Separator Design Guidelines

Hadi Veyse – Oil Processing & Transportation Superintendent

Separator
Nozzles
Sizing
Separator Nozzles Sizing

Feed Inlet Nozzle

The main purpose of an inlet device is to improve separation performance. This is achieved in the
following ways:
1) Maximization of gas-liquid separation occurring in the feed pipe
2) Minimization of droplet shearing
3) Optimization of downstream velocity distributions in the separated phases

Inlet devices are typically selected and sized based on the inlet momentum (sometimes referred to
as "dynamic pressure") of the separator feed stream. The intent is to reduce the kinetic energy
(velocity) of the feed to provide conditions favorable for phase separation.
The internal nozzle diameter may be taken equal to that of the feed pipe, but also a momentum
criterion (dependent on the inlet device, if any) shall be satisfied.
It is also necessary to maintain the inlet velocity head, J, within proper limits for the selected inlet
device to insure good gas distribution and minimum liquid shattering. Where:

J = (ρmix,inVmix,in²)

ρmix,in is the mean density of the mixture in the feed pipe in kg/m³
Vmix,in is the velocity of the mixture in the inlet nozzle in m/s

Where the inlet feed is practically gas phase, momentum can be increased to 8000 regardless of the
type of inlet device. Erosional and 80% of sonic velocity are other limitations that should be met for
inlet nozzle design.
The maximum mixed phase velocity head range used in the industry guidelines varies for the
different inlet devices. In addition, some users limit the inlet vapor phase velocity to 9 m/s or 18
m/s. The velocity should always be below the erosion velocity for the service.
Separator Nozzles Sizing

Typical Inlet Device Performance:

Separator Nozzles Sizing

Bulk Separation Factor:

Inlet Device Liquid Separation Efficiency and Effect on Droplet Sizes

Separator Nozzles Sizing

Feed Inlet Nozzle

2
ρmix Vmix,in < Recommended Design Limits

MG + ML MG + MO + MW ρG QG + ρO QO + ρW QW
ρmix = = =
QG + QL QG + QO + QW QG + QO + QW
QG + QO + QW
Vmix,in =
dminimum,in 2
π 4

QG + QO + QW
dminimum,in = π
4 Vmix,in
Separator Nozzles Sizing
Recommended Inlet Feed and Gas Outlet Nozzles Momentum + Liquid Outlet Nozzle Velocity Limits:
FEED INLET GAS OUTLET LIQUID OUTLET

Feed Inlet Nozzle Maximum Momentum (Velocity Head) (ρMixVMix,In2), kg/m.s2

Gas Outlet Nozzle Liquid

Maximum Outlet
Reference Momentum Nozzle Minimum
Simple Diverter Schoepentoeter (Velocity Head) Maximum Diameter, in
None (ρGVG,Out2), Velocity
Diverter Plate Half Open Reversed Pipe Vane Type Cyclone
Open Pipe V Baffle Multi Cyclone kg/m.s 2
(VL,Out), m/s
Dished Head Pipe 90° Elbow Diffuser (Conventional)
Flush Inlet
Deflector Baffle Multi Vane

ADMA-OPCO SP-1060 2008 1400 - - 2100 - 8000 10000 35000 3750 2 2

BP Upstream Process Engineering Course 1000 - - 1500 - - - - 3750 1 -

GPSA 13th Edition Section 7 975 - 2250 1500 - 3750 1500 - 3750 1500 - 3750 1500 - 3750 6000 - 9000 - - 4500 - 5400 0.9 - 1.5 -

IPS-E-PR-850 2009 1000 - - 1500 - - - - 3750 1 2

IPS-E-PR-880 2010 1000 1500 1500 1500 1500 6000 - - 3750 1 -

NORSOK Standard P-100 2010 - - - - - 6000 - - - - -

Natural Gas Processing Technology and Engineering Design by Alireza

1000 - - 1500 - 6000 - - 3750 1 2
Bahadori 2014

GCAP Volume 2 9th Edition 2017 1000 1250 - 1500 1250 5500? 10000? - 5350 1 - 1.2 1.5

Gas/Liquid Separators: Quantifying Separation Performance Part 1

by Mark Bothamley 2013
1040 1400 - 2100 1400 8050? 14900? - - - -

8050? 14900?
Worley KS-PR-DEG-0141 2019 Reference: Gas/Liquid Separators:
1040 1400 - 2100 1400 - 4500 1 2
Quantifying Separation Performance Part 1 by Mark Bothamley 2013

Three Phase Separators by Saeid Rahimi 2013 1000 1400 - 2100 - 8000 10000 35000 - 1 2

Shell DEP 31.22.05.11 2012 & Shell DEP 31.22.05.12 2012 1400 - - 2100 - 8000 - - 4500 1 2

Shell DEP 31.22.05.12 2017 1500 1500 - 3000 - 8000 20000 - 4500 1 2

Total Separator (ECP/PRO Knowledge Sharing) 2015 1000 2000 2000 2000 2000 6000 - - 3750 1.5 2

IFP Training 2010 6000 10000 1 - 1.4 -

SNC LAVALIN Demister Separator 2003 6000 3750 1 2

SNC LAVALIN KO Horizontal Drum without Mist Extractor 2003 1000 3750 1 2

SNC LAVALIN KO Vertical Drum without Mist Extractor 2003 1500 3750 1 2

https://www.cheresources.com/invision/topic/8158-sizing-of-the-
1400 - - 2100 - 8000 10000 35000 4500 1 2
feed-nozzles-for-gas-liquid-separator/
https://www.red-bag.com/engineering-guides/249-bn-eg-ue109-
1000 - - 1500 - - - - 3750 1 -
guide-for-vessel-sizing.html
Separator Nozzles Sizing

 ?
GCAP Volume 2 9th Edition 2017:
Separator Nozzles Sizing

 ?
Gas/Liquid Separators: Quantifying Separation Performance Part 1 by Mark Bothamley 2013:

Worley KS-PR-DEG-0141 2019:

Separator Nozzles Sizing

Gas Outlet Nozzle

The diameter of the gas outlet nozzle should normally be taken equal to that of the outlet pipe, but
also a momentum criterion shall be satisfied.
The sizing of the vapor outlet nozzle should be such that given the above placement of the mesh
pad, the velocity is not high enough to cause channeling of the gas through the mesh pad. The
nozzle outlet size is typically based on the lesser of that required for piping pressure drop, or a
maximum velocity head criteria. In addition some users limit the absolute velocity to 18 m/s. The
pipe size can be decreased to the appropriate size based on pressure drop considerations, 5-10 pipe
diameters downstream of the separator, as required.

Liquid Outlet Nozzle

Many users limit the liquid outlet nozzle velocity based on pump suction line criteria (i.e. 11 kPa/100
m for fluid at or near boil, 22 kPa/100 m otherwise) or other line sizing criteria. For three phase
separators, the velocity may be further reduced. Other users set a maximum outlet nozzle velocity
(i.e. 0.9-1.5 m/s) regardless of the service. The nozzle shall be equipped with a vortex breaker.
Separator Nozzles Sizing

Gas Outlet Nozzle

2
ρG,Out VG,Out < Recommended Design Limits

QG
VG,Out =
dGminimum,Out 2
π 4

QG
dGminimum,Out = π
4 𝑉𝑉𝐺𝐺,𝑂𝑂𝑂𝑂𝑂𝑂

Liquid Outlet Nozzle

QL
dLminimum,Out = π
4 𝑉𝑉𝐿𝐿,𝑂𝑂𝑂𝑂𝑂𝑂
Separator Nozzles Sizing

Minimum Size of Vent, Drain and Steam Out Nozzles

 Total GS EP ECP 103 2020

Utility Connections (Steam-out and Purging):

When utility connections are specified, they shall follow these requirements:
• Minimum diameter: 2”.
• If the vessel is equipped with internals (baffle), one connection provided on each compartment.
• Vertical drums with D > 4.5 m: two connections.
• Horizontal vessels with L > 6 m and operating in toxic service: two connections.
• Minimum diameter of utility connections on columns:
D ≤ 4 m: 2”
4 m < D ≤ 5.5 m: 3”
D > 5.5 m: 4”
Separator Nozzles Sizing

Minimum Size of Vent, Drain and Steam Out Nozzles

 Worley KS-PR-DEG-0141 2019
Separator Nozzles Sizing

Minimum Size of Vent, Drain and Steam Out Nozzles

 IPS-E-PR-200 2012
Separator Nozzles Sizing

Minimum Size of Vent, Drain and Steam Out Nozzles

 NIOEC-SP-00-50 2017
Separator Nozzles Sizing

Instrument Nozzles
 Worley KS-PR-DEG-0141 2019
Preliminary instrument nozzle sizes are:
Separator Nozzles Sizing

Instrument Nozzles
 API RECOMMENDED PRACTICE 551 2016
Typical Piping Interface with an Instrument:
Separator Nozzles Sizing

Manway
 Worley KS-PR-DEG-0141 2019
Unless otherwise indicated, manways should be 24” (20” to be used below 1.5 m diameter).

 Total GS EP PVV 211 2016 and Total GS EP PVV 212 2016

24 inches diameter manholes are preferred. Inside diameter of smaller manholes shall not be less
than 20 inches (500 mm).
Vessels longer/higher than 9 m are fitted with a minimum of two manholes.

 NIOEC-SP-00-50 2017
Size of manways shall be 24” (NPS). Minimum inside diameter shall be 18”. Larger size to be
specified when required accommodating internals.
Manways shall be provided as follows:
• Horizontal vessels:
900 to 1300 mm ID: Manway on the head, 18” ID
Larger than 1300 mm ID: Manway on the side or Top shell, 20” ID
• Vertical vessels:
Under 900 mm ID : Top head flanged
900 to 1300 mm ID : Manway , In shell , 18” ID
Larger than 1300 mm ID : Manway , In shell , 20” ID
 Separator
Slenderness
Ratio
L/D Ratio

API SPECIFICATION 12J:

A minimum length-to-diameter ratio of 2 is normally used.
Shell length is generally expanded in 2 ½ ft increments measured from head seam to head seam.
Vessel diameter is generally expanded in 6-in. increments, measured either as outside diameter
(OD) or inside diameter (ID).

Saudi Aramco:
An L/D ratio of 3 shall be used unless process or economic considerations dictate a more optimum
ratio:
 1/1 to 5/1 (typical).
 3/1 (recommended).

BP:
Typical L/Ds for horizontal separators:
L/D Ratio

GPSA 12th Edition:

 Typical vertical separator L/D ratios are normally in the 2-4 range.
 Typical L/D ratios for horizontal separators normally fall in the range of 2.5-5.

GPSA 13th Edition:

For horizontal separator typically a length to diameter (L/D) ratio of 3 is used as the starting point,
and the length to diameter ratio adjusted upward as required.

ExxonMobil Drum Design Course:

A 3:1 or 4:1 length/diameter (L/D) ratio is usually optimum. As design pressure increases the
optimum L/D ratio becomes greater.

ExxonMobil DP V-A:
For horizontal drums, use a length to diameter ratio of 3 to 4. Generally this results in minimum size
and lowest cost. The diameter of a vertical drum is typically based on critical velocity criteria.
L/D Ratio

FOSTER WHEELER:

JGC:
The length-diameter ratio is normally from 3:1 to 6:1 with 2:1 semi-ellipsoidal heads and from 2:1 to
4:1 with hemispherical heads. The higher the design pressure of the drum or grade of material of
construction is, the larger the length-diameter ratio is preferred, considering economical design.
Economical length-diameter ratio as a guide is shown below:
L/D Ratio

Monnery and Svrcek:

Horizontal separators L/D ratio guidelines:

Petroleum Engineering Handbook:

 For vertical separators, if the gas volume determines the size of the vessel, the L/D ratio of the
vessel should be from about 2 to 3; if the liquid volume determines the separator size, the L/D
ratio should be from about 2 to 6.
 For horizontal separators, the L/D ratio of the vessel should be from about 2 to 6. The gas and
liquid are added together to determine the size of a horizontal separator because the two fluids
flow concurrently through the vessel from the inlet end to the outlet end.

PetroSkills:
Recommended range for horizontal separators (normally 3 < L/D < 6).
L/D Ratio

Total:
Slenderness Ratio (L/D):

For vertical separators, L/D > 5 could lead to excessive dynamic load.

Chevron:
Use a length-to-diameter ratio (L/D) of at least 2 and limiting the L/D ratio to a maximum of 6 is
recommended for horizontal vessels.

Shell:
The L/D ratio of the horizontal vessel should be between 2.5 and 6.
L/D Ratio

Worley:
 For a horizontal vessel, if the L/D ratio is greater than 1 then all liquid droplets with a settling
velocity greater than the limiting vapor velocity will settle out, i.e. increasing the L/D will increase
the efficiency of separation. Horizontal vessels are generally used for three-phase separators
because of the more effective layout for removal of two liquid phases. Horizontal vessels are
generally used for reflux drums, three-phase separators, relief KO drums, reactor products
separator. A disadvantage is that as the liquid level rises the vapor space is reduced and the
effectiveness falls.
 For a vertical separator, the liquid droplets settle in a direction opposite to the gas flow. Liquid
droplets will only settle out if the settling velocity is greater than the vapor velocity. This is
independent of the L/D. Although vertical separators are less efficient they have the advantage
that their performance is independent of the liquid level. For this reason, vertical separators are
generally used for compressor suction KO drums and fuel gas KO drums.

Horizontal Vessel Geometry Guidelines:

L/D Ratio

Surface Production Operations Handbook:

 Two Phase Horizontal Separators Sizing - Half Full:
Experience has shown that if the gas capacity governs and the length divided by the diameter,
referred to as the “slenderness ratio,” is greater than 4 or 5, re-entrainment could become a
problem. Most two-phase separators are designed for slenderness ratios between 3 and 4.
Slenderness ratios outside the 3 to 4 range may be used, but the design should be checked to
assure that re-entrainment will not occur.

 Two Phase Vertical Separators Sizing:

In vertical separators whose sizing is liquid dominated, it is common to choose slenderness ratios no
greater than 4 to keep the height of the liquid collection section to a reasonable level. Choices of
between 3 and 4 are common, although height restrictions may force the choice of a lower
slenderness ratio.

 Three Phase Horizontal Separator Sizing – Half Full:

Experience indicates that the ratio of the seam-to-seam length divided by the outside diameter
should be between 3 and 5. This ratio is referred to as the “slenderness ratio” (SR) of the vessel.
Slenderness ratios outside the 3 to 5 range may be used but are not as common. Slenderness ratios
outside the 3 to 5 range may be used, but the design should be checked to assure that re-
entrainment will not occur.

 Three Phase Vertical Separators Sizing:

In vertical separators whose sizing is liquid dominated, it is common to choose slenderness ratios no
greater than 4 to keep the height of the liquid collection section to a reasonable level. Choices
between 1.5 to 3 are common, although height restrictions may force the choice of a lower
slenderness ratio.
Thanks for your attention