"OIL AND GAS PROCESSING PLANT DESIGN 2002

AND OPERATION TRAINING COURSE"

Page 1
DGEP/SCR/ED/ECP "VESSELS"

"VESSELS"

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DGEP/SCR/ED/ECP "VESSELS"

APPLICABILITY 3

SEPARATOR APPLICATIONS AND CONSIDERATIONS 3

1. 2 PHASE SEPARATORS (VERTICAL UNLESS STATED) 3
2. 3 PHASE SEPARATORS 4

HORIZONTAL OR VERTICAL DESIGN 4

CALCULATION THEORY AND EQUATIONS 5

1. LIQUID-VAPOUR SETTLING VELOCITY 5
2. LIQUID-LIQUID SETTLING VELOCITY (BASED ON STOKES LAW) 6
3. VESSEL VOLUMES 7
4. CALCULATION PROCEDURE FOR VERTICAL VESSELS (VAPOUR-LIQUID SEPARATION) 8
5. CALCULATION PROCEDURE FOR HORIZONTAL VESSEL (2 PHASES) 11
6. CALCULATION PROCEDURE FOR HORIZONTAL VESSEL (3 PHASES) 13
7. NOZZLE SIZING 16
8. VESSEL WALL THICKNESS 17

VESSEL INTERNALS 17
1. MIST ELIMINATORS 17
2. INLET INTERNALS 18
3. LIQUID PHASE INTERNALS 18

APPENDIX

Figure XVII-A1 – Sector area (A1) / Drum area function of h/D

Figure XVII-A2 – Vessel Weight Estimation
Figure XVII-A3 – Sector Area (A1)

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APPLICABILITY

Virtually all process schemes use phase separation. The design and sizing of a separator with
acceptable accuracy is required for both the feasibility and pre-project phases. Checking of sizing
made by engineering companies is required during project phase.

Consideration is given in this section to the specification of vertical and horizontal separators for
vapour-liquid and for vapour-liquid-liquid separation.
Details are also given concerning vessel internals.

Separation of solids from gas or liquids is not covered in this design guide.
Generally a vendor will be consulted for details of a proprietory designed vessel.

SEPARATOR APPLICATIONS AND CONSIDERATIONS

1. 2 PHASE SEPARATORS (VERTICAL UNLESS STATED)

• Compressor and Fuel Gas KO drums

Efficient separation of liquid from vapour is required. Generally, except for small diameter,
a mist eliminator is always required.
Economical approach has to be considered.

Provide sufficient surge time (1 to 2 minutes) between the high liquid level (HLL) and
tripping the compressor.

• Relief System KO drum - See section Flare Systems.

• Unit Feed KO drums

Required upstream of acid gas absorbers, glycol contactors and dessicant bed
dehydrators.
Can be incorporated into base of tower when packing is not used for weight and space
saving. Except for small diameter, a demister pad is generally required. Economical
approach has to be considered.

• Production separators (vertical or horizontal)

Liquid separation from gas not as critical as compressor KO drum unless a compressor is
located immediately downstream of separator.
Always consider start-up, shut-down and process slugs when designing.

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Use of demister pads is not compulsory and is related to the quality of the vapour-liquid
separation required and/or economical approach.

2. 3 PHASE SEPARATORS

3 phase production separators are generally horizontal. If good liquid-vapour separation is required
demisters are usually stated. Oil separation from the water phase must be sufficient so as not to
overload water treatment units. Chemical additives (demulsifiers, anti-foam, pour point
depressants) may be added to aid separation.
For waxy crude use of mesh pads shall be avoided as plugging may occur, and vane type is
recommended.
It is recommended to install the demister vertically for horizontal 3 phases separators.

HORIZONTAL OR VERTICAL DESIGN

• Vapour velocity in a horizontal drum can exceed the liquid settling velocity provided
(L/D > 1). For vertical drums the velocity cannot.

• Horizontal drums are more effective and geometrically more practical for a heavy liquid
phase removal than vertical drums.

• A rising liquid level in a vertical drum does not alter the vapour flow area.
Consequently vertical drums are preferred for compressor and fuel gas KO drums.

• Vertical drums utilise a smaller plot and are easier to instrument with alarms and
shutdown controls. For floating installations they are preferred as less "sloshing" occurs.

• Each design case must be evaluated separately but in general the following can be used
as a guideline.

• Vertical drums Compressor KO drums Degassing boots

Fuel gas KO drums Absorber feed KO
Floating installations Drums.

• Horizontal drums Production separator HP Reflux drums

3 phase separation Flare KO drums.

• Try to avoid vessels with wall thickness greater than 100 mm as these require special
fabrication and can prove expensive.

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CALCULATION THEORY AND EQUATIONS

1. LIQUID-VAPOUR SETTLING VELOCITY

Gas velocity

The liquid-vapour separation is function of the critical velocity determined from the Newton law.

0.5
ρ 
 l − ρv 
VC = 0.048  
 ρv 
 

Vc : Critical velocity in m/s

ρl : Liquid density in kg/m3
ρv : gas density in kg/m3

The gas velocity to be used for the design of a separator, and more specifically of the gas area is :

Vg = K x Vc

K is a coefficient depending of the type of separator and the use or the absence of demisters.

Recommended K values are the following for conventional carry over of 0.1 U.S. gallon/MMSCFD
3 6 3
(0.0134 m /10 Sm ) :

Service Without demister With demister

Fuel gas drum 0.8 1.7
Compressor suction drum 0.8 1.7
Steam drum ////////// 1.3
Feed KO drum with
foaming risks 0.8 1.7
(glycol-amine)
Reflux drum 1.7 2.2
Production separator 1.7 2.2

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Sizing

• The above K value shall be used in order to determine the gas velocity through the gas
area or through the mesh pad if any.

• For horizontal drums, the mesh pad could be installed vertically, horizontally or one part at
45 ° angle and another part in horizontal position.

For a mesh pad installed horizontally, the gas velocity calculated on the section between
mesh pad bottom line and liquid alarm high high (LAHH) should correspond to a K value not
exceeding 3.3.

• For horizontal drums with a large amount of gas, if the design is not based on the "stokes
law" a split flow type could be installed with one inlet located at the middle of the top of the
drum and two outlets on each side of the vessel. Gas flowrate is divided by two in each
separation section.

• For vertical drum with a large amount of liquid, the vessel size and more specifically the
vessel diameter is determined by the liquid residence time. In this case, if installed, the area
of the mesh pad could be lower than the vessel area in order to get a correct gas velocity
through it. Nevertheless, the mesh pad diameter should not be less than the half of the
drum diameter.

Remarks

• Vane packs could be installed instead of mesh pad. A K of 3.3 can be used for preliminary
design but final sizing should be done by vendors.

• Vessels using cyclone for separation purpose should be designed by vendors.

• For separators where liquid carry over is acceptable (presence of downstream liquid / gas
separators or liquid and gas mixed downstream of these separators) the API method (ref.
: API RP 521 third edition nov. 1991 § 5.4.2.1 page 52) could be used with a droplet of
600 µm.

2. LIQUID-LIQUID SETTLING VELOCITY (BASED ON STOKES LAW)

The following equation can be used for calculating the settling velocity of water in oil or the
upwards "settling" of oil in water. The important fact is to use the viscosity of the continuous phase
i.e. : for oil settling upwards through water use the water viscosity, for water settling in oil use the
oil viscosity.

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Ut = terminal velocity m/s

g = gravitation acceleration m/s2
ρH = density heavy fluid kg/m3
g xD 2 ( ρH − ρl )
Ut = ρl = density light fluid kg/m3
18 µ c
µc = viscosity (continuous phase) kg/m.s
D = particle diameter m

Setting the particle size to 125 microns and using more useful units gives :

Ut in mm/min
ρ − ρl
(5) U t = 0.5108 ( H ) µc in centipoise
µc
ρ in kg/m3

. The above equation is valid for REYNOLDS number of 0.1 - 0.3.

. If calculated settling velocity is > 250 mm/min use 250 max.

3. VESSEL VOLUMES

HORIZONTAL CYLINDER Vc = A1 x L in m3

. Partial volumes and areas of a horizontal vessel can be calculated using the charts
in Figures XVII-A1 or estimated using the following equations :

D 2  D −2h    D  1 
A1= 
 4
Arccos
 
D   2  
(
  −  − h Dh − h 2  in m
2


2
)
with :

D = inside diameter of the vessel, (m),

h = distance between the cylinder bottom and the liquid level, (m),

Arccos in radians
2
2 DISHED HEADS Vdh = 0.21543 x h x (1.5 x D - h) in m3

2 ELLIPTICAL HEADS Veh = 0.52194 x h2 x (1.5 x D - h) in m3

(most common)

2 HEMISPHERICAL HEADS Vhh = 1.047 x h2 x (1.5 x D - h) in m3

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• VOLUME UP TO BAFFLE (see Figure XVII-A3)

0.52194h 2 (1.5D − h))

for depth = + ( A1 x B)
2
(elliptical heads)

• These formula are accurate enough for general design and are easily programmed on to a
calculator for time saving.

• More accurate formula are available, see reference list, but are often too complicated to
be useful for multiple calculations.

• For greater accuracy the length L should be the tan-tan length and not the flowpath
length between nozzles. This is especially true with large vessels and a tight design.

4. CALCULATION PROCEDURE FOR VERTICAL VESSELS (VAPOUR-LIQUID SEPARATION)

• Calculate vapour settling velocity and calculate internal drum diameter (∅id)

• Check if wall thickness is less than 100 mm (See § 8).

• Calculate vessel height based on following criteria :

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h1

h2

h3 MINI

100 + d/2

h4 d 2 d mini

HLA
h5
HLL

NLL
h6
LLL

h7 LLA

h8

L
h1 : if ∅id≤1200, h1 = 400 mm
if ∅id>1200, h1 = 600 mm
if ∅id>4000, h1 = 0.15 x ∅id mm
(For hemispherical heads, h1 = 150 mm)

h2 : if mesh pad selected :

h2 = 100 mm for no carbone deposite service
h2 = 150 mm for carbone deposite service

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h3 : if ∅id≤900, h3 = 300 + d/2 in mm

if ∅id>900, h3 = the greatest value of :
(0.5 x ∅id) or (450 + d/2)
if no mesh use :
h1+h2+h3 = 0.75 x ∅id with 900 mm mini and 1800 mm maxi

h4 : h4 has the greatest value of :

(1.5 x d) or (400 + d/2) in mm

h5 : Calculate based on 1-2 minutes of residence time at maximum inflow (min 200 mm)

h6 : based on following hold up times, (minimum 300 mm)

Reflux Drum

- Liquid distillate feeding directly another column for which a constant feed flowrate
is required.
h6 has the greatest value of :
15 min on the other column feed
5 min on the reflux

- Liquid distillate sent to storage

h6 has the greatest value of :
2 min on the product
5 min on the reflux

- Vapour distillate only

h6 = 5 min on the reflux

Product Drum
h6 = 5 min with pump
3 min without pump

Heater Feed
h6 = 8 min

HP separator to LP separator
h6 = 3 min

h7 : 1 - 2 minutes of residence time (mini 150 mm)

h8 : 150 mm for bottom connected LT, see note 1.

300 mm for side connected LT, see note 1.

Note1 : Check if the residence time is compatible with the safety (closure time of shut down valve
(SDV) on liquid outlet)

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5. CALCULATION PROCEDURE FOR HORIZONTAL VESSEL (2 PHASES)

A guide for filling in the attached calculation sheet

• Calculate the vapour-liquid settling velocity.

• Evaluate the required vapour cross sectional area, or demister area,Av.

• Define required liquid holdup.

• Size the drum based in following criteria.

a) Without demister

FEED GAS

h1

HLA
h4 HLL
Øid h5 NOL
LLL
h6
LLA

h7

LIQUID

h1 : Defined by vapour area with a minimum of 0.2 x ∅id or 300 mm.

h4 : Calculate based on 1-2 minutes residence time at maximum liquid inflow (mini
100 mm).

h5 : Based on hold-up times. See vertical drum with height mini of 300 mm.

h6 : 1-2 minutes residence time (mini 100 mm)

h7 : Minimum 150 mm or 300 mm (see vertical drum), check if the residence time is
compatible with the safety
(closure time of shut down valve (SDV) on liquid outlet).

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b) With vertical demister

FEED h2 GAS

h1

h3 HLA
h4 HLL
Øid h5 NOL
LLL
h6
LLA

h7

WATER OIL

h1 : Defined by vapour area with a minimum of 300 mm.

h2 : 100 mm for no carbone deposite service.

150 mm for carbone deposite service.

h3 : 150 mm.

h4 : Calculate based on 1-2 minutes residence time at maximum liquid inflow (mini
100 mm).

h5 : Based on hold-up times. See vertical drum with height mini of 300 mm.

h6 : 1-2 minutes residence time (mini 100 mm).

h7 : Minimum 150 mm or 300 mm (see vertical drum), check if the residence time is
compatible with the safety
(closure time of SDV on liquid outlet).

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c) With horizontal mesh pad

FEED GAS

h1
h2

h3 HLA
h4 HLL
Øid h5 NOL
LLL
h6
LLA

h7

LIQUID

h1 : 300 mm minimum.

h2 : See b) here above.

h3 : Defined by vapour area with Vg=Vc x 3.3 with 300 mm minimum.

h4 : See b) here above.

h5 : See b) here above.

h6 : See b) here above.

h7 : See b) here above.

6. CALCULATION PROCEDURE FOR HORIZONTAL VESSEL (3 PHASES)

A guide for filling in the attached calculation sheet.

Sufficient residence time to allow separation of the oil-water mixture as well as the oil surge and
vapour flow area must be provided.

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1) Select : the separation residence time is generally 5 minutes on oil and water
phase. For light oil at relatively high temperature > 80°C, a residence
time of 3 minutes could be used for oil and water phase. For heavy oil
with an high viscosity, the residence time of 8 minutes could be used on
oil phase and 5 minutes on water phase.

The separation residence time is:

- for water, the volume contained between the inlet nozzle tangente
line side to the baffle and the bottom to the interface normal level
(INL)

- for oil, the volume contained between the inlet nozzle tangente line
side to the baffle and from the interface normal level (INL) to the
normal oil level (NOL).

2) Calculate Vapour- Liquid settling velocity.

3) Evaluate the Demister area.

4) Defined the required hold-up time

5) Drum sizing.

Note: If the water flowrate is very small, consideration may be given to use a water boot instead
of a baffle arrangement.
Water volume could be included totally or partially in the boot.
- Possible external diameter for a boot: 300 to 900 mm by step of 50 mm
- The boot diameter shall be lower than 1/3 of the drum diameter.
- The boot height generally does not exceed 900 mm due to installation problem.

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a) With vertical Demister

FEED h2 GAS

h1

HLA h3
HLL h4
Øid NOL h5
LLL h6
h IHL h7
h hw1 INL LLA
hw2 ILL
hw3 ILA h8
hw4

WATER OIL

B C

h1 : Defined by vapour, demister area with a minimum of 300 mm

h2 : 100 mm for no carbone deposite service.

150 mm for carbone deposite service.

h3 : 150 mm.

h4 : Calculate based on 1-2 minutes residence time at maximum oil inflow (mini
100 mm).

h5 : ditto h4.

h6 : ditto h4.

h7 : 1 to1.5 minute residence time at oil inflow (mini 100 mm).

h8 : 150 mm ; check if the residence time is compatible with the safety (closure
time of SDV on liquid outlet).

hw1 : 1 minute residence time at maximum water inflow (mini 100 mm).

hw2 : ditto hw1.

hw3 : 1 to 1.5 minute residence time at maximum water inflow (mini 100 mm).

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hw4 : mini 150 mm,check if the residence time is compatible with the safety (closure
time of SDV on liquid outlet).

b) With horizontal mesh pad

FEED GAS

h1
h2

HLA h3
HLL h4
NOL h5
LLL h6
h IHL h7
h hw1 INL LLA
hw2 ILL
hw3 ILA h8
hw4

WATER OIL
B C

h1 : 300 mm mini.

h2 : see a) here above.

h3 : defined by vapour area with Vg= Vc x 3.3 with 300 mm mini.

h4,h5,h6,h7,h8,hw1,hw2,hw3,hw4: see a) here above.

7. NOZZLE SIZING

See line sizing section for inlet and outlet nozzles. The nozzles shall at least have the same size of
the lines.
Minimum diameter = 2".
Manholes: 450 mm or 600 mm (20" or 24").

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8. VESSEL WALL THICKNESS

Estimate vessel wall thickness using the ASME VIII div. 1 formula. The wall thickness should be
calculated immediately after D is known to confirm if t < 100 mm.

Di = internal diameter mm
t = wall thickness mm
P = design pressure
barg
t = (P x Di) / (2SE - 1.2P) + C E = joint efficiency
use 1 for seamless shells, 0.85 otherwise
S = max. allowable stress in bar
use 1220 bar for Carbon Steel plate
1000 bar for Stainless Steel plate
C = corrosion allowance in mm
confirmed by corrosion specialist (default
value : 3 mm).
for t < 100 mm : no fabrication problems
100 < t < 150 mm : specialist advice may be needed
t > 150 mm : major fabrication problems

To reduce the thickness, other codes (ASME VIII Div2 or BS 5500) and more sophisticated
material could be used, in this case, the material specialist should be consulted.

In order to meet standard vessel head sizes and wall thicknesses the following ranges should be
observed :

Vessel diameter : 250 - 1250 mm in increments of 50 mm i.e. 250, 300, 350...

1300 - 4000 mm in increments of 100 mm i.e. 1300,1400, 1500...

Standard wall thicknesses : 1 - 30 mm in increments of 1 mm i.e. 1, 2, 3, 4...

30 - 60 mm in increments of 2 mm i.e. 30, 32, 34, 36...
60 - 140 mm in increments of 5 mm i.e. 65, 70, 75, 80...

VESSEL INTERNALS

1. MIST ELIMINATORS

• Mist eliminators or mesh pads are located under the vapour outlet nozzles of all
compressor suction drums and fuel gas KO drums. For production separators it is always
good practice to install an exit mesh pad.

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• For dirty or high viscosity liquids the efficiency falls to apprx. 75 %. Consult vendor for
further data.

• Mesh is usually made from 304 SS.

YORK DATA are as follows :

Types of pad : York n° kg/m3 Thickness Residual*entrainment

mm PPM

General Purpose 431 144 100 1.0 - 1.2

High efficiency 421 192 100 0.55 - 0.61
326 115 100 0.17 - 0.19
Dirty service 931 80 150 0.8 - 0.87
644 150

• The engineer should specify type, diameter and thickness of pad required on the vessel
data sheet.

• For particle sizes of 5 microns or less use two pads spaced by 300 mm eg: glycol
contactor.

2. INLET INTERNALS

Inlet internals can be specified to aid feed distribution and promote vapour-liquid separation.
Generally for pre-project stage details are not required.

3. LIQUID PHASE INTERNALS

• Vortex breakers should be detailed for each oil/condensate and produced water outlet
where the outlet flow direction is vertical.

• Vendors will sometimes specify internal packs of tilted plates or baffles or other
arrangements to promote phase separation.

• Sand jetting facilities should be provided for service where there is a risk of silting or
sediment build up in the vessel. Generally jetting facilities are not required on gas-
condensate systems.

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