Elementary process engineering

Eng.Siad Elsayed

Course Overview
1. Introduction

5. Conversion & Rearrangement

processes

2. Fundamentals of gas processing

6. Safety in refinery

3. Basics of Oil Refining process

7. Tanks & Valves

4. Towers internals

8. Pumps

9. Heat Exchangers & Fired

Heaters

10. Compressors

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Elementary Process Engineering

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Course Overview
1. Introduction

5. Conversion & Rearrangement

processes

2. Fundamentals of gas processing

6. Safety in refining

3. Basics of Oil Refining process

7. Tanks & Valves

4. Towers internals

8. Pumps

9. Heat Exchangers & Fired

Heaters

10. Compressors

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Separators

Session 2 : Gas Processing

From oil Facilities

Feed Gas Inlet Separator

Main Compression Area

Drying & Sweetening Area

4 Units, Max. Capacity 220 MMSCFD

2 Delaval comp./Thomassen Turbines
2 Creusot Loire Comp./ MAN Turbines

6 Molecular Sieves beds, Type 5A

Diethanolamine Unit

Sales Gas to GASCO

Booster & Sales Gas Compressors

6 Units, Max Capacity 210 MMSCFD
2 Delaval comp./MAN Turbines
3 Creusot Loire comp./MAN Turbines
1 Delaval Comp./Ruston Turbines

LPG Spheres

Turbo-Expanders

Chilling Area

4 Units, Atlas Copco

Gas/Gas Heat Exchangers

Gas/Liquid Heat Exchangers

Utilities

5 Spheres, 6,000 ton Capacity

Propane Ref. Package Air Compressors

Condensates Tanks

Fractionation Area

2 Floating Roof
TanksCONFIDENTIAL
PRIVATE
AND
2 De-propanizers
Capacity 38,000 bbl
2 De-butanizers
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DCS

Nitrogen Unit

Heaters

Water Makers

Elementary Process Engineering

Power House
Fire Fighting Pumps Cooling Water pumps Flare System
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Elsayed

Session 2 : Gas Processing

Well Production

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Session 2 : Gas Processing

Separators
A separator is a pressure vessel
designed to divide a combined
liquidgas system into individual
components that are relatively
free of each other for subsequent
disposition or processing.

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Session 2 : Gas Processing

Why we should use it?

Downstream equipment cannot handle gasliquid mixtures .
Pumps require gas-free liquid
Compressor and dehydration equipment require liquid-free gas
Product specification set limits on impurities
Measurement devices for gases or liquids are highly inaccurate
when another phase is present.

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Session 2 : Gas Processing

METHODS USED TO REMOVE OIL FROM GAS IN
SEPARATORS

1- Density Difference (Gravity Separation)

2-pressure reduction Flash drum
3- cooling
4-heating

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Session 2 : Gas Processing

1- Density Difference (Gravity Separation)
The difference of density will determine the gas flow rate that
allow the liquid drops to settle out
For example the liquid drops will settle out from the gas stream
at 750 psig when the gas speed not more than 1 ft / sec ( pipe line
usually design at 15 to 60 ft /sec).

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Session 2 : Gas Processing

1- Density Difference (Gravity Separation)
The flow of the gas through the separator is slow enough (no
turbulence) which will keep the gas stream stirred up so
that the liquid has chance to drop out.

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Session 2 : Gas Processing

2-Pressure reduction Flash drum

Refers to a conventional oil and gas
separator operated at low pressure .
With the liquid from a higher-pressure
separator being "flashed" into it.
3- cooling
The first-stage separator vessel on a
low-temperature or cold separation unit
(LTS).
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Session 2 : Gas Processing

The basic equipment for separation
liquid from vapor uses:
Gravitational force is used by reducing
velocity so the liquid can settle out in the
space provide.
Centrifugal force is used by changing the
direction of flow.
True separator depends on the
gravitational force and retention time
that allow vapor and liquid
disengagement.
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Session 2 : Gas Processing

Definitions
When the gas stream carry some liquid it
called carryover
When the liquid stream carry some gases
it called carry under

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Session 2 : Gas Processing

Factors Affecting Separation

1.gas and liquid flow rates (minimum,
average, and peak)
2.operating and design pressures and
temperatures
3.physical properties of the fluids such
as density
4.presence of impurities (paraffin, sand,
scale, etc.)
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Session 2 : Gas Processing

Separators should be sized to handle the maximum flow rate
expected during the predicted life of the separator.
Separators must also be capable of handling sudden slugs of
liquid.

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Session 2 : Gas Processing

Effect of factors that cause separation

Separation factor

Effect of factor

1.Difference in weight of
fluid.

Separation is easier when weight

difference is greater.

2. Residence time in
separator.

Separation is better with more time.

3.Coalescing surface area .

Separation is better with more area.

4.Centrifugal action

Separation is better at higher

velocity.
Makes separation more difficult.

5.Presense of solids.
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Session 2 : Gas Processing

Separators Classification

Geometry

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Function

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Pressure

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Session 2 : Gas Processing

Classification by Function
Two-phase , (vapor-liquid) .
Three-phase (gas-oil-water) .

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Session 2 : Gas Processing

Classification by Operating
Pressure
Low-pressure separators usually operate at
pressures ranging from 10 to 20 up to 180 to
225 psi.
Medium-pressure separators usually
operate at pressures ranging from 230 to 250
up to 600 to 700 psi.
High-pressure separators generally operate
in the wide pressure range from 750 to 1,500
psi.
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Session 2 : Gas Processing

Classification by Application
Test Separator
A test separator is used to separate and to
meter the well fluids.
They can be permanently installed or portable
(skid or trailer mounted).
Production Separator
A production separator is used to separate the
produced well fluid from a well, group of wells
Low-Temperature Separator.
The temperature reduction is obtained by the
Joule-Thompson

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Session 2 : Gas Processing

Classification by Geometrical
Vertical
Horizontal
Horizontal doubledouble-barrel
Spherical

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Session 2 : Gas Processing

Horizontal Separators
Advantage of Horizontal Gas Separators
Horizontal separators are favored for large liquid volumes
or if the liquid-to-gas ratio is high.
Installations where vertical height limitations indicate
the use of a horizontal vessel.

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Session 2 : Gas Processing

Separating foaming crude oil where
the larger liquid/gas contact area of the
horizontal vessel
The larger surface area provides better
degassing and more stable liquid level
They are also generally preferred for
three-phase separation applications.
Easy to hook-up, controls and easy to
reach safely.

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Session 2 : Gas Processing

Disadvantages
1. Limited liquid surge capacity.
2. Liquid level control is more critical than with a vertical
type.
3. Area limitation
4. High expensive
5. Solid particles removing problems

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Session 2 : Gas Processing

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Session 2 : Gas Processing

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Session 2 : Gas Processing

Separator two Phase

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Session 2 : Gas Processing

Three Phase Separator

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Session 2 : Gas Processing

Slug catcher

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Session 2 : Gas Processing

Vertical Separators
This type is capable of handling
large slugs of liquid without
carryover to the gas outlet.
Is best suited for well streams with
low liquid content and high gas
volume
and
is
usually
recommended, when the gas-oil
ratio is high

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Session 2 : Gas Processing

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Session 2 : Gas Processing

Advantages
1. Liquid level and control not as critical as for
horizontal;
2. Easier and cheaper to design for surge capacity;
3. With certain designs, more extraneous material (for
example, sand, mud, and corrosion products) can be
handled; and
4. Usually easier to clean.

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Session 2 : Gas Processing

Disadvantages
1. More expensive,
2. Does not adapt to skidmounted assemblies as well as
do horizontals in most cases,
and
3. Requires a larger diameter for
the same gas capacity.

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Session 2 : Gas Processing

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Session 2 : Gas Processing

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Session 2 : Gas Processing

Filter (gas filter or filter/separator), dust Scrubber, or
Coalescer.

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Session 2 : Gas Processing

Spherical Oil and gas Separators applications

Well fluids with high GOR's,
constant flow rate and no liquid
slugging or heading.
Installations where both vertical
and horizontal space and height
limitations exist.
Downstream of process units
such as glycol dehydrators and gas
sweeteners to scrub expensive
process fluids, such as glycol .
Installations where economics
favors the spherical separator.

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Separator internals

Session 2 : Gas Processing

Separator internals
Separators usually includes some
mechanical parts that improve the
separation efficiency ,each part is
designed for a given functions and
based on a given physical properties
of the separated
phases.
The internals are divided into
three categories
Inlet devices
Intermediate devices
Outlet devices

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Session 2 : Gas Processing

Inlet devices
The main objective of the inlet devices is a rapid
change in flow direction and velocity.
Change in velocity will cause the separation of both gas
and liquid due to the difference of energy level , different
kinetic energy.
Change in direction will cause the gas to goes around
the deflector plates where the liquid will strike the
diverter and fall down.

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Session 2 : Gas Processing

Separators internals
OUTLET

Wire mesh

MIN
0.85 D
- 150 mm

150 mm

Vortex Breaker

600 mm MIN

FEED NOZZLE

FEED NOZZLE

600 mm

HHLL
1 MIN

HLL
LLL

600 mm MIN
0.6 D
1200 mm MAX

DRY DRUM

1 MIN
600 mm (DRY DRUM)
1 MIN
300 mm MIN

Vortex Breaker if Continuous Flow

to Pump or Control Valve

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Session 2 : Gas Processing

Operation of separator
Pressure control
The main point is the pressure control is done via regulating
the gas flow rate outlet from the separator.
Level control
In horizontal separator the level control is very important
where this level will determine the residence time for gas
bubbles to break out from the liquid.
In vertical separator the level has no significant effect as
horizontal separator where the vapor space in vertical
separator usually some meters so the few inches will not effect.

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Session 2 : Gas Processing

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Session 2 : Gas Processing

Important notes:notes: To evaluate if the residence time is enough to break out all
the gas or not we can notice the oil at the storage tank is
more gas flashed out , this indicate that the time is not
enough.
If the level is over than what is required this will appears
in the down stream process via the carry over of liquid
with the outlet gas stream, this may be a load on
compressors scrubbers.
The problem of get some gas with outlet oil is not critical
as carry over of liquid with gas so finally it is
recommended to set the level lower a little better than
over a little.
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Session 2 : Gas Processing

Separators Control

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Session 2 : Gas Processing

Separators concepts

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