CRUDE PROCESS

DESIGN OF A 3 PHASE HORIZONTAL SEPARATOR

Training session: ................................................................................................

General purpose:
This practical session aims to design a 3 phase Horizontal separator regarding physical and geometrical
considerations. This exercise should be considered as preliminary sizing only.

Π = 3.14 1bbl = 159.2 L 1 inch =2.54cm ρ=

141 .5
131 .5 + API

Design of a 3 phase horizontal separator

3-phase horizontal separator is widely used in oil process. Even, if the well stream is dry at the beginning (BSW 0%),
it is recommended to anticipate the water breakthrough in the initial design of the process. The following calculation
is useful for project design, but also for field engineer to optimize an existing process.

Comment the previous picture: inlet & outlet

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What is the element on the floor? What is its function?

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I- Geometrical considerations

h1
h

The purpose of this section is to calculate the volume of the water and oil phase in the separator. The first
geometrical assumption is that the section is constant along the vessel. Thus the volumes are the product of
the cross section by the length of the compartment.

Find a relation between the angle β, the radius R and the interface level h

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What are the following cross section area S & T?

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S
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T ..............................................................................................................................................

Hence what is the water volume retained in the vessel?

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Using the previous formula, what is the oil volume retained in the vessel?

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Using EXCELL sheet, implement a program calculating these formula (SI units)

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2- Let’s talk bout physics.

The key parameter in a separator design is the gas section limited by the gas velocity. For gas / liquid
separation, a reasonable carry over (0,1USgallon/MMscfd) is achieved with the following critical speed:
ρ L − ρG
v = K .0,05 m.s −1 (density in kg/m3)
ρG

What is the critical gas velocity –considering gas density 10kg/m3 & K=1.7- ?

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The liquid separation is more based on retention time. If lab or field data are not available, a first
approximation is to consider the migration time of the liquids.
The speed of droplet of fluid A in a medium B is given by stokes law:

1000 g × d 2 × Δρ With V = vertical droplet speed (m/s); g = 9.81m.s2

V= d = droplet diameter (m); Δρ = difference of density (kg/m3)
18 μ μ = viscosity of the continuous medium (cP)

Fluid OIL WATER ………. …….. ……….

Density
850 1030
(kg/m3)

Viscosity (cp) 5cP 0,5 cP

What is the vertical speed of a 250μm droplet of water in oil?

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What is the vertical speed of a 120μm droplet of oil in water?

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Imagine that we have to treat very thick oil (API 15; 1000cp at ambient temperature)

What is the vertical speed of a 250μm droplet of water in that heavy oil?

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What problem will it induce?

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What technical can you propose to improve oil/water separation?

CAPEX > ..............................................................................................................................................................

OPEX > ................................................................................................................................................................

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Appendix1: (source Well Production Practical Handbook)

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III - Back to the design

The separator will handle 10,000 bbl of fluid (oil + water) per day, oil API 35, BSW 50%, GOR 4000scf/bbl at
operating conditions 30°c and 10barg. The oil residence time and the water residence time are 5 minutes
each.

A first approach of the design is to consider L = 4x D & H = 0.6 x D

The excel sheet “separator design” can be used for geometrical calculation

GAS OUTLET ................................................................

................................................................
INLET
................................................................
Niveau huile
................................................................

D
H
................................................................
Niveau interface h1
................................................................
h

L L1
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OIL OUTLET
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WATER OUTLET
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3.1 - Find the minimal diameter to design the gas section

ρL − ρg
The vapour cross section area must be large enough to have Vg ≤ 0,048 K
ρg
Vapour flow rate in actual conditions: Q = ....................................................................................... am3/s

Maximal horizontal speed (K=1.7) Vg = ............................................................................................m/s

Minimal Gas section area: .................................................................................................................... m2

Minimal Diameter: D = ........................................................................................................................ mm

Using ASME code, check that the wall thickness “e” is less than 100mm (fabrication issue)

P× D
e= +C
2080 − 1.2 P = ................................................................................................................. mm

[e & D in mm – Pdesign in barg =110% max operating pressure – C corrosion allowance 3mm by
default]

If “e” is greater than 100mm, change L/D ratio and go back to 3.1

3.2 - Adjust oil and water residence time with interface level h and vessel size (L&D)
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a - Does a 250 μm water droplet in oil have the time to settle?

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b - Does a 120μm oil droplet in water have the time to settle?

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3.3 - Alarm and ESD level

NB: safety level depends on process application and company rules-Water
section
The retention time between high and low alarm levels should be at least 2min
– mini 200mm
IH – Alarm High level
Retention time between IL and ILL should be 1 min – mini 100mm
Residence time below ILL should be at least the closure time of SDV – IL – Alarm low level
minimum 150mm ILL – ESD level

a - Does the water section comply with these recommendations?

…………………………………………………………………………………………………...

OIL Section
The residence time below LSLL should be at least the closure time
of SDV (estimated 20s) – minimum 150mm demister
The retention time between LSL alarm and LSLL ESD should be
1min – minimum 100mm LSHH –High level ESD
The retention time between LSL and LSH alarm levels should be at LSH – Alarm High level
least 3 min – mini 200mm – Oil regulation level can be above the
weird, be careful with volume calculation- Water
LSL – Alarm low level
The retention time between LSH alarm and LSHH ESD should be Section
1min – minimum 100mm LSLL – ESD level
The residence time between LSHH and demister inlet should be at
least 150mm (consider demister size equal 300mm for the exercise)

b - Adjust oil section length L1 to comply with these rules (focus on low level)

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c - Does the gas section comply with high level safety considerations? -If not, change H and go
back to 3.1

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3.4 - NOZZLE sizing

a - With gas, the limiting parameter is ρv2 (ρ in kg.m-3 and v in m.s-1) that should be limited to +
6000 at separator inlet & +10,000 at gas outlet

b - With liquids, flow velocity has to be limited to 1.4m/s

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