Separator Sizing Calculator

Flow Rates & Conditions

Gas Flow Rate

Gas flow at standard conditions (60°F, 14.7 psia)

Oil Flow Rate

Oil/condensate flow rate

Water Flow Rate

same

Produced water (same units as oil)

Operating Pressure

psig

Operating Temperature

°F

Fluid Properties

Gas Density

lb/ft³

At operating conditions

Gas Viscosity

At operating temperature

Oil Density

lb/ft³

At operating conditions

Oil Viscosity

At operating temperature

Water Density

lb/ft³

Typically 62.4 lb/ft³

Droplet Size

μm

100-200 microns typical

Design Parameters

Separator Type

Internals Type Affects K-factor for gas capacity

L/D Ratio (Horizontal)

3-5 typical for horizontal

Liquid Retention Time

min

API 12J: 1-3 min for oil

Surge Factor

1.15-1.25 for flow variations

Demister Thickness

4-6" for mesh pads

Include internals design

Include nozzle sizing

Design Formulas (API 12J)

Souders-Brown Equation:

V_t = K × √[(ρ_L - ρ_G) / ρ_G]

Stokes Law (Droplet Settling):

V_d = 1.78×10⁻⁶ × d_p² × Δρ / μ

Horizontal Liquid Volume:

V = 0.3927 × D² × L (at 50% level)

Shell Thickness (ASME VIII):

t = PR / (SE - 0.6P) + CA

K-factor: Mesh Pad (0.12-0.18), Vane Pack (0.27-0.35)
All calculations per API 12J, API RP 14E, ASME Section VIII

Sizing Results

Vessel Size

Diameter: -

Length/Height: -

Shell Thickness: -

Liquid Volume: -

Gas Velocity: -

Terminal Velocity: -

Separation Efficiency: -

Estimated Weight: -

Flow Rates & Conditions

Fluid Properties

Design Parameters

Design Formulas (API 12J)

Sizing Results

Internals Design

Nozzle Sizing

Recommendations

Separator Sizing Calculator

Flow Rates & Conditions

Fluid Properties

Design Parameters

Design Formulas (API 12J)

Sizing Results

Internals Design

Nozzle Sizing

Recommendations

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