3-Phase H-Calc

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calculated results and any equipment sold and manufactured based on those results.

This program is licensed to:

Sandstone Engineering

This program uses GPSA Engineering Data Book, 12th Edition, Design and Engineering Practices, and guidance

from publications by Manning, Thompson, and Svrcek to calculate 3-phase horizontal separator sizing.

User can input values into the Light Blue shaded cells. Program indicates acceptable checks with Green text or

shaded cells, and deficiencies with Red text.

This program was designed by Ryan K. Malone, P.E. for Sandstone Engineering and is licensed to customers for

a fee through a licensing agreement.

Version 1.0.1 - 101214 Developed by Sandstone Engineering, Ryan K. Malone, P.E.

3-Phase H-Calc

Project:

Client:

Job Number: Tag No:

General Notes:

Project Notes:

Rev.

1

2

3

4

5

Maximum Design Temp/Press °F psig °F psig

Operating Temp/Press °F psig °F psig

Atmospheric Temp/Press °F psig °F psig

Bulk Fluid Description

Fluid Flowrate

Oil API Gravity API API

Fluid Specific Gravity SG 1.076 SG SG SG 1.076 SG SG

Fluid Viscosity, μ

Gas MW

Compressibility/Density Correction, Z

Standard Fluid Flowrate #DIV/0! ft3/s #DIV/0! ft3/min - ft3/min #DIV/0! ft3/s #DIV/0! ft3/min - ft3/min

Actual Mass Flowrate #DIV/0! lb/s #DIV/0! lb/hr - lb/hr #DIV/0! lb/s #DIV/0! lb/hr - lb/hr

Fluid Density #DIV/0! lb/ft3- lb/ft3

- lb/ft3#DIV/0! lb/ft3

- lb/ft3- lb/ft3

Inlet Gas/Liquid Density at Operating Press and Temp, rm lb/ft3 lb/ft3

Inlet Liquid Density at Operating Press and Temp, rL #DIV/0! lb/ft3###### lb/ft3

Required Slug Capacity: BBL Required Slug Capacity: BBL

Direct Fired Allowable Liquid Level: % Allowable Liquid Level: %

Burner Tube: 3-Phase Liquid Retention Time: min 3-Phase Liquid Retention Time: min

Leff/D: Leff/D:

Burner Tube Nominal Diameter: NPS Burner Tube Nominal Diameter: NPS

Burner Tube Outside Diameter: #N/A in Burner Tube Outside Diameter: #N/A in

Burner Tube Total Length: ft Burner Tube Total Length: ft

Burner Tube Volume: #N/A ft3Burner Tube Volume: #N/A ft3

Mist Extractor: K Factor Pressure Adjustment: 100 100 K Factor Pressure Adjustment: 100 100

Flow Direction: Souders-Brown K Factor: Souders-Brown K Factor:

Pressure Adjusted K Factor: 0.30 ft/s Pressure Adjusted K Factor: 0.30 ft/s

Volume in Separator vL = #DIV/0! ft3vL = #DIV/0! ft3

Calculated Reqrd Vessel Inside Diameter D = #DIV/0! in D = #DIV/0! in

Approximate Reqrd Outside Diameter DO = #DIV/0! in DO = #DIV/0! in

Calculated Vessel Effective Length Leff = #DIV/0! ft Leff = #DIV/0! ft

Select Outside Diameter DO = in DO = in

Approximate Resulting Inside Diameter D = -0.25 in D = -0.25 in

Approximate Resulting Inside Diameter D = -0.02 ft D = -0.02 ft

Select Effective Length Leff = ft Leff = ft

Calculated Total Available Inside Area Atot = #N/A ft2Atot = AV = #N/A ft2

Verify Leff/D is between 3 and 5 Leff/D = 0.00 Leff/D = 0.00

Gas Capacity - Souders-Brown K Factor (Pressure Adjusted Lilly) KSB = #DIV/0! ft/s KSB = #DIV/0! ft/s

Gas Capacity - Souders-Brown K Factor KSB = #DIV/0! ft/s KSB = #DIV/0! ft/s

Maximum Gas Velocity Vmax = #DIV/0! ft/s Vmax = #DIV/0! ft/s

Min Reqrd Vessel Inside Area for Gas AG = #DIV/0! ft2AG = #DIV/0! ft2

Cross Sectional Area for Liquid Flow AL = #DIV/0! ft2AL = #DIV/0! ft2

Total Min Required Vessel Inside Area Amin = AG + AL #DIV/0! ft2Amin = AG + AL #DIV/0! ft2

Atot > Amin #N/A Atot > Amin #N/A

Dmin = #DIV/0! ft2Dmin = #DIV/0! ft2

Diameter Check D > Dmin #DIV/0! D > Dmin #DIV/0!

Liquid Phase Velocity Vliq = #DIV/0! ft/s Vliq = #DIV/0! ft/s

DEP Recommendation Check #DIV/0! #DIV/0!

Liquid Filled Fraction of Vessel M = #DIV/0! M = #DIV/0!

Liquid Level Depth to Diameter Ratio hD = #DIV/0! hD = #DIV/0!

Height to Top of Oil HL = #DIV/0! ft HL = #DIV/0! ft

Recommend 1.5ft minimum D-HL = #DIV/0! #DIV/0! D-HL = #DIV/0! #DIV/0!

Recommend 0.8 maximum HL/D = #DIV/0! #DIV/0! HL/D = #DIV/0! #DIV/0!

Water Volume Vw = - ft3Vw = - ft3

Water Area Aw = #DIV/0! ft2Aw = #DIV/0! ft2

Aw/Atot = #DIV/0! Aw/Atot = #DIV/0!

Ho/w/D = #DIV/0! Ho/w/D = #DIV/0!

Height to Top of Water Ho/w = #DIV/0! ft Ho/w = #DIV/0! ft

Actual Cross Sectional Area for Gas Flow AV = Atot - AL = #N/A ft2AV = Atot - AL = #N/A ft2

#N/A #N/A

Description

Vliq < 0.049 ft/s

Date

0.30 0.30

By

Case 1 - (Enter Case Description)

Oil Oil WaterGas

Assumptions:

3-Phase Horizontal Separator

Water

Input Data:

Case 2 - (Enter Case Description)

Checked Approved

Gas

#DIV/0! #DIV/0!

Liquid Phase Capacity - Retention Time:

Gas Capacity:

Vessel Specification:

Water Gas OilGas Oil Water

MSCFD/BPD

cP

Case 1 - (Enter Case Description) Case 2 - (Enter Case Description)

Fluid Calculations:

YOUR LOGO HERE

Version 1.0.1

Developed by Sandstone Engineering, Ryan K. Malone, P.E.

3-Phase H-Calc

Superficial Gas Velocity Vg =qg/AV = #DIV/0! ft/s Vg =qg/AV = #DIV/0! ft/s

#DIV/0! #DIV/0!

Gas Retention Time trg = #DIV/0! s trg = #DIV/0! s

Velocity of Oil Drop Falling in Gas Phase Vod = #DIV/0! ft/s Vod = #DIV/0! ft/s

Assume a drag coefficient CD1 = 1000.00 CD1 = 1000.00

Diameter of smallest oil drop that will fall dod = #DIV/0! μm dod = #DIV/0! μm

#DIV/0! in #DIV/0! in

Re = #DIV/0! Re = #DIV/0!

Iterate CD1 until CD1 = CD2 (+/- 0.02) CD2 = #DIV/0! CD2 = #DIV/0!

Velocity of Water Drop Vwd = #DIV/0! ft/s Vwd = #DIV/0! ft/s

Assume a drag coefficient CD1 = 1000.00 CD1 =

Diameter of smallest water drop that dwd = #DIV/0! μm dwd = #DIV/0! μm

will settle #DIV/0! in #DIV/0! in

Re = #DIV/0! Re = #DIV/0!

Iterate CD1 until CD1 = CD2 (+/- 0.02) CD2 = #DIV/0! CD2 = #DIV/0!

Velocity of Oil Drop Rising in Water Phase Vod = #DIV/0! ft/s Vod = #DIV/0! ft/s

Assume a drag coefficient CD1 = 1000.00 CD1 = 1000.00

Diameter of smallest oil drop that will rise dod = #DIV/0! μm dod = #DIV/0! μm

#DIV/0! in #DIV/0! in

Re = #DIV/0! Re = #DIV/0!

Iterate CD1 until CD1 = CD2 (+/- 0.02) CD2 = #DIV/0! CD2 = #DIV/0!

Height of Oil Weir How = #DIV/0! ft How = #DIV/0! ft

Height of Water Weir Hww = #DIV/0! ft Hww = #DIV/0! ft

Length, Option 1: L1 = 0.0 ft L1 = 0.0 ft

Length, Option 2: L2 = 0.0 ft L2 = 0.0 ft

Select next largest standard size: L = ft L = ft

Inlet Nozzle Allowable Erosional Velocity Ve = #DIV/0! ft/s Ve = #DIV/0! ft/s

A1 = #DIV/0! in2/1000bbl/day A1 = #DIV/0! in2/1000bbl/day

Minimum Allowable Inlet Nozzle Cross Sectional Area A = #DIV/0! in2A = #DIV/0! in2

Minimum Inlet Inside Diameter di = #DIV/0! in di = #DIV/0! in

Slug Flow Inlet Nozzle Allowable Erosional Velocity Ves = #DIV/0! ft/s Ves = #DIV/0! ft/s

Slug Flow Min Allow Inlet Nozzle Cross Sectional Area As = #DIV/0! in2As = #DIV/0! in2

Slug Flow Minimum Inlet Inside Diameter dis = #DIV/0! in dis = #DIV/0! in

Recommended Inlet Nozzle Inside Diameter di = #DIV/0! in di = #DIV/0! in

Recommended Inlet Nozzle Min Nom Size diNPS = #DIV/0! NPS diNPS = #DIV/0! NPS

Resulting Inlet Nozzle Mixture Velocity vm,in = #DIV/0! ft/s vm,in = #DIV/0! ft/s

Resulting Inlet Nozzle Feed Momentum ρmv2m,in = #DIV/0! lb/ft-s2

ρmv2m,in = #DIV/0! lb/ft-s2

Select Inlet Device, Allowable Momentum ρmv2m,in = Select Inlet Devicelb/ft-s2

ρmv2m,in = Select Inlet Devicelb/ft-s2

Select Feed Inlet Nozzle Nom Diameter diNPS = NPS diNPS = NPS

Resulting Inlet Nozzle Mixture Velocity vm,in = #DIV/0! ft/s vm,in = #DIV/0! ft/s

Resulting Inlet Nozzle Feed Momentum ρmv2m,in = #DIV/0! lb/ft-s2

ρmv2m,in = #DIV/0! lb/ft-s2

Momentum Criteria Check

Superficial Gas Velocity in Feed Nozzle vG,in = #DIV/0! ft/s vG,in = #DIV/0! ft/s

Superficial Liquid Velocity in Feed Nozzle vL,in = #DIV/0! ft/s vL,in = #DIV/0! ft/s

Gas Froude Number (see 'Flow Map' tab) FrG = #DIV/0! FrG = #DIV/0!

Liquid Froude Number ('Flow Map' tab) FrL = #DIV/0! FrL = #DIV/0!

Minimum Gas Outlet Nozzle ID dgo = #DIV/0! in dgo = #DIV/0! in

Resulting Gas Outlet Nozzle Nominal dgoNPS = #DIV/0! NPS dgoNPS = #DIV/0! NPS

Select Gas Oulet Nozzle Nom Diameter doNPS = NPS doNPS = NPS

Resulting Gas Outlet Nozzle Velocity #DIV/0! #DIV/0!

Resulting Gas Outlet Nozzle Momentum #DIV/0! #DIV/0!

Recommended Allowable Momentum 3025 3025

Gas Outlet Momentum Criteria Check

Minimum Water Outlet Nozzle ID dwo = 0.00 in dwo = 0.00 in

Minimum Water Outlet Nominal Pipe Size dwoNPS = #N/A NPS dwoNPS = #N/A NPS

Minimum Oil Outlet Nozzle ID doo = 0.00 in doo = 0.00 in

Minimum Oil Outlet Nominal Pipe Size dooNPS = #N/A NPS dooNPS = #N/A NPS

Mist Extractor Velocity Vmistex = #DIV/0! ft/s Vmistex = #DIV/0! ft/s

Minimum Mist Extractor OD Mod = #DIV/0! in Mod = #DIV/0! in

Outside Diameter (in) -6 6 12 -6 6 12

Seam to Seam Length (ft) -2 2 4 -2 2 4

Approximate Wall Thickness (in) 0.063 0.063 0.063 0.063 0.063 0.063

Approximate Shell Weight (1,000lb) 0.01 0.01 0.03 0.01 0.01 0.03

Approximate Head Weight (1,000lb) 0.000 0.001 0.003 0.000 0.001 0.003

Approximate Vessel Weight (1,000 lb) 0.11 0.11 0.14 0.11 0.11 0.14

Relative Cost/1000 0.00 0.00 0.02 0.00 0.00 0.02

#DIV/0! #DIV/0!

#DIV/0! #DIV/0!

0

0

0.063

0.00

0.000

0.10

0.00

Calculated

Design Optimization:

0

0

0.063

0.00

0.000

0.10

0.00

Possible Alternatives Calculated Possible Alternatives

Nozzle Dimensions:

Gas Capacity - Oil Drop in Gas Phase

Liquid Capacity - Water Drop in Oil Phase

Liquid Phase Capacity: Oil Drop in Water Phase

Weir and Bucket Heights:

Separator Dimensions:

Version 1.0.1

Developed by Sandstone Engineering, Ryan K. Malone, P.E.

ASME VIII, Div. 1 Design OptimizationProject:

Client:

Job Number: By:

Date: Checked By:

Revision: Revision Date:

General Notes:

Project Notes:

MAWP, P (psi) 500 f (x) 0.55 Input Vessel MAWP Shows Objective Function Results

O.D. (in.) 24 Input Vessel Outside Diameter

C.A. (in.) 0.0625 Input Vessel Corrosion Allowance

Design Variables and Constraint Functions

Thickness, t (in.) 0.360 Optimized Vessel Wall Thickness

Yield Strength, S (ksi) 20.00 Optimized Yield Strength

Joint Efficiency, E 1.00 Optimized Joint Efficiency

Thickness Weight, tw 0.70 g 1(x) -10 Input Manufacturers Relative Cost for Material Weight

Material Grade Weight, Sw 0.15 g 2(x) 0.00E+00 Input Manufacturers Relative Cost for Material Grade

Joint Efficiency Weight, Ew 0.15 g 3(x) -0.3 Input Manufacturers Relative Cost for NDT/NDE

g 4(x) 0

Total Weight 1.00 g 5(x) -0.172 Weight Inputs Must Total to 1.00

2. Select the Solver command from the Analysis box under the Data tab.

3. Make sure the objective function is set to cell E11 (Green Cell), if it is not, click on the green cell (E11)

4. Make sure the "Min" box is selected, if not select "Min"

5. Make sure the "Make Unconstrained Variables Non-Negative" check box is selected

6. Make sure the GRG Nonlinear Solving Method is selected

7. Click "Solve"

8. Make sure "Keep Solver Solution" check box is selected, and click OK

9. The resulting output provides the most efficient thickness, material, and NDE combination based on the input weights assigned by the manufacturer

Weight Function Constraints

Yellow = Spreadsheet Input Cells Blue = Spreadsheet Calculation Cells

1. Load the Excel 2013 Solver Add-in: Click File tab, then click Options. Click Add-Ins, and then in the Manage box, select Excel Add-Ins. Click Go. In the Add-Ins available

box, select the Solver Add-In check box and click OK. If Solver Add-Ins is not listed in the Add-Ins available box, click Browse to locate the add-in. If you get prompted that

the Solver add-in is not currently installed on your computer, click Yes to install it. After you load the Solver add-in, the Solver command is available in the Analysis group

on the Data tab.

Design Variables Equations

These calculations run a GRG nonlinear solver to minimize an objective function with given constraints to determine the most efficient vessel design

Design Parameters Objective Function

𝑓 𝑥 = 𝑡 ∗ 𝑡𝑤 +𝑆

20∗ 𝑆𝑤 + 𝐸 ∗ 𝐸𝑤

𝑡 =𝑃 ∗ 𝑅0

𝑆 ∗ 𝐸 + 0.40 ∗ 𝑃10.0 ≤ 𝑆 ≤ 20.0

0.70 ≤ 𝐸 ≤ 1.0

𝑡 ≥ 0.188

Version 1.0 - 090114 Developed by Sandstone Engineering, Ryan K. Malone, P.E.

Project:

Client:

Job Number: Tag No:

General Notes:

Project Notes:

Rev.

FrL = #DIV/0!

FrL = #DIV/0!

Case 1: FrG = #DIV/0!

Case 2: FrG = #DIV/0!

Note:

Description By Checked Approved Date

3-Phase Horizontal Separator

Two-Phase Flow Map for Horizontal Feed Pipes Two-Phase Flow Map for Vertical Feed Pipes

Case 1:

Case 2:

The flow maps are only applicable to very long pipes with equilibrium two-phase flow. However, if the feed pipe is longer than ten pipe diameters, the flow maps still

give a fair indication of the prevailing flow regime for a given set of conditions.

Hydrocarbon/Water Separators

Above 35º API hydrocarbon

Below 35º API hydrocarbon

100ºF and above

80ºF

60ºF

15-20 min at 80ºF

10-15 min at 90ºF

5-10 min at 100+ºF

Typical Liquid Retention Times

Table 7-4

Electrostatic Treater

Free-Water Knockouts

8 - 24 hr

0.5 - 4 hr

0.5 - 4 hr

15 - 120 min

25-30 min at 60ºF

20-25 min at 70ºF

Typical Liquid Phase

Retention TimeType of Treater

Gun Barrels or Wash Tanks

Vertical Heater-Treater

Horizontal Heater-Treater

5 - 10

10 - 20

20 - 30

Type of Separation

FIG. 7-22

Typical Retention Times for Liquid-Liquid Separation

Retention Time,

minutes

3 - 5