proper sizing balances economical aller vessel diameters against larger Liquid re-entrainmentis the process of previously sep- ed liquid droplets breaking away from the gas/liquid interface and becoming suspended in the gas. The re- trainment process generally occurs in two steps. First, tigh gas velocity produces disturbances in the gas/iquid Fnterface, such as waves and ripples. Secondly, the gas hears some of the liquid from its surface through momen- rransfer from the high-velocity gas to the low-velocity Piquid. This process reverses the desired result of settling Squid droplets cut of the gas. This article supplements two earlier articles on horizontal separator design. The quations presented here are based on correlations pro- by Ishii and Grolmes."* [THEORY J For purposes of determining if re-entrainment will ‘two dimensionless numbers are used to charactar- ‘the state of the gas-liquid interface. These are the eynolds film number, Rey, and the viscos! defined as: PVD: , Pe o a and N= @ Where Re, = Reynolds film number, dimensionless 1N, = viscosity number, dimensionless iy = density of liquid, 1bq/t® average liquid velocity, Us hydraulic diameter, ft iy = dynamic liquid viscosity Iby/ft-s Ap = density difference between liquid and ges; Iby/t? surface tension betweon gas and liquid, Ib, /s* = acceleration of gravity, 32.2 fUs* Fora horizontal separator half filled with liquids, the tydraulic diameter is equal to the vescels inside diameter. tn general, Djyis equal to four times the area for liquid flow divided by the contact perimeter between the liquids and the vessel wall. PRODUCTION REPORT ape 0 MMecta noma capacity 185 oravtv ass 4,000 gor Lt a Maximum sordemaes aio, Ud 2 30 #0 30 % potty ius 4, Maximum slondemess rato versus AP! gravity anc pressure; Fe an oe el worpreseronaoral sopra Given the cross-sectional area for liquid flowin a eylin- drical separator, A; in 2, the average liquid velocity in isis given by: BPD : 11,750 x A, ie Fora separator half-filled with oil, the area for liquid flow in fis given by: A,~ 0.002727 @) where dis the inside diameter of the separator in inches. For three-phase separators, ui is the oil viscosity, Vi is pased on the area for oil flow, and Djyis calculated from the total area for both oil and water flow. ‘A useful correlation for surface tension of oil and gas in dynes/em, as a function of temperature, pressure, and API gravity®, is: 9 =[42.4 - 0.047 (7 — 460) - 0.267°APTe- 907? (5) Mi where: tomperatare, °R pressure, psia ‘To convert to Ib,,/s?, multiply dynes/em by 0.0022. The state of the gas-liquid interface may be categorized into one of three regimes, depending on the value of Rey. Flow is considered to be in the low Reynolds number regime if Re, is less than 160. Flow is rough turbulent if Rey exceeds 1,65, Flow is in the transition regime if Rey 2160 Gnd 21,635. Criteria for maximum gas velocity for vari- ous Reynolds film numbers and viscosity numbers, before e-entrainment occurs, are given in Table 1 With the maximum ges velocity set, the maximum gas WoRLDOIL/ NOVEMBER 1902 88Table 1. Maximum gae velocity, halt-filled horizontal separators Equation Rey a 100 160 Rr, 1.85 1605 Ao, <1,895 >0.0007 capacity of the separator can be determined. For a sepa trator half-illed with liquids, the cross-sectional area for gas flow is half the total area, and gas capacity is given by: Ards TZ @, = 0.00838. 6) gas flow rate, MMscfgd maximum gas velocity, fUs essel’s inside diameter, P = operating pressure, psia 7 = operating temperature, "R Z = ges compressibility factor ‘Afier sizing the separator using normal design proce- dures, Equation 6 may be used to verify that liquid re- ‘entrainment will not be a problem atthe design flow rate. “Alternately, the engineer may solve the re-entrainment equations for the minimum diameter allowed, based on the required ges flow rate. Rearranging Equation 6 to solve ford gives: d= 10.955 Site o eda? “Actual dotormination of the minimum diameter involves ‘an iterative procedure. First, a reasonable guess for the diametor is made, and the liquid velocity, V;, is calculated from Equation 3. Next, Reris calculated from Equation 1, and Nj» is found from Equation 2. ¥,, does not change between iterations. (Vplnux is then calculated from Equa- tion 3. Finally, d is determined from Equation 7 and com- pared to that assumed, This procedure.is repeated with Subsequent values for d until the assumed and calculated values agree. Figure 1 illustrates the maximum allowable slender ness ratio for horizontal separators, sized on remeval of {140-micron liquid droplets from the gas by the design pro- cedures from the previous articles. It ean be seen that a limitation of 3 to 4 on maximum slenderness ratio for 30°API and above is reasonable. For lower gravity crude ils, unless lower slenderness ratios are used, re-entrain- 40. WORLD OIL NOVEMBER 1992 ‘ment may make it appear that the crude oil is “f0 ‘This would be recognized in the field as both liq ryover with the gas and gas bubbles entrained in the uid at the outlets. Figure 1 is only valid for those separators whose! determined by gas capacity. In most low-oil gravity rators, the size is determined by the need to provid ficient retention time for the liquid. Thus, the actual velocity in separators with slendemness ratios on the or of 3 to-4 may be below (V,)mar, and re-entrainment igi, noticed. an RE-ENTRAINMENT PREDICTION General guidelines for predicting re-entrai include: ‘° Re-entrainment is generally a problem for aga capscity-dominated horizontal separator designe slenderness ratios greater than 8 or 4, although i coeur at lower slenderness ratios where oil gravity i ‘than 30° AP ‘The operating temperature and API gravity of theo al have the greatest effect on liquid re-entrainment. Thigig duc to their substantial effect on oil viscosity, wh ‘major variable in Rey and N,. Re-entrainment b ‘more likely with higher viscosity ’e For a given gas production rate, prossure affe ‘entrainment through its effect on surface tension bet ‘the liquid and gas phases. This is partially offset by gas density at higher pressures resulting in lower Velocity, High pressure requires less slender designs. = Example probiem. Given: + Operating conditions are 80°F, 1,200 psia #20 MMsefad of .65 specific gravity gas, Z = 0.7 + 1,000 bopd of 85°APT oil ©) =4.2 ep X 0.000672 = 0.0025 Iba ft-s * Separator to operate half-filled with oil # Cp (140-micron droplets) = 0.84 + L-min, liquid retention time Procedi 1. Design the separator using the normal described in the previous articles" u 2. Determine the entrainment-limited gas capacity al ‘check the design. ‘Then, calculate liquid density: us onan 225 pase (aes ‘APL ‘Also calculate gas density: PS 1,200.65 (0:782 x (460 + 80) From the design equations (reference 1), calculate: ‘Leg = 73:97 in. Xf gas capacity @Lg~ 1428in? x ft Tiquid eapacity Summary of designs GasLey Liquidley = Le 4.55 5.41 65 344 3.09 45 a7. 192 36 d,in. 16.25 21.50 27.25= [42.4 ~ 0.047180) ~ 0.267 (35)}2- 007.200 % 0.0022 = 0.0278 Iby/e? Hiso calculate viscosity number (does not depend on diam- ‘avity sep : vrovide | sactul gaa N= —— gone mn thea fet) mee 78 8 4 53.00.0278 eet = 0.0354 trainmegy Assuming d = 16.25 in, other values are at follows: et afor aged * A, = 0.002727 (16,25)? =0.72 igned wit 1,000 = |g rouse (ssoxoust 135 0.0028 rom Table 1, equation D: affects re m between thy higher) lower gas: esigns. -[cess (2.23 x (16.25)? 1200 B40 x 0.782 J 0.02542 = 2.99 74 0.782 @, = 0.00883; = 13.9 MMSCFD Re-entrainment is possible above a 13.9 MMscfgd flowrate. oroceduré |The design above is inadequate (Consider the next ease: d = 21.5 in 1,748 (Vphgx = 2.23 fs (Table 1, Equation D) Q, = 24.4 MMsefga Inthis caso, re-entrainment will not bea problem at @ 20- MMscfid Mowrate. This design is adequate. Inancther ease: d = 27.25in. Rey = 1,884 (Ve)mux = 2.36 f/s (Table 1, Equation B) 0, = 41.5 MMsefgd This design also is acceptable. pacity and ate 12 Lagld | SR aes cmap it erat oo 4.00. falta endain oop ero ota 261 rit Win (Gesu da 1869128, SOMETING BETTER FOR PRODUCTION THAN...ESP” Aigikad pogesive at (P {toe agen pee etry nelson dt, doy hols te hole faa Te pars ama UD seria de ttn grr vel ee die Seambniie Betlal eitas pp da ohm of id iri ‘otolmciy oct urtle Pap (5) or acon bg, orig rarteocec plea rpg ‘erate = rok of to 3,000 BPD. oCortmuos pocixtonunder men oparing andion. clang, wc Sala Vide cel ein pesueip 60 prorated ct Highland's PC pump ~ better for production than ESP.