. .. .

Society of Petroleum Engineers

6200 North Central Expwy.
Dallac, Texas 75206

011 andGasSeparation
Theory,Application
and Design

by
Leon Katapodis, Member SPE-AIME, CE-NATCO

THIS PAPER IS SUBJECT TO CORRECTION

(Q Copyright 1977
American Institute of Mlnh?g,Metallurgical, and Petroleum Engineers, inc.
Thispaper was prepared for the 1977 Oklahoma City Regional meeting on Operating Practices in Drilling and
Production of the Society of Petroleum Engineers of AIME, held in Oklahoma City February 21-22, 1977.
Permission to copy is restricted to an abstract of not more than 300 words. Illustrationsmay not be copied. The
abstract should contain conspicuous acknowledgement of where and by whom the paper is presented.
Publication elsewhere after publication in the JOURNAL OF PETROLEUMTECHNOLOGYor the SOCIETYOF
PETROLEUMENGINEERSJOURNAL is usually grented upon request to the editor of the appropriate journal,
provided agreement togiveproper credit is made. Discussion of this paper is invited.

INTRODUCTION 2. Refine the primary separation by

The physical separation of fluids is the
most basic and necessary segregation in oil
and gas processing. An oil and gas separator
is one of the most fundamental pieces of
production equipment used. Because of its
front end position in on-strecm processing,
its performance is vital to the operation of a
production facility. Oil and gas separators
were one of the first pieces of production
equipment introduced in the oil industry. But
regardless of this longevity, the separator
has not Iost any of its original and vital
importance in the separation of liquids and
gases. This paper will discuss on a limited
basis some, but notal?, of separator design
considerations.
DESIGN REQUIREMENTS
All separators must achieve the following
functions:
1. Make a primary phase separation of
the predominantly liquid hydrocarbons
from those which are predominantly
gaseous.
removing the entrained remnant mist
of 1iquid hydrocarbons from the gas.
3* Further refine the separation by
providing for the removal of entrained
gas phase bubbles from the liquid
phase so that the liquid contains
not substantially more physically
entrained gas than would exist as
potenti?.llygaseous material at
theoretical equilibrium conditions
at the pressure and temperature
within the vessel.
4. Assume proper control, by devices
which will provide for the removal
of this separated liquid phase from
the vessel without allowing an
opportunity for re-entrainment of
one r)haseinto the other.
All separators, whether vertical or
horizontal, to achieve the functions listed
above, consist primarily of four (4) basic
sections.
1. A primary phase separation section
which will control or dissipate the
energy of the fluids as they leave

OIL AND GAS SEPARATION
86
-. THEORY.
. ------ . . APPLICATION
. .. . -------- .. AND
——
the flow line and enter the vessel.
The design will vary with the
application.
2. A gravity settling section to ensure
that the gas and liquid flow rates
are always within the maximum permis- degree of turbulence that exists in the flowing
sible superficial velocity limits
which will allow adequate separation, turbulence results in carrying potentially
3. A mist extraction or coalescing
section which will minimize turbulence severe this condition, the larger will be the
in the gas section. Another design
variance from application to applica-
tion.
4. A liquid collecting and removal
section which prevents re-entrain-
ment from the separating phases.
Three physical principles are used in
liquid-gas separation. These are gravity,
centrifugal force and impingement. Gravity
separation is used in all,separators and
frequently in combination with centrifugal
force and/or impingement.
PRIMARY
The inlet stream enters the vessel as a
high velocity turbulent liquid phase mixed
with gas. Thus, the first step in effective
controlled gravitational separation is to
dissipate the high momentum of the inlet
fluids at the separator inlet. This high
momentum is due to the velocity at which the
fluids leave the flow line. The inertial
effect on exiting the flow line and entering
the vessel must be quickly and effectively
overcome. After this natural gravity separa-
tion under normal velocities can occur. To
accomplish this, a carefully designed and
compact “momentum absorber” is required for
producing controlled directional acceleration
of the incoming fluids, A reduction in
momentum thus occurs without detracting from
the ability to affect subsequent natural
gravitation separation, in spite of the high
turbulence at the inlet point. Downstream of
the momentum absorber, the predomina~tly
liquid material with entrained gas has separated one containing a lot of mass metal, the final
generally downward. Above this predominantly
liquid material is a predominantly gaseous
material with entrained liquid moving longitu-
dinally towards the mist extraction section.
The configuration of the inlet diverter
or momentum absorber varies as to the vertical
or horizontal configuration of the separator
and also to the conditions of flow which will
be imposed upon it.
SECONDARY
The refinement of the separation process
b.,
4
DESIGN
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1
is the next step. This must be controlled to
provide a gas free liquid and a liquid free
gas in the smallest vessel size possible for a
given set of design and conditions; the smallest
vessel size being the economic consideration
with respect to user and seller alike. The
stream is of considerable importance. Excess
separable liquid particles in the eddy current
reflecting this turbulent condition. The more
particle diameter affected.
A normal measure of turbulence in any
flowing stream is the dimensionless Reynolds
number DVP/M, specific to the given conditions.
In full flowing, circular pipe “D” is equal to
4 times the hydraulic radius. Hydraulic
radius being defined as the cnoss-sectional
area divided by the wetted pfrimeter. The
wetted perimeter is defined JS the length of
the intersection of the flufldcross-sectional
area and the wall of the cr,nduit. All other
factors remaining constan’.,the Reynolds
number varies directly as the hydraulic radius.
As the wetted perimeter is increased with
constant cross-sectional area, the hydraulic
radius is decreased sequentially lowering the
magnitude of the Reynolds number, It naturally
follows, that mechanical devices installed in
the form of internal baffles and/or mist
extractors would provide an optimum number of
flow passages of dimension that would have a
low Reynolds number, regardless of the diameter
of the separator itself.
The factors that control mist extractor
design areas variables the designs which
emerge. Flow rates, temperatures, viscosities,
gas.and liquid chemistry, upstream and down-
stream processes, environmental restrictions,
“ economics, weight, and other factors influence
mist extractor design. At one time, factors
such as the weight of the separation vessel
itself were not considered. Today, with
separators designed to process in excess of
100,000 BOPD, and at high pressures, weights
pose a real logistic problem. If the recom-
mended mist extractor of such separators were
design weight might be prohibitive for trans-
portation. The point is that not only must
the process requirement be satisfied with
proper internal design, but the internal
design must also vary with such influencing
factors as weight limitations.
The gas flow upon leaving the inlet
device is seldom laminar. The effect of
natural forces on separable phases, such as
expressed in Stoke’s Law, cannot be depended
on to produce liquid and gas separation.
Turbulence is high as the gas moves
. $.,
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wTrv
IFON
--”,
——
horizontally towards the mist extractor in a
more or less homogeneousmixture of gas and
liquid particles. Depending upon the liquid
and gas properties, the operating conditions,
and the desired outlet conditions, one or more
of the variable forms of mist extractors, or
elements, is placed at an optimum location
downstreamof the inlet device. The mist
extractor may take on the form of specially
designed baffles, plates or high density mesh.
Whatever the form of mist extractor, one or
both of the following will be its purpose:
1. To control the Reynolds number;
i.e., to reduce “turbulence”.
2. To project a drainable surface for
liquid particle impingement.
FINAL SEGREGATION
The process of separation is complete
after the liquid entrained gas product passes
through the mist extractor. Assuming that all
design conditions were properly met, liquid
free gas and gas free liquid at operating
conditions should exit the separator providing
there is no re-entrainment. But, re-entrainment
can occur if foam buildup occurs or if exit
velocities are too high in relationship to the
gas liquid interface or if properly selective
removal of dry gas and degassed oil does not
occur. Unless gas discharge and liquid dis-
charge from the vessel is controlled, vortexing
can occur. Liquid will be lifted by the
vortex action and carried out with the gas.
On liquid discharge, the vortex action will
cause excess gas to be discharged with the oil
or with the water if the separator is three-
phase. The design and positioning of good
vortex controls is important to total separa-
tion.
FOAM
Foam in separators is the chief cause for
poor performance in many instances. Foam
separation frequently limits the gas capacity
of crude oil separators. Foam separation is
different from particle separation in that
foam bubbles must.be broken. The controlling
parameters are foam surface area, retention
time and foam stability which can be reduced
by silicones or other chemical agents on some
susceptible oils.
!dhenfoam occurs during the expansion of
the liquid stream upon entry into the separator,
the separator, regardless of the nature of the
design, cannot prevent foam formation. What
good design does is to control the levels of
foam, to keep the rateof foam buildup in
proper relationship to the rate of depreciation,
to contain the foam, to retain it during
.
KATAPf)f)T~
,“, ,,.. ““--
87
I
dissipation, and to prevent re-entrainment of
the foam with the dry gas.
THREE-PHASE SEPARATION
The term three-phase separation refers to
separating oil, gas and free water, Water is
the most prevalent impurity produced with oil
and gas, and must be removed before the product
can be sold. Free water is defined as not
emulsified with another substance, If the
liquid is emulsified itwill require chemical
additives, heat, or a treater which is outside
the intwit of this article.
Retention time is the most important
consideration in the sizing of a three-phase
separator. Retention time is the length of
time liquids are allowed to remain in the
separator. This time is related to volume of
the vessel, amount of liquid to be processed
and the relative specific gravities of vhe
liquids.
A retention time of three minutes will
usually give acceptable results for most oil-
free water applications, For very viscous
oils or those close in specific gravity to
water more retention time may be required and
Stokes Law for particle settling velocity
should be used. In those applications where
condensate or distillate is being separated
from water less than three minutes will usually
be”adequate. One minute retention time is
mually adequate for two-phase, gas-iiquid,
separation.
In regard to retention time, when a
decision has to be made between increasing
diameter or length to obtain the desired
volume, in most all cases, it is more econom-
ical to increase vessel length rather than
vessel diameter. The reason for this is
because a greater shell and head thickness is
required, at the same working pressure, as the
diameter increases.
Once in the liquid collecting section the
oil and water will separate by natural gravity.
The oil, being lighter than water, will rise
to the top and the water will settle to the
bottom. There are various methods ofcontrollin
the separated liquids, two of which will be
discussed.
The first method is by a spill-over weir
and interface control. This method utilizes a
vertical weir plate, sometimes called a dam
plate, which allows the water to collect on
the upstream side of the weir and the oil to
spill over the top of the weir and into an oil
compartment from which the oil is periodically
dumped, The oil is forced over the weir due
to the difference of the specific gravities of
 9 ..”
“OIL AND GAS SEPARATION
88
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1
the two liquids and the volume of the incoming
liquids. The water is dumped by means ofan
interface controller located on the upstream
side of the weir plate. Two advantages of Where:
this system are -- it is relatively inexpensive
and greater utilization of retention time. v= Allowable.velocity through
separator, ft/sec
The main disadvantage is that the inter-
face controller is activated by its ability to K = Empirical constant, based dn
sense the difference in specific gravities mist extractor selection,
between the two liquids. If the liquids are dimensionless
slightly emulsified the contoller will not
operate properly and will allow oil out with P1 = Densityof liquid, #/ft3 at
water or vice versa. flowing conditions

The second control method is by means of = Densityof gas, #/ft3 at

an oil bucket and weir plate. This method ‘9 flowing conditions
utilizes the difference in specific gravity of
the oil and water with the “head” of the Flow rate is given in standard Cubic Feet
liquid. Once again a vertical weir plate is Per Day and converted to actual Cubic Feet Per
used with a “U” shaped oil bucket mounted in Second.
the vertical position. A hydrostatic “U” tube
effect has now been created. The oil and We now know two of the three unknowns and
water head on one side push the water head on can solve for the cross-sectional area of the
the other side up and over the weir plate. veSSel required for the gaseous phase.
The oil spills over into the oil bucket as
described in the first method. The oil and Separator liquid sizing is determined by
water are now in separate compartments and the following formula:
dumped as required. The main advantage of
this system is that the level controls are (.oo389)(Q,
)(Rt)
sensing the difference between a liquid and
gas. Disadvantages are more internal baffling ‘1 = L
is required and there is less effective reten-
Where:
tion volume.

Both control methods described above were ‘1 = Cross-sectional area of the

vessel allocated to the
for use in the horizontal vessel configuration.
Both methods could also be applied in the liquid phase in ft2
vertical vessel configuration.
Q, = Flow rate of liquid in barrels
SIZING per day

Separator gas sizing is based on a basic = Retention time, minutes

‘t
relationship between quantity of fluid.,.the
area through which it flows.,,and its linear L = Seam to seam length of a
velocity. horizontal vessel or liquid
height in a vertical vessel in
feet
Q = Av
Note: When sizing for three-phase
Where:
separation in a horizontal
Qu~ntity of fluid flow in vessel, L, should be reduced by
Q= the distance the weir plate is
ft /see at the flowing
conditions located upstream of the outlet
head.
A= Cross-sectional area of the
vesse allocated to the gaseous The total vessel area required is the sum
in ftA of the gaseous phase and liquid phase cross-
sectional areas. However, care should be
v = Velocity of the flowing fluid taken to allow adequate area within the vessel
in ft/sec at the flowing so that the liquid phase is not carried too
conditions high in the vessel or the gaseous phase
carried too low in the vessel,
Velocity is determined by the generally
accepted formula:
 .“.
>r
-K
cA7n
Uvlu
IbkullmN kn-rfltmnTc
Iu-tlrll Uwb -
“9 89

\DVANTAGESAND DISADVANTAGES SUMMARY

Some of the advantages and disadvantages Finally, it should be noted, that sizing
~f horizontal and vertical separators are as of oil and gas separators is not an exact
‘Ollows: science. While the hydraulic characteristic
and separating techniques are calculable: the
Horizontal matter of determining what any given size and
design separator will process must be lool’ed
Advantages: at purely on the basis of comparative opera-
tional data and parametric analyses. This
1. Direction of flow does not oppose then, puts a very real responsibility on both
drainage of mist extractor the operator and the designer.
2* Greater control of turbulence
3. Better use of retention volume The only basis for proper sizing of
4* Greater liquid surface area separators, other than resorting to extremely
Easier to service and maintain high safety factors to protect against unknowns,
:: Better for handling foaming crude is operational data, It is absolutely necessar~
Lends itself to piggyback stacking that information, however sketchy, be available
i; Higher liquid capacity with high GOR to indicate tilesusceptibility to separation
of the stream concerned.
Disadvantages:
Specifi~ally, the observed capacity limit
More installation space is required of a separw.tingdevice, however large or
;: Mist extractors sometimes plug up small, at ;iven pressure and temperature
and blow out conditions with a known flow rate is the
3. Not as good for handlinj sand or mud ,minimum fully reliable data required for
starting the sizing process. A reputable
Iertical manufacturer with wide experience and good
engineering background can take these data and
Advantages: from them, develop a parametric relationship
which when applied with his own empirical
1, Can handle larger quantities of sand relationships can be used to determine size,
and/or mud shape, and the best design of separating
2. Good surge capacity equipment to handle the desired load.
3. Good space saver where space is
limited Whenever possible, to produce the best
4. Can be cleaned easier possible separator for the application, such
sizing and design should include foaming
Disadvantages: tendency analysis in the field and laboratory
and test separator performance data.
1. More expensive for processing equal
amounts of gas ACKNOWLEDGMENTS
2. Less drainage capacity of mist
extractor I wish to thank the management of C-E Natcc
Not good for foam for permission tc publish this paper, I
:: Not good for skid mounting that has gratefully acknowledge the assistance of J. D.
to be moved frequently, due to Lewd, R. W, Coggins, P. E. Meyer and N. E.
height Lowrie, C-E Natco, Tulsa, Oklahoma. Suggestions
5, Reaching and servicing of top mounted of colleagues at C-E Natco have been very
accessories and nozzles is difficult helpful.
6, Lower liquid capacity with high GOR