Example separator performance metrics [1]

Separator Components

The main components of a separator, shown in Figure 3, are the feed pipe, inlet device, gas gravity separation
section, mist extractor and the liquid gravity separation section. The gas/liquid separator components will be briefly
discussed in regards to their effects on gas/liquid separation performance. These effects need to be understood and
quantified in order to troubleshoot separator operations, and to identify modifications that can be made to improve
performance. The liquid gravity separation section will not be discussed

Figure 3. Parts of a Conventional Separator [2]

Inlet Feed Pipe

The inlet feed pipe sizing and geometry is important as it is desired to keep the multiphase flow pattern “stabilized” in
the piping to minimize the production of small liquid droplets, and liquid entrainment into the gas phase. Figure 4 [2]
shows the effect of feed pipe velocity on liquid entrainment. Figure 5 [2] demonstrates how quickly the liquid
entrainment increases once the entrainment inception point is reached.
Figure 4. Effect of feed pipe velocity on liquid entrainment [2]

Figure 5. Example of liquid entrainment behavior in a gas-liquid system [2]

Some general guidelines for inlet piping to minimize liquid entrainment are:

 Provide 10 diameters of straight pipe upstream of the inlet nozzle without valves, expansions/contractions or
elbows.
 If a valve is required, only use full port gate or ball valves.
"Typically the following maximum inlet momentum for the inlet stream should be used on
scrubbers:

 No inlet device: rV2 <= 1,000 kg/m2s

 Half pipe: rV2 <= 1,500 kg/m2s
 let vane: rV2 <= 6,000 kg/m2s"
 Inlet Device
 The main purpose of an inlet device is to improve separation performance. This is achieved by maximizing
the amount of gas-liquid separation occurring in the feed pipe, minimizing droplet shearing, and optimizing
the downstream velocity distributions of the separated phases into the separator. Schematics for inlet
devices are shown in Figure 6. In large capacity, more critical separation applications, the vane-type and
cyclonic inlet devices are commonly used. The simpler, and less expensive, impact (or diverter plates) are
often used where the separation performance is less critical.


 Figure 6. Various separation equipment inlet devices [2]
 Table 2 provides a comparison of the performance of various inlet devices.
 Table 2. Comparison of inlet devices [2]
 
 The inlet momentum (ρmV2m – density*velocity2 of the mixture) of the feed stream is typically used to select
and size inlet devices. Table 3 provides the suggested upper limits of inlet momentum values. For conditions
where it is not practical to avoid higher feed pipe velocities, it must be recognized that failure to do so will
result in higher entrainment loads, smaller droplet sizes, and more difficult separation conditions.
 Table 3. Inlet device ρV2 upper limits [3]

The quality of the flow distribution downstream of the inlet device is critical to mist extractor performance. Historically,
tracer surveys have been used to provide an approximate indication of the continuous phase velocity within
separators. In more recent years, the use of CFD (Computational Fluid Dynamics) has provided insight into the flow
behavior of fluids, and has resulted in significant improvement in separator internals design. Separator performance
is to a large degree dependent on the removal of droplets/ bubbles from the continuous phase. The efficiency of this
removal is a function of the continuous phase velocity, thus the importance of understanding the factors that affect
velocity profiles. Figure 7 provides an example of ideal versus actual gas velocity profiles within a separator.
Figure 7. Ideal and actual gas velocity profiles [3]

Gas Gravity Separation Section

The gas gravity separation section of a separator has two main functions: 1) reduction of entrained liquid load not
removed by the inlet device, 2) improvement / straightening of the gas velocity profile.

Most mist extractors have limitations on the amount of entrained liquid droplets that can be efficiently removed from
the gas, thus the importance of the gas gravity section to remove the liquids to an acceptable level upstream of the
mist extractor. This is particularly important for separators handling higher liquid loads. For scrubber applications with
low liquid loadings, the Ks value will be primarily dependent on the mist extractor type, and the gas gravity separation
section becomes less important.

For the higher liquid load applications, there are two approaches for sizing the gravity separation section to remove
liquid droplets from the gas: 1) Ks method, 2) Droplet settling theory.

Historically the Ks method has been employed as it can provide reasonable results and is easy to use, but has
shortcomings in terms of quantifying separator performance. References 3-5 provide the details on the droplet
settling theory methods which can be used to more accurately quantify separator performance. The K s approach is
limited in that it only informs of the average droplet size, but cannot quantify the amount of liquid droplets exiting the
gas gravity section.

The Ks method (Equation 1) is an empirical approach to estimate the maximum allowable gas velocity to achieve a

desired droplet separation.

Where:

ρL = liquid density kg/m3 (lbm/ft3)

ρg = gas density kg/m3 (lbm/ft3)

Vgmax = maximum allowable gas velocity m/s (ft/sec)

KS = an empirical constant m/s (ft/sec)

Figure 8 provides the relationship of Ks values for various droplet sizes and separator operating pressures for the gas
gravity section. Typically, a Ks value is selected that will achieve removal of all entrained droplets larger than a
specified target droplet diameter in the original design of the separator. For conventional separators the target droplet
diameter is typically 150 microns, and for scrubbers the target droplet size should not exceed ~500 microns. This
correlation can also be used to determine the performance of the gas gravity section based upon current operating
conditions. The separator Ks value can be estimated from the actual velocity and fluid conditions, and the droplet size
removed in the gas gravity section can be estimated from Figure 8.

Figure 8. Ks vs. pressure and droplet size for empty vessels [2]

Mist Extraction Section

The mist extractor is the final gas cleaning device in a conventional separator. The selection, and design to a large
degree, determine the amount of liquid carryover remaining in the gas phase. The most common types include wire
mesh pads (“mesh pads”), vane-type (vane “packs”) and axial flow demisting cyclones. Figure 9 shows the location
and function of a typical mist extractor in a vertical separator.
Figure 9. Typical mist extractor in a vertical separator [2]

Mist extractor capacity is defined by the gas velocity at which re-entrainment of the liquid collected in the device
becomes appreciable. This is typically characterized by a K s value, as shown in Equation 1. Mesh pads are the most
common type of mist extractors used in vertical separator applications. The primary separation mechanism is liquid
impingement onto the wires, followed by coalescence into droplets large enough to disengage from the mesh pad.
Figure 10 provides some mesh pad examples. Table 4 provides a summary of mesh pad characteristics and
performance parameters.

Figure 10. Mesh pad examples [1]

 Table 4. Mesh pads summary of characteristics and performance parameters [1,4]

Notes:

 Flow direction is vertical (upflow).

 Assume mesh pad Ks values decline with pressure as shown in Table 5. Table 5 was originally developed
for mesh pads, but is used as an approximation for other mist extractor types. [6].
 If liquid loads reaching the mesh pad exceed the values given in Table 4, assume capacity (K s) decreases
by 10% per 42 L/min/m2 (10% per gal/min/ft2). [3-5].
 These parameters are approximate.

Table 5. Mesh pad Ks deration factors as a function of pressure [2]

Vane packs, like mesh pads, capture droplets primarily by inertial impaction. The vane bend angles force the gas to
change direction while the higher density liquid droplets tend to travel in a straight-line path, and impact the surface of
the vane where they are collected and removed from the gas flow. Figure 11 shows a schematic of a single-pocket
vane mist extractor. Table 6 provides vane pack performance characteristics.

Figure 11. Single-pocket vane schematic [2]

Table 6. Typical vane-pack characteristics [1,4]

Notes:

1. Assume vane-pack Ks values decline with pressure as shown in Table 5.

2. If liquid loads reaching the vane pack exceed the values given in Table 4, assume capacity K s decreases by
10% per 42 L/min/m2 (10% per gal/min/ft2). [3-5].
3. These parameters are approximate only. The vane-pack manufacturer should be contacted for specific
information.

In the case of demisting cyclones, the vendor should be consulted in regards to performance for the current
operations of interest.
As presented in the Appendix, substitution of expressions for the drag and gravity forces in Equation 1,
the maximum allowable gas velocity, VGmax, which prevents entrainment of liquid is obtained.

(2)

Equation 2 is called Souders-Brown [6] equation and KS is referred to as the design or sizing parameter.
The terms ρG and ρL are the gas phase and liquid phase densities, respectively.

Once the maximum gas velocity, VGmax, through the vessel is determined by Equation 2, one can calculate
the minimum vessel diameter, Dmin by Equation 3.

(3)

Where:

FG = Fraction of cross section area available for gas flow (FG = 1 for vertical separators
and is a function of liquid height for horizontal separators)

qa = Gas flow rate at the actual flowing condition

1. API 12 J

The API 12J [7] recommends ranges of KS –values for vertical and horizontal gas-liquid separators. These
values are presented in Table 1. The equivalent of API 12J for the North Sea region is NORSOK P-100.

Table 1. API 12 J recommended range of KS –values for vertical and horizontal separators [7]

Per API 12J, “the maximum allowable superficial velocity, calculated form the above factors, is for
separators normally having a wire mesh mist extractor. This rate should allow all liquid droplets larger
than 10 microns to settle out of the gas. The maximum allowable superficial velocity or other design
criteria should be considered for other type mist extractor. Mist extractor manufacturer's recommended
minimum distances upstream and downstream of the wire mesh between gas inlet and outlet nozzles
should be provided for full utilization of the mist extractor. These values assume separators are equipped
with standard mesh pad mist extractors” [7].

1. Campbell Book

The Ks method, Equation 2, is an empirical approach to estimate the maximum allowable gas
velocity to achieve a desired droplet separation. For vertical separators with no mist extractor
devices, Chap 11, Vol 2 of the Gas Conditioning and Processing book presents KS as a function
of pressure and liquid droplet size [5]. This dependency of KS on pressure and droplet size is
presented in Figure 2 [5]. Note for each droplet size a range of KS –values are given for a
specified pressure.

For horizontal separators, the sizing depends on (in addition to the droplet size, density of gas
and liquid phases, and gas velocity) separator effective length, Le, and the depth available for gas
flow, hG, (i.e. liquid level) in the separators.

Figure 2. KS as a function of pressure and liquid droplet size for vertical separators with no mist
extractor devices [5]

Sizing of the horizontal separators are more complicated. Referring to Figure 3, the effective Le
may be defined in terms of separator actual length and diameter like Le=L-D. Therefore, the
Souders-Brown parameter for horizontal separators, KSH, can be estimated in by Equation 4 in
terms of KSV (read from Figure 2) for vertical separator [3].

(4)

If the calculated value of KSH by Equation 4 is greater than the maximum value of 0.7 ft/sec (0.21
m/s), it should be set equal to this maximum value.

Figure 3. Schematic of a horizontal gas-liquid separator [5]

The horizontal separator sizing is a trial-and-error procedure. Normally, the Le/D and hg/D (or
hL/D) are assumed and KSH, Vgmax, D are calculated by Equations 4, 2, and 3, respectively. The
effective length and actual lengths are calculated by Equation 5.

(5)

Where:

D = Diameter
FL = Fraction of cross section area occupied by liquid (function of liquid height in horizontal
separator)

qL = Liquid actual volume flow rate

t = Residence time per API 12J [7]

If the calculated L/D is outside of its recommended range (normally 3 < L/D < 6), the liquid
height in the vessel is changed and the calculations are repeated. For detail of calculations
procedure refer to chapter 11 of reference [5].

Separator Performance Test

Fluid and Solids Monitoring and Analysis

Before conducting any detailed troubleshooting, it is critical that the performance of the
separator is mapped over a period of time that allows the collection of some consistent
data to provide a baseline. Ideally, mapping the system performance will have been
done as part of the day-to-day operations and include regular BS&W measurement
(inlet and outlet), OIW measurement, and solids quantification and
characterization. Having this historic data will make the troubleshooting much easier,
but often it is not available or inconsistently collected.

System Performance Mapping

BS&W. Measure and compare BS&W of the inlet fluids and the outlet oil stream. It is
important to understand if the vessel is helping to break some of the emulsion, or
whether it is just separating some or all of the free water. If there is only minimal
reduction in the percentage of emulsion, then the vessel, operating conditions, the
emulsion-breaking chemical, etc. need to be reassessed.
OIW. Measure the OIW of the water stream. Rather than just obtaining a total
hydrocarbon content, identify whether the hydrocarbon content is free oil that easily and
quickly separates, or if it is more finely dispersed (or soluble) and difficult to separate.

Oil/water interface. If the separator has sample nozzles at the interface, these should
be utilized to determine the sharpness of the interface or if there is a “rag” layer (stable
emulsion) and if there is, how thick it is. Collecting a sample and having it analyzed at
an onshore laboratory can identify what is stabilizing the emulsion.

Solids content and type. Regular sampling of the oil and water streams using Millipore
filters should be done to collect solids and obtain concentration data (total suspended
solids [TSS]). The filters should be sent for analysis at an onshore laboratory to
determine the composition.