294 Surface Production Operations

SI Units

ho + hw + d + 1016
Lss = for diameters >914 mm (5-26b)
1000
8. Check the slenderness ratios. Slenderness ratios between 1.5 and 3
are common. The following equations may be used:
Field Units

12 Lss
SR =  (5-27a)
d
SI Units
 
Lss
SR =  (5-27b)
1000 d
9. If possible, select a standard-size diameter and seam-to-seam length.

Examples

Example 5-1: Sizing a vertical three-phase separator (field units)

Given:
Qo = 5000 BOPD,
Qw = 3000 BWPD,
Qg = 5 MMscfd,
Po = 100 psia,
To = 90  F,
Oil = 30  API,
SGw = 107,
Sg = 06,
tr o = tr w = 10 min,
o = 10 cp,
w = 1 cp,
g = 03 lb/ft3 ,
l = 547 lb/ft3 ,
CD = 201
Droplet removal = 100 microns liquids, 500 microns water, 200 microns
oil.
 Three-Phase Oil and Water Separation 295

Solution:

1. Calculate difference in specific gravities.

 1415
API = − 1315
SGo
= 0876
SG = 107 − 0876 = 0194

2. Calculate the minimum diameter required to settle a liquid droplet

through the gas phase [Eq. (5-19a)].
    1/2
550 099 5 03 201
d2 = 5040 
100 547 − 03 100
d = 349 in

3. Calculate the minimum diameter required for water droplets to

settle through the oil phase [Eq. (5-21a)].
 
Qo 
d = 6690
2
SG dm2
 
5000 10
= 6690 
0194 5002
d = 830 in

4. Calculate the minimum diameter required for oil droplets to rise

through the water phase [Eq. (5-23a)].
 
Qo 
d = 6690
2
SG dm2
 
3000 1
= 6690 
0194 2002
d = 508 in

5. Select the largest diameter from steps 2–4 as the minimum inside
diameter required.

dmin = 830 in

296 Surface Production Operations

6. Calculate ho + hw .

tr o Qo  + tr w Qw

ho + hw = 
012 d2
10 5000 + 3000
ho + hw =
012 d2
667000
= 
d2
Refer to Table 5-2 for results.

Table 5-2
Vertical Three-Phase Separator Capacity Diameter vs. Length for
Retention Time Constraint tr o = tr w = 10 min
 
do (in.) ho + hw (in.) Lss (ft) SR 12Lss
do

84 94.5 18.2 2.6

90 82.3 17.7 2.4
96 72.3 17.4 2.2
102 64.1 17.2 2.0

7. Compute seam-to-seam length (Lss ). Select the larger value from

Eq. (5-25a) or (5-26a).

ho + hw + 76
Lss = for diameters ≤36 in
12
h + hw + d + 40
Lss = o for diameters >36 in
12
Refer to Table 5-2 for results.
8. Compute the slenderness ratio.
Slenderness ratio = 12Lss
d

Choices in the range of 1.5 to 3 are common.

Refer to Table 5-2 for results.
9. Make final selection: compute combinations of d and ho + hw for
diameters greater than the minimum diameter. See Table 5-2 for
results. Select 90 in outside diameter OD × 20 ft seam-to-seam
length (s/s).
 Three-Phase Oil and Water Separation 297

Example 5-2: Sizing a vertical three-phase separator (SI units)

Given:

Qo = 33 m3 /hr,
Qw = 198 m3 /hr,
Qg = 5902 sm3 /hr,
Po = 690 kPa,
To = 3220  C,
Oil = 30  API,
SGw = 107,
Sg = 06,
tr o = tr w = 10 min,
o = 10 cp,
w = 1 cp,
g = 49 kg/m3 ,
l = 866 kg/m3 ,
CD = 201

Droplet removal = 100 microns liquids, 500 microns water, 200 microns
oil. Vessel is half-full of liquid.

Solution:

1. Calculate difference in specific gravities.

 1415
API = − 1315
SGo
= 0876
SG = 107 − 0876 = 0194

2. Calculate minimum diameter required to settle a liquid droplet

through the gas phase [Eq. (5-19b)].
    1/2
TZQg g CD
d = 34500
2
P l − g dm
    1/2
306 099 5902 49 201
= 34500 
690 866 − 49 100
d = 886 mm
298 Surface Production Operations

3. Calculate the minimum diameter required for water droplets to settle

through the oil phase [Eq. (5-21b)].
 
Qo 
d = 637 × 10
2 8
SGdm2
 
33 10
= 637 × 10 8

0194 5002
d = 2081 mm

4. Calculate the minimum diameter required for oil droplets to rise

through the water phase [Eq. (5-23b)].
 
Qo 
d = 637 × 10
2 8
SG dm2
 
198 1
= 637 × 108 
0194 2002
d = 1274 mm

5. Select the largest diameter from steps 2–4 as the minimum diameter
inside required.
dmin = 2081 mm
6. Calculate ho + hw .
10 33 + 198
ho + hw =
4713 × 10−8 d2
112 × 1010
=
d2
Refer to Table 5-3 for result.
7. Compute seam-to-seam length (Lss ). Select the larger value from
Eq. (5-25b) or (5-26b).
ho + hw + 1930
Lss = for diameters ≤ 914 mm
1000
h + hw + d + 1016
Lss = o for diameters >914 mm
1000
Refer to Table 5-3 for results.
 Three-Phase Oil and Water Separation 299

Table 5-3
Vertical Three-Phase Separator Capacity Diameter vs. Length for
Retention Time Constraint tr o = tr w = 10 min
 
do (mm) ho + hw (mm) Lss (m) SR Lss
1000do

2286 2144 5.4 2.4

2438 1884 5.3 2.2
2591 1669 5.3 2.0

8. Compute the slenderness ratio.

 
Lss
Slenderness ratio =
1000 do
Choices in the range of 1.5 to 3 are common.
Refer to Table 5-3 for results.
9. Make final selection: compute combinations of d and ho + hw for
diameters greater than the minimum diameter. See Table 5-3 for
results. Select 2286 outside diameter OD × 54 m (s/s).

Example 5-3: Sizing a horizontal three-phase separator

(field units)

Given:
Qo = 5000 BOPD,
Qw = 3000 BWPD,
Qg = 5 MMscfd,
P = 100 psia,
T = 90 F,
Oil = 30 API,
SGw = 107,
Sg = 06,
tr o = tr w = 10 min,
o = 10 cp,
w = 1 cp,

Droplet removal = 100 microns liquid, 500 microns water, 200

microns oil. Vessel is half-full of liquids.
300 Surface Production Operations

Solution:

1. Calculate difference in specific gravities.

 1415
API = − 1315
SGo
1415
SGo = = 0876
30 + 1315
SG = 107 − 0876 = 0194

2. Calculate maximum oil pad thickness ho max . Use 500-micron

droplet size if no other information is available.

 t  SG dm2
ho max = 128 × 10−3 r o

10 0194 5002
= 000128
10
= 621

Aw
3. Calculate :
A

Aw Qw tr w
= 05
A tr  Qo + tr w Qw
198 10
= 05
33 10 + 198 10
= 01875

4. Determine  from Figure 5-20. With Aw/A = 01875, read

 = 0257.
5. Calculate dmax .

ho max
dmax =

621
= 
0257
dmax = 2416 in
 Three-Phase Oil and Water Separation 301

6. Calculate combinations of d, Leff for d less than dmax that satisfy

the gas capacity constraint. Use 100-micron droplet size if no other
information is available.
    1/2
TZQg g CD
dLeff = 420
P l − g d
   1/2
550 099 5 03 201
= 420
100 547 − 03 100
= 120

Refer to Table 5-4 for results.

Table 5-4
Horizontal Three-Phase Separator
Diameter vs. Length for Gas Capacity
Constraint
d (in.) Leff (ft)

60 1.7
72 1.4
84 1.2
96 1.1

Since the values of Leff are low, the gas capacity does
not govern.

7. Calculate combinations of d, Leff for d less than dmax that satisfy

the oil and water retention time constraints.

d2 Leff = 142 Qw tr w + Qo tr o

= 142108000
= 113600

Refer to Table 5-5 for results.

8. Estimate seam-to-seam length.
d
Lss = Leff + for gas capacity
12
4
Lss = Leff for liquid capacity
3
302 Surface Production Operations

Table 5-5
Horizontal Three-Phase Separator Capacity Diameter vs. Length for
Liquid Retention Time Constraint tr o = tr w = 10 min
 
12Lss
d (in.) Leff (ft) Lss (ft) SR d

60 31.6 42.1 8.4

72 21.9 29.2 4.9
84 16.1 21.5 3.1
96 12.3 16.4 2.1
108 9.7 13.0 1.4

Refer to Table 5-5 for results.

9. Select slenderness ratio (12 Lss /d). Choices in the range of 3 to 5
are common.
10. Choose a reasonable size that does not violate gas capacity restraint
or oil pad thickness restraint. Possible choices are 72 in diameter
by 30 ft seam-by-seam and 84 in diameter by 25 ft seam-by-seam.

Example 5-4: Sizing a horizontal three-phase separator

(SI units)

Given:
Qo = 33 m3 /hr,
Qw = 198 m3 /hr,
Qg = 5902 sm3 /hr,
P = 690 kPa,
T = 3220  C,
Oil = 30  API,
SGw = 107,
Sg = 06,
tr o = tr w = 10 min,
o = 10 cp,
w = 1 cp,
g = 49 kg/m3 ,
l = 866 kg/m3 ,
CD = 201
Droplet removal = 100 microns liquid, 500 microns water, 200 microns
oil.
 Three-Phase Oil and Water Separation 303

Solution:

1. Calculate difference in specific gravities.

 1415
API = − 1315
SGo
1415
SGo = = 0876
30 + 1315
SG = 107 − 0876 = 0194

2. Calculate maximum oil pad thickness ho max . Use 500-micron

droplet size if no other information is available.

tr o SG dm2

ho max = 0033

10 0194 5002
= 0033
10
= 1600

Aw
3. Calculate :
A
Aw Qw tr w
= 05
A tr  Qo + tr w Qw
198 10
= 05
33 10 + 198 10
= 01875

4. Determine  from Figure 5-19. With Aw /A = 01875, read

 = 0257.
5. Calculate dmax .

ho max
dmax =

1600
= 
0257
dmax = 6226 mm
304 Surface Production Operations

6. Calculate combinations of d, Leff for d less than dmax that satisfy

the gas capacity constraint. Use 100-micron droplet size if no other
information is available.
    1/2
TZQg g CD
dLeff = 345
P l − g dm
   1/2
306 099 5902 49 201
= 345
690 866 − 49 100
= 3095

Refer to Table 5-6 for results.

Table 5-6
Horizontal Three-Phase Separator
Diameter vs. Length for Gas Capacity
Constraint
d (mm) Leff (m)

1524 0.52
1829 0.43
2134 0.37
2438 0.34

Since the values of Leff are low, gas capacity does not
govern.

7. Calculate combinations of d, Leff for d less than dmax that satisfy

the oil and water retention constraints.

d2 Leff = 42000 Qw tr w + Qo tr o

= 42000 10
528

= 22410432

Refer to Table 5-7 for results.

8. Estimate seam-to-seam length.
d
Lss = Leff + for gas capacity
1000
4
Lss = Leff for liquid capacity
3
Refer to Table 5-7 for results.
 Three-Phase Oil and Water Separation 305

Table 5-7
Horizontal Three-Phase Separator Capacity Diameter vs. Length for
Liquid Retention Time Constraint tr o = tr w = 10 min
 
d (mm) Leff (m) Lss (m) SR Lss
d1000

1524 9.65 1287 8.4

1828.8 6.70 893 4.9
2133.6 4.62 656 3.1
2438.4 3.77 503 2.1
2743.2 2.98 397 1.4

Lss
9. Select slenderness ratio, . Choices in the range of 3 to
d 1000
5 are common.
10. Choose a reasonable size that does not violate gas capacity
restraint or oil pad thickness restraint. Possible choices are
1828 mm × 893 m and 21336 mm × 656 m.

Nomenclature
A = cross-sectional area of the droplet, ft2 m2 
Ag = cross-sectional area of vessel available for gas
settling, ft2 m2 
Al = cross-sectional area of vessel available for liquid
retention, ft2 m2 
AT = total cross-sectional area of vessel, ft2 m2 
Aw = cross-sectional area of vessel available for water
retention, ft2 m2 
B = weir width, ft (m)
C = coefficient of discharge, dimensionless
API = API gravity of oil,  API
CA = corrosion allowance, in. (mm)
CD = drag coefficient, dimensionless
D = drop diameter, ft (m)
D = vessel internal diameter, ft (m)
Dh = hydraulic diameter, ft (m)
d = vessel internal diameter, in. (mm)
dl = water leg standpipe internal diameter, in. (mm)
dm = drop diameter, micron ( m)
dmax = maximum vessel internal diameter, in. (mm)
Dm = droplet diameter micron (m)