Two Phase & Three

Phase Separators
Work Instruction

A0 Issued for Information M. Jalali / M. Sabeti A. Javanpour A. Ghahremani 2018-11-13

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 Two Phase & Three Phase Separators
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Rev. Description Prepared Checked Approved Date

Table of Contents

1 Objective.................................................................................................................................................4

2 Scope.......................................................................................................................................................4

3 Responsibilities.......................................................................................................................................4

4 References...............................................................................................................................................4

5 Description..............................................................................................................................................4
5.1 Separator applications and considerations......................................................................................4
5.2 Horizontal or vertical design...........................................................................................................5
5.3 Sizing procedure..............................................................................................................................6
5.4 Comparison of different procedures:.............................................................................................19
5.5 Design pressure and temperature..................................................................................................21
5.6 Vessel connection..........................................................................................................................23
5.7 Pressure drop.................................................................................................................................28
5.8 Conditions requiring winterization................................................................................................29
5.9 Vessel internal...............................................................................................................................29

6 Attachment............................................................................................................................................39

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 Two Phase & Three Phase Separators
Work Instruction

Change Matrix

No. Description Pag Date Comment

e
1 First issue All Pages 2018-11-13 -

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 Two Phase & Three Phase Separators
Work Instruction

1 Objective
This instruction is used to describe properties of separators.

2 Scope
The main aim of this guideline is to specify the properties of vertical and horizontal separators for both
vapor-liquid and vapor-liquid-liquid separators. Its field of application is that associated with oil and gas
plants in basic and detail design stages.

3 Responsibilities
Process discipline is responsible for preparing properties of Separators.

4 References
- IPS-E-PR-880 “Engineering standard for process design of gas-liquid separators”
- IPS-E-PR-850 “Engineering standard for process requirements of vessels and separators”
- IPS-E-PR-420 “Engineering standard for process design of heat tracing and winterizing”
- NIOEC-SP-00-50 “NIOEC specification for design criteria for process and mechanics”
- NIOEC-SP-70-01 “NIOEC specification for instrumentation”
- W.D. Monnery, W.Y. Svrcek “Design Two-Phase Separators within the Right Limits”, 1993.
- W.D. Monnery, W.Y. Svrcek “Successfully Specify Three-Phase Separators”, 1994.
- TOTAL Process Engineering Design Manual.

5 Description
This section aims to describe the relevant information, including application, sizing procedure, design
consideration and required internal and external tools, about separators.

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 Two Phase & Three Phase Separators
Work Instruction

5.1 Separator applications and considerations

The term separator in oilfield terminology designates a pressure vessel used for separating well fluids
produced from oil and gas wells into gaseous and liquid components. Separators may be oriented
either vertically or horizontally. In some cases, it may be necessary to compare both designs to
determine which is more economic.
5.1.1 Two phase separators
A two phase separator is usually used for separation of gas and liquid which appears in the following
categories:
• Compressor and Fuel Gas KO drums: It is needed to separate liquid from vapor according to the
mentioned equipment. To effectively do so, a mist eliminator always set in the separators, and a surge
time of 2 min is held for LLL and HLL.
• Unit Feed KO drums: It is needed at upstream of acid gas absorbers, glycol contactors and
desiccant bed dehydrators. A demister pad is required in the separators.
• Relief system KO drum: All flare, vent and relief systems must include a knock out drum. The
knock out drum removes any liquid droplets that carry over with the gas relief sent to the flare stack.
5.1.2 Three phase separators
Three phase separators are commonly used in the oil and gas industry for the separation of oil, water and
hydrocarbon gases from raw product streams. These separators are almost horizontal. A demister helps
vapor-liquid separation happen better. Typical process applications are:
• Crude/Water separators (in E&P applications)
• Overhead Accumulators (in refinery applications)
• Ejector Effluent Separators (in refinery applications)

5.2 Horizontal or vertical design

Each design case must be evaluated separately but in general the following can be used as a guideline:
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 Two Phase & Three Phase Separators
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 Vertical Drums:
- Compressor K.O. drums,
- Degassing Boot,
- Fuel Gas K.O. Drums,
- Absorber K.O. Drums,
- Floating Installation.
 Horizontal Drums:
- Production HP Separators,
- Reflux Drums,
- 3 Phase Separation,
- Flare K.O. drum.
Generally for gas/liquid separation, a vertical vessel should normally be selected for the following
reasons:
- When the gas/liquid ratio is high (< 10-20% by weight);
- A smaller plan area is required (critical on offshore platforms);
- Easier solids removal.
- Liquid removal efficiency does not vary with liquid level (area in vessel available for gas flow
remains constant).
- Vessel volume is generally smaller. However,
• Also horizontal vessel should be chosen in case of:
- Large volume of total fluid is available;
- Large amount of dissolved gas is available;
- Large liquid slugs have to be accommodated.
- There is restricted head room.
- A low downward liquid velocity is required (for de-gassing purposes or for foam breakdown).
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 Two Phase & Three Phase Separators
Work Instruction

There are different variations of horizontal three phase separators. The liquid separation section is usually
a variation of a device to provide interface level control, which may include a boot or a weir. A boot
typically is specified when the volume of heavy liquid is not substantial (< 15-20% of total liquid by
weight) while a weir is used when the volume is substantial.

5.3 Sizing procedure

Roughly available manuals for separator sizing accompany a general rule. Vertical vessels’ diameters are
determined with gas flow rate while horizontal vessels’ diameters are fixed through residence time of
each liquid in the vessels. The length of the vertical vessels as well as the diameter of the horizontal
vessels is affected by the controlling levels. The levels should be justifies so good that dispersed droplets
find their time to be extracted from the continuous phase.
The separation is usually accomplished in three stages. The first stage, primary separation, uses an inlet
diverter so that the momentum of the liquid entrained in the vapor causes the largest droplets to impinge
on the diverter and then drop by gravity. The next stage, secondary separation, is gravity separation of
smaller droplets as the vapor flows through the disengagement area. The final stage is mist elimination
where the smallest droplets are coalesced so that larger droplets are formed which will separate by
gravity.
For secondary separation, the allowable velocity must be calculated so that disengagement area can be
subsequently determined. Performing a force balance on the liquid droplet settling out provides the
necessary relationship. When the gravity force, given by Eq. 1,

M P ( ρ L− ρV ) g 1
F G=
gC ρ V
Balance the drag force, given by Eq. 2.

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 Two Phase & Three Phase Separators
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( π / 8 ) C D D 2P U V2 ρV 2
FD=
gC
The heavier liquid droplets will settle at a constant terminal velocity, U t . Equating Eqs. 1 and 2 results in,

√ 4 g DP ( ρ L −ρV ) 3
UT=
3C D ρ V
Hence, as long as U V <U T , the liquid droplets will settle out. Typically, the allowable vertical velocity,
U V , is set between U T and 0.75 U T . Eq. 3 can be rearranged as Eq. 4:

√ ( ρ L −ρV ) 4
U V =K
ρV
Where K can be determined by the following table.

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Table 1: Methods developed for calculating K.

5.3.1 Calculation procedure vertical vessel (2-phase)

1- Calculate the vertical terminal vapor velocity:

( )
1 /2
ρ L− ρV
U T =K , ft /s 5
ρV

Calculate the K value, using one of the methods mentioned before and set U V =0.75 U T for a
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conservative design.
2- Calculate the vapor volumetric flow rate:

WV 3
QV = , ft / s 6
3600 ρV
3- Calculate the vessel internal diameter, DVD :

( )
1/ 2
4 QV
D VD = , ft 7
π UV

If there is a mist eliminator, add 3-6 in. to D VD to accommodate a support ring and round up to the next 6
in increment to obtain D ; if there is no mist eliminator, D=D VD .
4- Calculate the liquid volumetric flow rates, Q L:

WL 3
Q L= , ft /min 8
( 60 ) ( ρ L )
5- Select holdup time and calculate the holdup volume:
3
V H =T H .Q L , ft 9
6- Select holdup time and calculate the holdup volume:
3
V S =T S .Q L , ft 10
7- Obtain low liquid level height, H LLL from The following table:

Table 2: Low liquid level height detection.

Vessel diameter Vertical LLL (in) Horizontal LLL

<300 psia >300 psia

(ft) (in)
≤4 15 6 9
6 15 6 10
8 15 6 11
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 Two Phase & Three Phase Separators
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10 6 6 12
12 6 6 13
16 6 6 15

8- Calculate the height from low liquid level (LLL) to normal liquid level (NLL):

VH
H H= , ft
()
π 2
D
4 V
11

9- Calculate the height from normal liquid level (NLL) to high liquid level (HLL):
VS
HS= , ft
π
()
4 V
D 2 12

(6 in minimum)
10- Calculate the height from high liquid level to the centerline of the inlet nozzle:

H LIN =12+d N ,∈ ( With inlet diverter ) 13

1
H LIN =12+ d ,∈ ( Without inlet diverter ) 14
2 N
11- Calculate the disengagement height, from the centerline of the inlet nozzle to:
a) The vessel top tangent line if there is no mist eliminator or
b) The bottom of the demister pad.

H D=0.5 DV ∨a minimum of
1
H D=36+ d ,∈ ( Without mist eliminator ) 15
2 N
1
H D=24 + d ,∈ ( With mist eliminator )
2 N

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12- If there is a mist eliminator, take 6 in. for the mist eliminator pad and take 1 ft. from the top of the
mist eliminator to the top tangent line of the vessel.

H ME=12+6 ,∈ ( With mist eliminator )

16
H ME=0 ,∈ ( Without mist eliminator )
13- Calculate the total height, HT of the vessel:

H T =H LLL + H H + H S + H LIN + H D + H ME , ft 17

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 Two Phase & Three Phase Separators
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Figure 1: Vertical Two-phase separator

5.3.2 Calculation procedure horizontal vessel (2-phase)

1- Calculate the vapor volumetric flow rate, QV .
2- Calculate the liquid volumetric flow rates, Q L.
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 Two Phase & Three Phase Separators
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3- Calculate the vertical terminal vapor velocity, U T ,( K value as per Table 1 for no mist eliminator).
Set UV = 0.75UT for a conservative design.
4- Select holdup and surge times and calculate the holdup and surge volumes, V H and V S .
5- Obtain an estimate of L/D from Table 3 and initially calculate the diameter according to:

( )
1 /3
4 (V H+ V S)
D= , ft ( Round ¿nearest 0.5 ft .) 18
0.6 π ( L/ D )
Table 3: L/D ratio guidelines.

Vessel Operating Pressure (psig) L/D

0<P≤250 1.5-3.0
250<P≤500 3.8-4.0
500<P 4.0-8.0

6- Calculate the total cross-sectional area:

π 2 2
AT = D , ft 19
4
7- Calculate the low liquid level height.

H LLL=0.5 D+7 ,∈. 20

Where D in ft. and round up to the nearest in. if D≤ 4”, HLLL =9 in.
8- Using HLLL/D. Obtain ALLL/AT and calculate the low liquid area ALLL.
9- If there is no mist eliminator pad, the minimum height of the vapor disengagement area (AV) is the
largest of 0.2D or 1 ft. If there is a mist eliminator pad, the minimum height of the vapor disengagement
area is the largest of 0.2D or 2 ft. Hence, using HV/D, obtain AV/AT and calculate AV.
10- Calculate the minimum length to accommodate the liquid holdup/surge:

( V H +V S )
L= 21
AT − AV − A LLL
11- Calculate the liquid dropout time, ∅ .

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HV
∅= ,s 22
UV
12- Calculate the actual vapor velocity, U VA .

QV
U VA = , ft / s 23
AV
13- Calculate the minimum length required for liquid/vapor disengagement, Lmin.

Lmin =U VA ∅ , ft 24
14- If L< Lmin, then set L=Lmin (vapor/liquid separation is controlling). This simply results in some extra
holdup and residence time. If L<¿ Lmin, then increase H V and repeat calculation from the step 9. If L> Lmin
, the design is acceptiable for vapor/liquid separation. If L≫L min, liquid holdup is controlling. L can only
be reduced and Lminincreased if H V is reduced. H V is may only be reduced if it is greater than the
minimum specified in Step 9. (Calculations would have to be repeated from the step 9 with reduced HV).
Calculate L/D. If L/D > 6.0 then increase D and repeat calculations from the step 6. If L/D <1.5, then
decrease D and repeat calculations from the step 5.
15- Calculate the thickness of the shell and heads. (Process Department isn’t responsible for vessel
thickness calculation).
16- Calculate the surface area of the shell and heads.
17- Calculate the approximate vessel weight. (Process Department isn’t responsible for vessel weight
calculation).
18- Increase and decrease the diameter by 6 in. increments and repeat the calculations until L/D has
ranged from 1.5 to 6.0.
19- With the optimum vessel size (minimum weight). Calculate normal and high liquid levels:

VH
A NLL= A LLL + 25
L
20- With ANLL /AT obtain HNLL.

H HLL=D−H V 26

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Figure 2: Horizontal Two-phase separator

5.3.3 Calculation procedure vertical vessel (3-phase)

1- calculate the vertical terminal vapor velocity

( )
ρ L− ρV 1 /2
27
U T =K
ρV

Calculate the K value, using one of the methods mentioned before and set U V =0.75 U T for a
conservative design.
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2- calculate the vapor volumetric flow rate:

WV 28
QV =
3600 ρV
3- calculate the vessel internal diameter, D VD :

( )
4 QV 1/ 2
29
D VD =
π UV

If there is a mist eliminator, add 3-6 in. to D VD to accommodate a support ring and round up to the next 6
in increment to obtain D ; if there is no mist eliminator, D=D VD .
4- Calculate the setting velocity of the heavy liquid out of the light liquid using Stokes’ law (the
maximum is 10 in./min):

k S ( ρ L−ρV ) 30
U HL=
μL
5- Similarly, calculate the rising velocity of the light liquid out of the heavy liquid phase using Stokes’
law:

k S ( ρL −ρV ) 31
U LH =
μH
6- Calculate the light and heavy liquid volumetric flow rates, Q¿ and Q HL:

W¿ 32
Q¿ =
60 ρ L

W HL 33
Q HL=
60 ρ H
7- Assume H L=1 ft (minimum) and calculate the settling time for the heavy liquid droplets to settle
through this distance (12 is a conversion factor for ft to in.):

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12 H L 34
t HL =
U HL
8- Assume H H =1 ft (minimum) and calculate the settling time for the light liquid droplets to rise
through this distance:

12 H L 35
t LH =
U HL
9- If there is a baffle plate, calculate the area of the baffle plate.
10- Calculate the residence time of each phase based on the volumes occupied by the light and heavy
phases:

HL AL 36
θ¿ =
Q¿

H H AH 37
θ HL =
Q HL
If θ¿ <t HL or θ HL <t LH , increas the diameter and repeat the procedure from Step 7.
11- Calculate the height of the light liquid above the outlet (holdup height) based on the required
holdup time:

Q¿ T H 38
H R=
AL
Check this value with that assumed in Step 9 to ensure that the assumed value is reasonable. If surge is
not specified, calculate the surge height based on surge time:
( Q¿ +Q HL ) T S 39
HS=
A
12- Calculate the vessel height using the guidelines:
H R=6∈. minimum

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1
H BN = d N + greater of ( 2 ft∨H s+ 0.5 ft )
2

H D=0.5 D∨a minimum of 36∈.+

( 1
2dN )
, or 24 in. +1/2d N (with mist eliminator)

H T =H H + H L + H R + H A + H BN + H D 40
If a mist eliminator pad is used, additional height is added.

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Figure 3: Vertical Three-phase separator

5.3.4 Calculation procedure horizontal vessel (3-phase)

1- Calculate the vapor volumetric flow rate, QV .
2- Calculate the light and heavy liquid volumetric flow rates, Q¿ and Q HL.
3- Calculate the vertical terminal velocity, U T , using and set U V .
4- Select holdup and surge times and calculate the holdup and surge volumes, V H and V S .
5- Determine L/ Dand set the diameter according to:

( )
4 (V H+ V S)
1 /3
41
D=
0.6 π ( L/ D )
6- Set the vapor space height, H V , to the larger of 0.2 D or 2 ft. Using H V / D , obtain AV / A T and
calculate AV .
7- Set the light liquid heights in the vessel and boot, H LLV and H LLB.
8- Calculate the cross-sectional area of the light liquid above the bottom of the vessel, A LLV , using
H LLV / D .
9- Calculate the minimum length to accommodate the liquid holdup/surge:

(V H+ V S) 42
L=
AT − AV − A LLV

10- Calculate the liquid dropout time, Φ .

11- Calculate the actual vapor velocity, U VA .
12- Calculate the minimum length required for liquid/vapor separation, Lmin.
13- If L< Lmin, then set L=Lmin (vapor/liquid separation controls). This simply results in some extra
holdup and residence time. If L<¿ Lmin, then increase H V and recalculate AV , then repeat from Step 9. If
L> Lmin, the design is acceptiable for vapor/liquid separation. If L≫L min, liquid holdup controls. L can
only be reduced and Lminincreased if H V is reduced. H V is may only be reduced if it is greater than the
minimum specified in Step6. With reduced H V , recalculate AV and repeat from Step 9.
14- Calculate the settling velocity of the heavy liquid out of the light liquid phase, U HL.
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15- Calculate the settling time of the heavy liquid out of the light liquid phase:

( H LLB+ D−H V ) 43
t HL =12
U HL
16- Calculate the residence time of the light liquid:

( A T − AV ) L 44
θ¿ =
Q¿
17- If θ¿ <t HL then increase the vessel length:

t HL Q ¿ 45
L=
( A T − AV )
L
18- Calculate L/ D. If L/ D<<1.5 then decrease D (unless it is already at a minimum and if ≫6.0
D
then increase D; repeat from Step 5.
19- With the optimum vessel size (minimum weight), calculate the normal and high liquid levels:

H HLL=D−H V 46

A NLL= A LLV + V H / L 47
Determine H NLL.
20- Design the heavy liquid boot:

Set the height of the heavy liquid, H LH ; calculate the rising velocity of the light liquid out of the heavy
liquid phase, U LH . Set U LH =0.75 U LH ; calculate the heavy liquid boot diameter:

√ 4 ×12 QHL 48
DB =
πUP
Then calculate the settling time of the light liquid out of the heavy liquid phase:
t LH =12 H HL /U LH 49

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Calculate the residence time of the heavy liquid:

2
π D P H HL 50
θ HL =
4 Q HL
If θ HL <t LH , then increase the boot diamter.

Figure 4: Horizontal Three-phase separator

5.4 Comparison of different procedures:

Two phase vertical separators are sized by Monnery, Total 1985, Total 1998 and JGC procedures.
- Total 1985 and Total 1998 procedures make more detailed results about various levels comparing
with the others. Total procedures give HLA, HLL, LLL and LLA. Monnery procedure gives
HLL, NLL and LLL, and JGC gives only HHLL.
- Monnery, Total 1985 and JGC produce the same value of diameter.

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- One should note that Monnery may produce a larger diameter in some cases.
- At the same diameter, the mentioned methods produce the height of vessel with the following
order:
- HMonnery < HJGC < HTotal1985 < HTotal1998
Two phase horizontal separators are sized by Monnery and Total 1998.
- Monnery and Total 1998 follow two different methods to size the diameter of vessels, so it is
somewhat impossible to compare the methods.
- The length of vessel coming out from Total 1998 is larger than Monnery procedure if their
diameter is supposed to be the same.
Three phase horizontal separators with boot are sized by Monnery and Shell procedures.
- The recommended value of L/D in Shell procedure is something between 2.5 and 6 while that in
Monnery is between 1.5 and 6.
- Outlet and inlet compartment increase the length of vessels in Shell procedures.
- The volume of vessel in Shell is more than that of Monnery.
- Unlike Monnery, Shell can determine exact values for HHLL and LLL.
- Shell needs more calculation investment than Monnery.
- Bothe the procedures require the same number of input data.
Three phase horizontal separators with weir are sized by Monnery and Total procedure.
- Monnery and Total has almost the same results. However there is drag coefficients which affects
largely on the volume of vessel sized by Total. It is important to determine it correctly.
Three phase vertical separators are sized only by Monnery.

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5.5 Design pressure and temperature

5.5.1 Pressure

The design pressure is the maximum and / or minimum pressure for which the mechanical calculation
shall be performed. The operating pressure is defined as the maximum anticipated normal operating
pressure.

The design pressure shall be established according to the following criteria except in special cases
approved by the Company. In addition, where, process fluid static head or other appropriate loads
significantly increase the internal pressure, the design pressure shall be increased accordingly for the
vessel section concerned.

A) For maximum normal operating pressure less than 1.5 barg (except item “G” below), whichever is
greater:

- 3.5 bar gage, or

- Flare design pressure if the vessel is connected to flare.

B) For maximum normal operating pressures between 1.5 and 20 barg, use the maximum normal
operating gage pressure +2 bar.

C) For maximum normal operating pressures between 20 and 80 barg, use 110% of the maximum
normal operating gage pressure.

D) For maximum normal operating pressures between 80 and 140 barg, use the maximum normal
operating gage pressure +8 bar (see Note 2).

E) For maximum normal operating pressures above 140 barg, use the maximum normal operating gage
pressure + 5% (see Note 2).

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F) Equipment normally operated under vacuum shall be designed for full vacuum and for the highest
pressure which the equipment can experience in case of vacuum system failure, (see Note 3).

Full vacuum shall be specified for isolable equipment containing fluid having a vapor pressure lower
than atmospheric pressure at ambient temperature.

For equipment operated under vacuum, minimum internal pressure shall be 3.5 barg.

For vacuum rating designation, pressure shall be noted as external.

G) For equipment operating under Atmospheric pressure, use hydrostatic (water) pressure + 50 mm
Water column (see Note 4).

NOTES: The following design notes shall be taken into consideration for establishing design pressure:

1) In case of equipment connected in series, without block valves in between, the design pressure for the
upstream equipment shall be the same as the design pressure for the downstream equipment
(equipped with safety valve) increased by 120% of the pressure drop foreseen between the two
equipment, under safety valve discharge accordingly.

2) When design pressure lower than 110% max. operating pressure is specified, safety valves blow
down shall be selected accordingly.

3) Design for vaccum:

a) Steam drums shall be designed for full vacuum conditions.

b) Vacuum design conditions shall not be required as consequence of equipment block-in after steam
out operation. However, vacuum conditions shall be studied during start-up, shut-down and
regeneration and shall be considered for equipment design where applicable.

c) Due consideration shall be taken to establish external design pressure for vessels subject to internal
pressure but connected to the suction of compressor or other evacuating equipment .
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d) Low pressure vessels that may be affected by decreasing in ambient temperature shall be designed
for such vacuum conditions. As an example, main column overhead receiver which is operating at
low pressure and receive feed from air cooled exchanger.

e) Vacuum design shall be specified for vessels which normally operate liquid full and can be
blocked in and cooled down.

f) Vacuum design shall be specified for fractionators and associated equipment that can undergo a
vacuum condition through the loss of heat input.

4) The set pressure of the relief valve must be lower than or equal to the equipment design pressure.

5) Design pressure of the overhead condenser and reflux drum for fractionators and towers shall be
calculated based on the column top maximum normal operating pressure.
5.5.2 Temperature

a) Unless otherwise specified, equipment design temperature shall be established according to the
following criteria:

Operating Temperature (OT) Design Temperature (DT), Min./Max.

- Less than – 100 ºC - Min. oper. temp./ 85 ºC min.
- Between – 40 ºC and –100 ºC - 100 ºC/85 ºC min.
- Between – 30 ºC and – 39 ºC - 45 ºC/85 ºC min.
- Between – 29 ºC and +60 ºC - Min. oper. temp. / 85 ºC
- Between + 60 ºC and 343 ºC - Max . oper. temp. +25 ºC.
- Above 343 ºC - To be specified according to the selected
material and process requirement.
b) The design temperature is determined for the maximum temperature coincident with the design
pressure as determined above. Indicate any higher temperatures as alternate design conditions.

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c) When, due to the possible loss of flow of the cooling medium in coolers, the tubes, tubes sheets
and floating heads may be subject to the full inlet temperature, it shall be indicated on the
individual process data sheet and these components shall be designed for the maximum
anticipated operating temperature of the hotter medium.

d) The overhead receivers shall be designed for operating temperature plus 25 ºC or the overhead
maximum operating temperature of upstream columns, whichever is greater.

5.6 Vessel connection

5.6.1 Blanked off ventilation & manway
Blanked off ventilation: On unlined horizontal vessels, a manway shall be provided on the top or side of
the vessel at or below the horizontal centerline. If the bottom half of the horizontal vessel is lined, the
manway shall be located on the upper side or the top of the vessel. Additionally, on horizontal vessels
over 3 meters in tangent length, a blanked off ventilation nozzle shall be provided on the top of the vessel
near the end, opposite the manway. The ventilation nozzle shall be sized as follows:
Vessel Tangent Length blanked off
Nozzle size
- 3.0 meters through 4.4 meters 4”
- Over 4.4 meters through 7.5 meters 6”
- Over 7.5 meters 8”

Manway: 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:
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* 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
5.6.2 Vent, drain and steam out nozzles
Vessel vents, drains and steam out nozzles shall be independent of the normal process flow lines and
shall be in accordance with the following criteria:

Table 4: Procedure for finding proper vent, drain and steam out nozzles.

Vessel Volume (m3)

Vent size Drain size Steam out Nozzle
and ID (mm) (Note 1)

DN 40
V<45, D<1200 DN 40 (1½”) DN 25 (1”)
(1½”)

45<V<75, 1200<D<2500 DN 50 (2”) DN 50 (2”) DN 40 (1½”)

45<V<75, 2500<D<3500 DN 80 (3”) DN 80 (3”) DN 40 (1½”)

45<V<75, 3500<D<4500 DN 100 (4”) DN 80 (3”) DN 50 (2”)

75<V<220,
DN 100 (4”) DN 80 (3”) DN 80 (3”)
4500<D<6000

220<V<420, D>6000 DN 100 (4”) DN 100 (4”) DN 80 (3”)

V>420, D>6000 DN 150 (6”) DN 100 (4”) DN 100 (4”)

Notes:
(1) Size of nozzles shall be selected based on vessel volume and vessel inside diameter, whichever to be greater.
(2) Drain on vertical vessel may be located on bottom line.
(3) Select drain size to be same as process line, when process connection is to be smaller than the above table.
(4) Vent connections must be located on top of the vertical and horizontal vessels.
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5.6.2.1 Steam out connection

Separate steam out connections shall be provided for each vessel. The nozzle sizing of steam out
connection should be complied with Table 4. The configuration in case of permanent steam-out
connection, shall include check valve, ¾” bleeder, pressure blind and gate valve adjacent to the vessel on
the low pressure steam supply line towards the vessel.

Figure 5: Permanent steam-out connection

Also the configuration of temporary steam-out connection is similar to the following schematic:

Figure 6: Temporary steam-out connection

5.6.3 Instrument connection

The following table shall be conformed for instrument to process connection size and type:
Table 5: Instrument to Process Connection
Connection to vessel
Instrument
Size Type

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Without Diaphragm Seal 1" Flanged

Pressure/DP Transmitter
With Diaphragm Seal 2" Flanged
Pressure/DP Gauge or Without Diaphragm Seal 1" Flanged
Switch With Diaphragm Seal 1 1/2" Flanged
External Side Mounted 1 1/2" Flanged
Level Displacer Transmitter Internal Side Mounted 4" Flanged
Internal Top Mounted 6" Flanged
Without Diaphragm Seal 1" Flanged
DP Level Transmitter
With Diaphragm Seal 2"/3" Flanged
Level Gauge 1" Flanged
External Displacer/ Float Type Side Mounted 1" Flanged
Level Switch Internal Displacer/ Float Type Side Mounted 4" Flanged
Internal Top Mounted 4"/6" Flanged
Level Standpipe 3" Flanged
Radar Level Transmitter 6"/8" Flanged
Tank Gauging
Thermo Element 4" Flanged
DP Flow Transmitter - -
Thermo-well 1 1/2" Flanged

Minimum flange rating for instrument nozzles on vessels shall be as follows:

a) Level instrumentation standpipes: ANSI 300 #.
b) Pressure relief valve: ANSI 300 #.
c) All nozzle sizes equal or lower than 1-½ inches: ANSI 300 #.
5.6.4 Nozzles
5.6.4.1 Feed nozzle
Vertical knock-out drum without mist extractors: The feed nozzle shall be fitted with a half open pipe
or a flow diverting box inlet device. The nozzle diameter, dn, may be taken equal to that of the feed pipe
but the product ρ m × V 2m shall not exceed 1500 kg/m.s².

Horizontal knock-out drum without mist extractors: The nozzle diameter, dn, may be taken equal to

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that of the feed pipe, but the product

ρ m× V m
2
51
Shall not exceed 1000 kg/m.s2.

Vertical demister separators: When the vessel diameter is less than 0.8 m the feed nozzle should be fitted
with a halfopen pipe inlet device.
For vessel diameters of 0.8 m and greater, a vane-type inlet device is recommended. The diameter of the
nozzle dn, may be taken equal to that of the feed pipe, but the following two criteria shall also be
satisfied:
ρ m.V 2 < 6000 kg / m. s2 52

ρ g.V 2g −¿ < 3750 kg / m. s2 53

Horizontal demister separators: The feed nozzle shall be fitted with a vane type or another type of inlet
device. The diameter of the nozzle, dn1, may be taken equal to that of the feed pipe but the following two
criteria shall also be satisfied:

ρ m.V 2 < 6000 kg / m.s2 54

ρ g.V 2g −¿ < 3750 kg / m.s2 55

The length of the vane type inlet nozzle should be taken equal to approximately 5 times the feed nozzle
diameter.

5.6.4.2 Gas outlet nozzle

The diameter of the gas outlet nozzle should normally be taken equal to that of the outlet pipe, but the
product ρ g × Vg²-out shall not exceed 3750 kg/m.s².

5.6.4.3 Liquid outlet nozzle

The diameter of the liquid outlet nozzle shall be chosen such that the velocity in it does not exceed 1 m/s,
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but should preferably be lower. The nozzle shall be equipped with a vortex breaker.

5.6.4.4 Nozzles identification

The following symbols shall be used for identification of the nozzles on pressure vessels, tanks,
exchangers, pumps, compressors, etc.

Nozzle Identification Symbol

A,A1,A2 Inlets
B Outlet
C Condensate
D Drain
E*
F Feed
G Level Gauge or Gauge Glass
H Hand hole
J Pumpout
K*
L Level Instrument (Also LT, LI)
M Manhole
N Reboiler Connection
P Pressure Connection (Also PT, PI)
R Reflux
S Steam or Sample Connection
T Temperature Connection (Also TI,
TE, TW)
V Vapor Vent

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W Relief Valve Connection (Oversize

unless actual size known )
Use E or K when none of the other
(*) symbols apply. Do not use I, O, Q, U,
X, Y or Z.

5.6.5 Relief valves

All separators, regardless of size or pressure, shall be provided with pressure protective devices and set in
accordance with ASME Code requirements. The size and the number of required valves should be
specified through API-526.

5.7 Pressure drop

The differential pressure between inlet and vapor outlet is:
Pin - Pout = 8 × 10-4 × ρ g × V 2 g ,out kPa 56
If a mist eliminator is applied into a separator, an extra pressure drop of 10 mm of liquid is added too. It
should be noted that, the vane type inlet does not cause any significant pressure drop.

5.8 Conditions requiring winterization

Vessel separators shall be winterized when any of the following conditions apply to fluids contained:
a) Pour point or freezing point is above the lowest ambient temperature.
b) Undesirable phase separation, deposition of crystals or hydrate formation will occur at any ambient
temperature.
c) Ice or hydrate formation occurs due to pressure reduction of moisture-bearing gases.
d) Viscosity at any ambient temperature, is so high that an inadequate flow rate is obtained with the
pressure available for starting circulation.
e) Corrosive compounds form if condensation occurs.
 A drum or vessel containing hydrocarbon and water which operate normally at 52°C or above,
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shall be protected by insulating the nozzles, block valves and drain piping in contact with water.
 A drum or vessel containing hydrocarbon and water which operates normally below 52°C shall be
protected by steam tracing and insulating the nozzles, block valves and drain piping in contact
with water.
 All other process vessels containing fluids which may congeal during dormant periods shall be
insulated and if necessary shall be heat traced.
 Bottoms of fuel gas drums and low points in above ground gas lines shall be insulated and steam
traced.
 Separators and sumps should be provided with steam injection points or steam coils where
necessary to keep the fluid in pumpable condition.
 Drain lines from equipment should be suitably sloped and traced where necessary.

5.9 Vessel internal

5.9.1 Inlet Diverters
An inlet diverter should always be included as this will break up the bulk of the inlet stream into smaller
particles. There are many types of inlet diverters. The main types are
 Deflector Baffle
 90 Elbow
 Half open pipe
 Vane type distributor
 Slotted tee distributor
 Tangential inlet with annular ring
 Cyclone
5.9.1.1 Deflector baffle
Deflector baffles are historically one of the most common types of inlet devices in oil and gas industries

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before inlet devices with higher separation efficiency become so popular. This device simply uses a
baffle plate in front of the inlet nozzle to change the direction of the inlet stream and separate the bulk of
the liquid from the gas. However, an increasing number of contractors and operators are moving away
from traditional types of inlet devices towards more advanced designs with higher separation
efficiencies.

Figure 7: Baffle Plates

5.9.1.2 90 Elbow
This inlet device is used in the horizontal vessels to direct the inlet stream towards the vessel dish end.
Long Radius (LR) elbows are normally preferred for this purpose and there is no straight run of pipe
downstream of the elbow. However, Short Radius (SR) elbows can be used if installing LR elbow
increases the height of the vapor space. They can be also provided with a straight run of pipe with a
length equal to two times of the inlet nozzle diameter (2d1) to direct the feed to the dish end rather than
the surface of liquid inside the vessel and minimize the liquid re-entrainment.
5.9.1.3 Half open pipe
Half open pipes are the modified versions of 90° elbow devices, suitable for both vertical and horizontal
separators, with slightly improved bulk liquid removal and reasonable gas distribution. In this type, a

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piece of pipe with a length up to three times the inlet nozzle diameter is welded to the inlet 90° elbow.
In horizontal vessels, the last section of the half open pipe should be horizontal, pointing opposite to the
flow direction in the vessel and with its opening directed upward (Figure 8 A). In vertical vessels, the last
section is closed and its opening is directed downward (Figure 8 B). The same configuration is used
when the half open pipe is used for a horizontal vessel with a side nozzle (Figure 8 C).

Figure 8: Half open pipe installation configuration in horizontal and vertical vessels. A) Horizontal vessel – Top entry B)
Vertical vessel C) Horizontal vessel – Side entry.

5.9.1.4 Vane type distributor

The simplest form of the vane distributor is the dual vane inlet device (shown in Figure 9 A) which offers
a reasonable flow distribution with low shear and pressure drop. In horizontal vessels, it is suited for top
entry only. The benefits of this device compared with simpler deflectors such as deflector plates include
reduced agitation and hence improved phase operational performance, more stable level control, and
reduced foaming. For liquid slugging applications, usually where there is a long incoming flow line, this
device provides excellent mechanical strength. The dual vane works by smoothly dividing the incoming
flow into two segments using curved vanes to suit the overall geometry of the inlet nozzle. The gas phase
readily separates and disperses along the vessel, whilst the liquid phase velocity is reduced and the flow
directed to the vessel walls where it further disperses and falls into the bulk liquid layer at relatively low
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velocity.
For services where there is a high gas flow relative to the liquid flow, the multi-vane inlet device
provides excellent vapour distribution allowing a reduced height to the mass transfer or mist eliminator
internals. The vane distributors work by smoothly dividing the incoming flow into various segments
using an array of curved vanes to suit the overall geometry of the inlet nozzle and distributor length. To
achieve this effect the vanes start with a wide spacing and gradually reduce the gap, giving the unit its
characteristic tapering shape. It can be installed in both vertical and horizontal (top and side entry) three
phase separators. Figure 9 B shows the internal details of multi-vane inlet distributor.
Some vendors have tried to employ the multivane distributor benefits together with tangential entry
(which provides considerable centrifugal force) to improve the bulk separation. Figure 9 C shows a
typical type of vane developed for vertical separators only.

Figure 9: The different types of Vane inlet devices. A) Dual Vane B) Multivane C) Multivane (only vertical vessel).

5.9.1.5 Slotted tee distributor

The slotted T-shaped distributor consists of a vertical pipe extended inside the vessel to bring the
distributor to the right elevation and a slotted pipe with large holes or rectangular slots (perpendicular to
the inlet pipe) ensuring a reduced feed stream velocity and minimized flow turbulence. It can be used in
both vertical and horizontal (top entry only) separators.
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The openings of the slots are usually 120 º (±60º) and towards the dish end and liquid interface in
horizontal and vertical vessels, respectively.

Figure 10: Tee distributor

5.9.1.6 Tangential inlet with annular ring
Tangential inlet devices have been exclusively developed for vertical vessels. The feed flow radially
enters the vessel and accelerates passing through the inlet device, the cyclonic action of the inlet device
helps the liquid droplets flow on the inner wall of the vessel and the stripped gas to flow through the
central section of the inlet device (annular ring) to the gas outlet nozzle.
There are two options with regards to the inlet nozzle arrangements shown in Figure 11. The type
depicted in Figure 11A generates higher centrifugal force and slightly better separation efficiency.
However, it is not recommended for pressures higher than 5.0 bar due to its construction difficulties at
high pressures. Furthermore, both types can have a circular or rectangular inlet nozzle. A larger cross
sectional area can be provided when a rectangular (with height larger than the width) nozzle is used.

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Figure 11: Tangential inlet entry arrangements. A) Round Entry B) Straight Entry.

5.9.1.7 Cyclone
The cyclonic inlet device is used in horizontal and some vertical separators where there is a requirement
for high momentum dissipation, foam reduction and high capacity. They work on the principle of
enhanced gravity separation by accelerating any incoming stream to a high g-force, which particularly
helps foam to break down into separate liquid and gas phases. Unlike most inlet devices that are
positioned in the gas phase, the inlet cyclone is partly submerged in the liquid phase. The liquid phases
are also separated centrifugally through the perimeter of the cyclone tubes and fall down in to the bulk
liquid layers, whilst the gas forms a central vortex core and escapes through a top outlet hole into the gas
space. The mixing elements on top of the cyclone outlet section usually provide a proper distribution of
the cleaned gas to downstream devices.
The device has a high pressure drop associated with it. The designs of the inlet cyclones have evolved
over the past decades from short single (conventional cyclones) or dual cyclones into multi-cyclone
arrangements (Figure 12). A main characteristic of the cyclone inlet device is its high flow capacity,
meaning that more throughput is possible through any given size separator.

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Figure 12: Multi cyclone inlet device.

5.9.2 Wave Breakers

In large volume 3 phase separators it is sometimes necessary to install an anti-wave baffle(s) to eliminate
disturbances of oil/water interface. This is a partial cross sectional area plate with punched holes which
act as a wave breaker while still letting liquid pass through.
5.9.3 Defoaming Plates
Foam at the interface may occur when gas bubbles are liberated from the liquid. This foam can be
stabilized with the addition of chemicals at the inlet. Many times a more effective solution is to force the
foam to pass through a series of inclined parallel plates or tubes to aid in coalescence of the foam

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bubbles.
5.9.4 Vortex Breaker
A vortex could suck some gas out of the vapor space and re-entrain it in the liquid outlet. Vortex breakers
should always be installed on liquid outlet nozzle (2 phase), or water and oil nozzle in the case of 3 phase
separators.

Figure 13: Typical vortex breakers

5.9.5 Mist Extractor

Mist extractors can be made of wire mesh, vanes, centrifugal force devices, or packing. Wire mesh pads,
Figure 14, are made of finely woven mats of stainless steel wire wrapped into a tightly packed cylinder.
The liquid droplets impinge on the matted wires and coalesce. The effectiveness of wire mesh depends
largely on the gas being in the proper velocity range. If the velocities are too high, the liquids knocked
out will be re-entrained. If the velocities are low, the vapor just drifts through the mesh element without
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the droplets impinging and coalescing.

The construction is often specified by calling for a certain thickness and mesh density. Experience has
indicated that a properly sized wire mesh eliminator can remove 99% of 10-micron and larger droplets.
Although wire mesh eliminators are inexpensive they are more easily plugged than the other types. Vane
eliminators Figure 15 force the gas flow to be laminar between parallel plates that contain directional
changes. Figure 16 shows a vane mist extractor made from angle iron. In vane eliminators, droplets
impinge on the plate surface where they coalesce and fall to a liquid collecting spot.
They are routed to the liquid collection section of the vessel. Vane-type eliminators are sized by their
manufacturers to assure both laminar flow and a certain minimum pressure drop.

Some separators have centrifugal mist eliminators Figure 17 that cause the liquid drops to be separated
by centrifugal force.
These can be more efficient than either wire mesh or vanes and are the least susceptible to plugging.
However, they are not in common use in production operations because their removal efficiencies are
sensitive to small changes in flow. In addition, they require relatively large pressure drops to create the
centrifugal force. To a lesser extent, random packing is sometimes used for mist extraction, as shown in
Figure 18. The packing acts as a coalescer.

Figure 14: Wire mesh mist extractor

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Figure 15: Vane mist extractor

Figure 16: Angle iron van mist extractor.

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Figure 17: Centrifugal mist extractor.

Figure 18: Coalescing pack mist extractor.

5.9.6 Coalescing Plates

The installation of coalescing plates in the liquid section will cause the size of the water droplets
entrained in the oil phase to increase, making gravity settling of these drops to the oil-water interface
easier.
Thus, the use of coalescing plates or the use of free-flow turbulent coalesce will often lead to the ability
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to handle a given flow rate in a smaller vessel. However, because of the potential for plugging with sand,
paraffin, or corrosion products, the use of coalescing plates should be discouraged, except for instances
where the savings in vessel size and weight are large enough to justify the potential increase in operating
costs and decrease in availability.
5.9.7 Sand Jets and Drains
In horizontal three-phase separators, one worry is the accumulation of sand and solids at the bottom of
the vessel. If allowed to build up, these solids upset the separator operations by taking up vessel volume.
Generally, the solids settle to the bottom and become well packed.
To remove the solids, sand drains are opened in a controlled manner, and then high pressure fluid,
usually produced water, is pumped through the jets to agitate the solids and flush them down the drains.
The sand jets are normally designed with a 20 ft/s jet tip velocity and aimed in such a manner to give
good coverage of the vessel bottom.

To prevent the settled sand from clogging the sand drains, sand pans or sand troughs are used to cover
the outlets. These are inverted troughs with slotted side openings.
5.9.8 Three-Phase vessel weir plates
The weir plate is a device which separates oil and water into two compartments. Weir plates can be either
fixed or adjustable. Fixed weir plates should be used in cases where the water content is constant.
Adjustable weir plates are required when the water content is expected to increase.
Generally, the weir plate should always be 150 mm (minimum) above the oil/water interface. It can vary
in height from the bottom inside shell wall to the top of the plate from 300 mm to the mid point of the
vessel.

6 Attachment
 To perceive the calculation procedure described here beside the other related approaches, see the
developed spreadsheet attached along with this manuscript.
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