contacting the bulk of vapor entrained liquids with vane mist eliminators prior to flowing to the wire mesh pad enhances the pad's ability to quickly drain. This application also increases the effective operating range of the demister pad, particularly during unusual liquid loading scenarios. Figure P-5 plots the liquid scrubbing performance of a vane mist eliminator installed upstream of a woven wire mesh pad.
Fig. P-5 The point at which pressure drop indicates flooding is plotted for different rates of liquid loading. The wide range of liquid handling capacity is attributed to the installation of a vane mist eliminator in front of a demister pad to relieve the pad of excessive liquid load.

In addition to the added removal capacity of vanes, another reason for enhanced mesh pad performance in tandem configuration is the straightening of the gas flow entering the pad. Swirling and lateral gas flow entry promotes pooling in the pad, thus increasing the likelihood of pad flooding and re-entrainment.

February 1998

P-8

Chevron Corporation

Compressor Manual

Appendix P

Combination installations are well suited for minimizing mesh pad fouling and corrosion. Fouling solids are effectively removed in the vane section and corrosive liquids that pool in the mesh pad can be minimized. The result of combination installations is reduced pad fouling and corrosion, as well as enhanced removal efficiency over a wide range of loading. It is a good retrofit alternative for systems that are operated beyond original design. Figure P-6 illustrates how a combination installation might look.

Wire Mesh Mist Eliminators

Generically known as demister pads, wire mesh has been used for decades as a contacting media for coalescing liquid aerosols. First introduced as a woven wire screen, the construction was relatively stiff and usually applied as a thin, single layer. The technically superior design now predominantly used is a thick knitted wire mesh pad. Knitted mesh pads possess high void volume and contact surface area. The result is high removal efficiencies for aerosols smaller in size than what can be removed by vane mist eliminators. Figure P-2 and P-4 illustrate these efficiencies. The variables that control void volume, area and density of the mesh are: 1. 2. 3. Wire size - typically .002" to 0.020" in diameter Size of knitted loops Amplitude of wire crimping for added surface area.

Pad density varies from 2 to 24 lb per cubic foot and can possess surface areas from 44 to 1200 square feet per cubic foot of mesh. Separation efficiency is governed by the relation of wire diameter and density. As wire diameter decreases, density and efficiency increase. Practical application requirements and cost narrow the range of styles readily available, although a large array of styles and materials are still available. As an example, a commonly used selection would consist of 0.011" diameter wire mesh possessing a void volume of approximately 97%, have a density of 12 lb/cu.ft., and a surface area of approximately 110 sq. ft./cu. ft. The mesh is typically available in thicknesses of 4", 6" or 12", or can be rolled into a much thicker pad configuration for special applications. Mesh pads can be made from almost any material that can be extruded or drawn. In addition to carbon steel alloys, some examples of other available materials are: 300 and 400 Series Stainless Steel Titanium, Tantalum Copper, Aluminum Synthetics (Polypropylene, Teflon)

The material of choice depends on the known characteristics of the contaminants in the gas. Representative samples of the gas for analysis are recommended prior to making design changes or specifying a new purchase. Mesh pad manufacturers and

Chevron Corporation

P-9

February 1998

Appendix P

Compressor Manual

Fig. P-6

Combination Vane/Wire Mesh Knockout

February 1998

P-10

Chevron Corporation

Compressor Manual

Appendix P

CRTC materials specialists are excellent resources for consultation on material choice. Figure P-7 is a guide of K values for standard demister pad and vane styles offered by Otto York Company. Special conditions which change this value are discussed in the Section, Effects of Pressure on K Value. Similarly, other manufacturers should offer recommended K values for their products.
Fig. P-7

K Values for Common Otto York Demisters

Style

K
.35 .35 .35 .28 .28 .28 .35 .40 .65

Application Heavy duty, high efficiency design for heavy liquid loading Generic style, good efficiency and capacity Low density for fouling and high liquid loading Ultra high efficiency at reduced capacity Polypropylene, corrosion resistance, good efficiency Teflon design for extremely corrosive services Chevron style vanes for fouling applications Chevron style vanes for fouling, high liquid loadings and low pressure drop Vanes designed for horizontal flows with a potential for fouling, high liquid load and/ or low pressure drop.

709 172 708 194 241 221 Vane Type 1 Vane Type 3 Vane Type 4

Considerations for Retrofits

Often, little can be done to reduce mass velocity or contaminant loading. When changes must be made in an attempt to increase the removal efficiency without penalizing the process, combinations of vanes and mesh pads are often the best choice. Figure P-6 illustrates a knockout drum configuration suitable for high liquid loading or viscous, fouling contaminants such as paraffins.

Effects of Pressure on K Value

A K factor of 0.35 will give a safe velocity for practically all applications where operating pressure is reasonably close to atmospheric. Giving account to the previously mentioned factors that can influence K value, Figure P-8 gives recommended K values at various pressures:

Vessel Outlet Nozzle Clearance

The distance between the outlet nozzle opening and top of the mist elimination device is recommended to be a minimum of 12 inches, increasing in relation to the diameter of the mist elimination device. The objective is to prevent channeling by promoting equal velocities across the entire surface area of the mist elimination device. Two policies are commonly used for determining the appropriate distance. The rule of thumb is 12 inches minimum or half the diameter of the mist elimination device, whichever dimension is greater. Figure P-9 illustrates examples for minimum nozzle outlet distance.

Chevron Corporation

P-11

February 1998

Appendix P

Compressor Manual

Fig. P-8

Effect of Pressure on K Value PSIA 7.5 10.0 20.0 50.0 100.0 .34 .35 .35 .34 .33 Subtract .01 for every 100 psi above 100

Over 100
Note

Pressure derating is influenced by drainage, while vacuum derating is influenced by pressure drop.

Fig. P-9

Minimum Recommended Clearance Between Outlet Nozzle and Top of Mist Elimination Device

February 1998

P-12

Chevron Corporation

Compressor Manual

Appendix P

P2.0

Horizontal Separator Vessels

P2.1 Determining Vessel Length
Vessel length is based on liquid holding volume and residence time. The length is adjusted to achieve the necessary liquid holding volume to satisfy proper process control. This is usually considered to be the minimum amount of time for liquid surge. In general, the vessel length and diameter is sized to provide the required vapor space (velocity) plus liquid retention volume. Note It is a good idea to involve process design/control engineers when making liquid volume determinations.

P2.2

Determining Vessel Diameter

The maximum allowable gas velocity determines the required vapor space area above the highest liquid operating level. One method used to determine the required vapor space uses a variation of Souders Brown equation. The method takes into account particle settling velocity and horizontal gas velocity by ratioing them to the distance each must travel per unit time. The equation is expressed as: Vh Vs = ( L t ) ( D t ) = L D where: Vh = horizontal gas velocity, ft/sec. Vs = particle settling velocity, ft/sec. t = time in seconds L = length between inlet and outlet, ft D = vessel diameter, ft The equation is further modified to provide five feet for entrance and exit flow stabilization. The allowable horizontal gas velocity is then expressed as: V h = [ ( L 5 ) D ] [ K ] [ ( L g ) g ] 0.5 Re-writing the equation into the form of the Souders Brown equation, it is expressed as: V h = K ( ( L g ) g ) 0.5
h

where: Kh = K ( L 5 ) D

Chevron Corporation

P-13

February 1998

Appendix P

Compressor Manual

SEPDES
When designing or modifying two- and three-phase separators, an easier alternative to hand calculations would be to use SEPDES, a PC program for designing liquid/gas separators for hydroprocessing units. Information for this program is available through your local process engineer or through CRTCs Process Engineering Specialists.

Horizontal Knockout Vessels

The basic horizontal knockout pot shown in Figure P-10 can have internals configured many different ways. As with vertical vessels, careful consideration must be given to the nature of the fluids the impingement device is to deal with. Corrosives and foulants play a significant role in the selection of the types of internals used.
Fig. P-10 Basic Horizontal Liquid / Gas Separator

The velocity limits described in Section P1.0 still apply, as they are meant to ensure that the selected internals are operated within their efficiency range. As with all other mist elimination applications, the inlet surface area of the mist elimination device is used when determining the optimum velocity or K factor, not the crosssectional area of the vessel. Figure P-11 illustrates an example of a horizontal vessel equipped with mesh pad and liquid storage area. Figure P-12 illustrates several other alternative internal configurations that, if designed within the criteria previously discussed, will provide good protection from liquid carryover.

February 1998

P-14

Chevron Corporation

Compressor Manual

Appendix P

Fig. P-11 Horizontal Knockout Vessel (Example Configuration)

N O TES: 1. U pperand l ersupportgri ar ow ds e r equi f red orphysi calstr engt h.The m esh pad and gri assem bl i ted d y s i t ogetherusi " ng J"bol and m ounted ts on an annul arsupportrng.The i assem bl i secured to t annul y s he ar rng usi ti w i f i ng e res orm ost applcati i ons.B oli orot tng herel abor ate m et hods f orsecurng t m esh pad i he ar usualy unnecessary. e l

2. I etsur ace area ofthe m esh pad i nl f s used as t basi f he s ordeterm i ng ni optm um vel ty or K f i oci actor .Typi cal t al esh pad m i o lm stelm i i nator applcati i ons,a K f actorof0. -0. 28 35 i used dependi on t type ofpad. s ng he

Chevron Corporation

P-15

February 1998

Appendix P

Compressor Manual

Fig. P-12 Variations of Horizontal Knockout Internals

February 1998

P-16

Chevron Corporation

Compressor Manual

Appendix P

P3.0

High Efficiency Filters

Liquid/Gas Coalescer Cartridge
Liquid/gas coalescer cartridges are similar to cartridge filters in appearance and size. The media is designed for the gas flow inside to out, thus allowing the coalesced liquids to wick down the special outer media wrap into a basin for removal. This design is extremely effective due to the media pore structure of 0.3 micron absolute. Basically, this rating means that particles greater than 0.3 micron in size cannot flow through the media. The extremely small pore structure is due to the unique flow characteristics of submicron particles. Liquid and gas particles 0.1 to 0.6 micron in size tend to flow along the path taken by the gas, as opposed to impinging on pipe walls and dropping out. The particles are not large enough to be removed by inertial impingement and not small enough to be removed by Brownian motion. The 0.3 micron pore media is designed to trap this unscrubbed portion of gas. This design has proven to be highly successful in numerous refinery and producing field applications. In most instances, installing a high efficiency coalescer is less costly and more effective than making machinery modifications or adding additional knockout capability. It is recommended for use in such applications as produced gas streams, refinery hydrogen recycle streams, gas recovery compression and gas turbine fuel gas supply. Figure P-13 illustrates a high efficiency liquid/gas coalescer.

Brownian Motion Media

Brownian motion media consists of a thick fiber mesh made from ultra-fine glass or polypropylene fibers. The media is packed between reinforcing screens for strength and can vary in thickness from one to several inches. Depending on the application requirements, the fiber diameter, mesh density and thickness can be varied to achieve very high removal efficiencies. Configured into large candles or square columns, this design lends itself to high volume, low velocity applications such as blowers. This design is best used for mist elimination in highly corrosive services or applications where the gas is relatively free of solids. It is not recommended for general compressor suction protection due to its relative large size and difficult maintenance. Figure P-14 illustrates a Brownian motion high efficiency mist eliminator.

Chevron Corporation

P-17

February 1998

Appendix P

Compressor Manual

Fig. P-13 Cartridge Design - High Efficiency Liquid/Gas Coalescer

Fig. P-14 Brownian Motion - High Efficiency Mist Eliminator

February 1998

P-18

Chevron Corporation