SECTION 8

DRUM DESIGN

8.1
 DRUMS

Basic Concepts

Configurations

Services

Design Considerations

Sizing and Rating

8.2
 PRINCIPLES OF GRAVITY SEPARATION

Physical separation of:

Vapours from liquids
Immiscible liquids into light and heavy phases

Utilise density difference between phases

Minimize velocity and momentum to improve

separation efficiency

Force balance

8.3
FORCES ACTING ON LIQUID DROPLETS IN A GAS STREAM

8.4
 SEPARATOR TYPES

General types of separators:

Vapour - Liquid
Liquid - Liquid
Liquid - Liquid - Vapour

Accomplish one or more of the following:

De-entrain liquid or prevent liquid entrainment
Settle water/hydrocarbons
Provide surge capacity

8.5
SEPARATOR CONFIGURATIONS/SECTIONS

Configurations or Orientations
Horizontal
Vertical

Sections
Primary Separation (A)
Secondary or Gravity Settling (B)
Coalescing (De-entrainment) (C)
Liquid Collection (D)

8.6
 VAPOUR-LIQUID SEPARATORS

A = Primary Separation
B = Gravity Settling
C = Coalescing
D = Liquid Collecting

8.7
 SEPARATOR SERVICES

Liquid Surge and Distillate

Compressor Suction and Interstage
Fuel Gas Separators (K.O.)
Steam Drums
High Pressure Separators
Crude Preheat Flash Drums
Water Disengaging Drums
Blowdown Drums

8.8
BASIC DESIGN CONSIDERATIONS FOR
VAPOUR-LIQUID SEPARATORS

Drum configuration or orientation

Liquid separation efficiency
Critical vapour velocity
Inlet piping flow regime
Inlet nozzle/distributor arrangement
Liquid re-entrainment
Liquid holdup guidelines
CWMS and anti-vortex baffle design

8.9
 DRUM ORIENTATION

Horizontal
More efficient than vertical drums (cross-flow vs. countercurrent
flow) especially for one inlet nozzle design
Almost always used when relatively large quantities of liquid and
vapour must be separated
More flexible in choice of nozzle arrangement (e. g., split flow)
Chosen for liquid - liquid systems and when flow in inlet piping
is slug or bubble flow
Smaller in volume for high liquid loading service

Vertical
Commonly used for very low liquid loading (fuel gas K.O.)
Main advantage is smaller plot area

8.10
 LIQUID SEPARATION EFFICIENCY

Liquid separation of drums varies from 95 to 99.5%

Crinkled wire mesh screen increases this to 99.9%

CWMS is porous blanket of wire mesh

Vapour moves freely but liquid drops cannot follow due to their
greater inertia

CWMS and drum should be sized to avoid flooding

If fouling an issue, may need to switch to other devices such as

Vane-Type Mist Eliminator

8.11
 CRITICAL/ALLOWABLE VAPOUR VELOCITY
Ensures vapour velocity is sufficiently low to prevent
excessive liquid carryover. Not related to sonic velocity.
0.5

VC = 0.048 r L - r G (r = Density, kg/m)

rG
Allowable vapour velocity, % of VC (with CWMS)
Surge drums, distillate drums -- 100-125%
Compressor suction & interstage -- 100-225%
Fuel gas K.O. and Steam drums -- 100%
High pressure separators -- 100-125%
Crude preheat flash drums -- 40%

Minimum vapour space: 300 mm or 20% of drum diameter

8.12
 INLET PIPING FLOW REGIMES

Drum inlets normally designed for annular/spray flow

Reduces required inlet piping diameter
Increasing vapor velocity increases liquid carryover

Designing for stratified/wavy flow

Increases separation efficiency
However, will require a relatively large inlet pipe diameter

Slug/bubble flow
Causes excessive liquid carryover and pipe vibration
Carryover can be reduced for horizontal drum with 2 inlet
nozzles and central outlet nozzle

8.13
INLET NOZZLE/DISTRIBUTOR ARRANGEMENT

Choice depends on flow regime, drum internals

and type of service

Horizontal drums (with CWMS)

90 elbow at each end facing nearest head
Slotted-T distributor - same orientation

Vertical drums
Slotted-T distributor - 120 included angle on bottom
Tangential inlet with annular ring if no CWMS

8.14
 LIQUID RE-ENTRAINMENT

After collection in the drum, liquid can be swept from the

surface and entrained to the outlet (especially at high
pressure and temperature).

Factors involved:
Velocity in the inlet nozzle
Distance from inlet nozzle to liquid surface
Physical properties of fluids
Inlet nozzle type (flush, 90 elbow, slotted T)

Criteria established for estimating maximum inlet mixture

velocity
Can Increase inlet nozzle size to greater than line size to
prevent entrainment.
8.15
 SEPARATOR LIQUID HOLDUP
The basic criterion for selecting a holdup is how fast the level
will change for given upset in flow rate, flywheel effect.

Holdup time needed to give acceptable stability to flow is

determined by:
what flow fluctuations are acceptable, e.g. to tankage vs processing
controller tuning adjustments - pretty much unknown
type, size, frequency of upsets - also uncertain

Really comes down to time set by logic plus experience

For level control, only holdup that counts is within LRC range.

8.16
 TYPICAL LIQUID HOLDUP REQUIREMENTS
(refer to DP V-A Table 1)
Surge Drums, Distillate Drums generally 5-10 minutes on
product if onto processing.
Just 2 minutes if onto
storage. 5 minutes on
reflux (if gives larger drum)
Compressor Suction & Interstage 10 minutes liquid spill or 5
min.based on lean oil rate if
suction from absorber.
Fuel Gas K.O. Volume of 15 m of inlet
line slug; after absorber
use 5 min. on lean oil rate.
Steam Drums 2 minutes on feedwater or
1/3 the volume of steam
generator and piping

8.17
 DESIGN CRITERIA FOR CWMS
CWMS sized for 100% of critical velocity .
Distance from top of CWMS to gas outlet nozzle should be
adequate to prevent flow maldistribution through CWMS:

ho = ( D - do ) / 2 (ho = min distance, mm)

(DCWMS = CWMS dia or long side,mm)
if distance impractical, use slotted gas collector

Typical design is 150 mm thick, 80 kg/m3 CWMS

Need 300 mm minimum distance between CWMS and

emergency liquid level (ELL)

8.18
PLASTIC MESH AND KNITTED WIRE CWMS

8.19
 ANTI-VORTEX CONSIDERATIONS

Use of baffles prevents vortex formation (and gas carry-

under) in liquid circulation above outlet nozzle.

Minimum distance from low liquid level to outlet nozzle

defined by larger of 230 mm or from equation below:

hLL = C16Q 0.4 (from DP V-A equation 14)

( 1 - pG/ pL ) 0.2

hLL = min permissible height, mm

C16 = empirical constant = 56 metric units
Q = liquid discharge rate, dm3/s
pG , pL = gas ,liquid density at conditions, kg/m3

8.20
 ANTI-VORTEX BAFFLES

Consist of three square sections of subway grating

evenly spaced one above the other

Grating bars are 25mm deep by 3mm thick on a

25mm by 100mm spacing

Further details on baffle design covered in

ExxonMobil IPs

Length of baffle side should be smaller of: 4 times the

outlet nozzle diameter, or half the drum diameter

8.21
TYPICAL DIMENSIONS OF HORIZONTAL CYLINDRICAL
DRUMS

8.22
 Notes - Typical Horizontal Drums:
1. Design for appropriate % of VC. Minimum vapor space is 300 mm or
20% of drum diameter whichever is greater.
2. Ten minutes holdup if applicable, otherwise ELL is HLL.
3. If water drawoff is present, the hydrocarbon liquid outlet nozzle should
extend above the bottom of the drum.
4. Set at minimum distance considering reinforcement and fabrication
requirements.
5. Refer to DPM Section V-A under Design Procedures for Horizontal
Drums with and without CWMS for nozzle selection or from experience.
6. The minimum distance above CWMS is calculated from:
ho = D CWMS - do
2
7. The minimum distance between LLL and the outlet nozzle is the larger
of hLL (DPM Section V- A) or 230 mm.
8. Impingement baffles should be installed opposite 90 elbow inlet
nozzles to protect the drum shell. The baffle diameter should be twice
the inlet nozzle diameter.
8.23
 VERTICAL DRUM SIZING GUIDELINES
Vertical drums with CWMS (minimal liquid entrainment)
VC, max (%) = 100 (foaming service). For other services, the larger of this or:
VC, max (%) = 225 Ksu (0.932) LL (D-2W)
D
(also refer to DPM Section V - A Table 1 for selected services)

Where:
VC, max (%) = maximum allowable percent of critical velocity at
maximum gas low rate, %
Ksu = surface tension - viscosity parameter, dimensionless
LL = maximum liquid loading which is the maximum liquid feed
rate divided by the drum horizontal cross-sectional area, dm3/s m2
D = drum diameter, mm
W = CWMS support ring width, mm
mL = liquid viscosity, mPa s (needed to calculate Ksu from
DPM V-A Figure 3)
s = surface tension, mN/m (needed to calculate Ksu from
DPM V-A Figure 3)

8.24
 VERTICAL DRUM SIZING GUIDELINES

Vertical drums without CWMS (moderate liquid carryover

permissible)

Vapor Space sized for 100% of VC

Vertical Drum with horizontal tangential inlet and annular ring

VC,max(%) = 200 (based on horizontal cross-sectional area)

= 300 (based on horizontal cross-sectional area minus
the annular ring area)

8.25
 TYPICAL DIMENSIONS OF
VERTICAL CYLINDRICAL DRUMS

8.26
 Notes - Typical Vertical Drums:
1. Ten minutes holdup if applicable, otherwise ELL is HLL.

2. Design for appropriate % of VC.

3. Inlet nozzle type depends on service.

4. Minimum distance from bottom of inlet nozzle to HLL should be

adequate to prevent or minimise re-entrainment at the liquid surface.

5. The minimum distance between LLL and the outer nozzle is the larger
of HLL (DPM Section V- A Equation 14) or 230 mm.

6. The minimum distance between the top of a flush inlet nozzle and the
top tangent line of the drum should be 900 mm.

7. The minimum distance above CWMS is calculated from:

ho = D CWMS - do
2

8.27
 GENERAL DESIGN PROCEDURE

(1) Tabulate rates and physical properties of the fluids to be separated

(from H&MB)
(2) Locate typical design criteria for drum service(using mainly DPM V-
A Table 1) from which to select drum configuration.
(3) Ascertain needed liquid separation, i.e. does it need CWMS?
(4) Calculate vapor flow area required based on VC
(5) Assume first-pass drum diameter and length (or height) to calculate
total drum volume and surface areas. Beginning of trial and error.
(6) Working from holdup and minimum distance criteria , calculate
liquid volumes (and related areas, heights). Deduct this from total
drum volume to determine if vapour space is inadequate or too
much.
(7) Select type of inlet nozzle/distributor; calculate diameter of nozzle
to prevent re-entrainment. If slotted distributor, design slots.
(8) Calculate size and position of CWMS, followed by anti-vortex baffles.
(9) Prepare a sketch showing nozzles, instrument tap locations and
positions of interface (LLL, HLL and ELL if required).
8.28
 DEBOTTLENECKING HORIZONTAL DRUM
What can be done with existing drum which fails to
meet DPM criteria?
flow rates have increased over time
drum service has changed

Allowable vapour velocity can be increased through

use of two inlet nozzles

Holdup requirements can be relaxed in certain cases

operating experience and procedures a key factor

Use of slotted gas collector to reduce distance from

CWMS to gas outlet
8.29
 LIQUID-LIQUID
SEPARATION CALCULATIONS

Settling liquid phases based on:

each phase dispersed in other
holdup time time for drops to reach interface

Separation velocity calculated

using appropriate settling rate equations and assumed
droplet size
maximum droplet separation velocity: 10 in./min(4.2 mm/s)

Settling pots used for small amounts of heavy phase

Settling baffles used to reduce drum size

8.30
 Separation Velocity Equations
Range of Applicable
SEPARATION VELOCITIES: Reynolds Numbers, Re

Stokes Law: Vs = (544) d 2 DS <2 (Eqn. 1)

m

Intermediate Law: Vs = (108) (d) 1.143 (DS) 0.714 2, 500 (Eqn. 2)

m 0.429 (Sc) 0.286

Newtons Law: Vs = (172) d DS 0.5 >500 (Eqn. 3)

Sc

Reynolds Number: Re = 0.999 dVsSc (Eqn. 4)

m

where: Vs = Separation velocity of dispersed phase droplets or bubbles, mm/s

(Maximum 4.2 mm/s).
d = Diameter of dispersed phase droplet or bubble, mm.
DS = Difference in specific gravities of continuous and dispersed phases (with
respect to water at 15C), dimensionless (absolute value).
Sc = Specific gravity of continuous phase at conditions, dimensionless.
m = Viscosity of continuous phase at conditions, mPa s.
Re = Reynolds number of droplet or bubble, dimensionless.

8.31
 DESIGN PROCEDURES FOR LIQUID-LIQUID
SETTLERS

(1) Set liquid holdup times

(2) Calculate minimum distance from LIL to heavy phase outlet

(3) Calculate minimum distance from HIL to light phase outlet

(4) Assume settler diameter; calculate settler length to satisfy required

holdup

(5) Check separation criteria; if volume inadequate, increase diameter

or add settling baffles

8.32
TYPICAL LIQUID-LIQUID SETTLING DRUM

8.33
TYPICAL THREE-PHASE SEPARATOR

8.34
 Notes for Typical Three-Phase Separator:

1. Design for appropriate % of Vc. Minimum vapor space is 300 mm or 20%

of drum diameter, whichever is greater.

2. Ten minutes holdup is applicable, otherwise ELL is HLL.

3. The hydrocarbon liquid outlet nozzle should extend above the bottom of
the drum.

4. Minimum distance considering reinforcement and fabrication

requirements.

5. Inlet nozzle selection based on prior experience. For Exxon jobs see
DPM Section V-A.

6. The minimum distance above CWMS is calculated from:

ho = DCWMS - do
2

8.35
 Notes for Typical Three-Phase Separator:

7. The minimum distance between LLL and outlet nozzle is the larger of
hLL (DPM Section V-A) or 230 mm.

8. Impingement baffles should be installed opposite 90 elbow inlet

nozzles to protect the drum shell. The baffle diameter should be twice
the inlet nozzle diameter.

9. L = 3 to 4D.

10. Minimum distance between HIL and the light phase outlet nozzle is
the larger of hHI (DPM Section V-B) or 100 mm.

11. Minimum distance between LIL and the heavy phase outlet nozzle is
the larger of hLI (DPM Section V-B) or 230 mm.

8.36
 ADDITIONAL INFORMATION
VENDOR LITERATURE

EXXONMOBIL REPORTS

Distillate Drying
Handbook
8.37
 GLOSSARY
Coalescer A device for removing small quantities of water or brine from crude
oil or petroleum products by means of either an electrostatic field or
inert packing with a highly extended surface, for example, wire
mesh.
Crinkled Wire Mesh Screen Porous blankets of wire or plastic knitted mesh, which are used for
(CWMS) removing entrained liquid droplets from a vapor stream.
Critical Velocity (Vc) An empirically calculated vapour velocity used to ensure that the
superficial vapour velocity through the separator drum is sufficiently
low to prevent excessive liquid carryover.
Cyclone (Centrifugal) A vessel provided with a tangential inlet for a gas stream containing
Separator fine solids or liquid droplets and normally provided with a centrally
located overhead gas withdrawal line. The solids and liquid droplets
are separated by centrifugal force and pass down to a centrally
located outlet. A drain is connected to the bottom outlet.
ELL Emergency liquid level.
Flash Drum A vessel used to separate gas evolved from liquid flashed from a
higher pressure to a lower pressure.
Free Water Entrained water in hydrocarbon.
HIL High interface level.
HLA High level alarm.
HLL High Level liquid.

8.38
 GLOSSARY (Continued)
Knockout (K.O.) Drum A vessel designed to handle streams with high gas-to-liquid ratios.
The liquid is generally entrained as mist in the gas. These vessels
usually have a small liquid holdup.
Liquid-Liquid Settler A vessel used to separate two immiscible phases using the same
principles as for vapor-liquid separators, except that separation is
more difficult because the difference in density between two liquids
is less than between vapor and liquid, and liquid-liquid separators
are designed for much lower velocities.
LIL Low interface level.
LLL Low liquid level.
NIL Normal interface level.
NLL Normal liquid level.
Three-Phase Separator A vessel used to separate vapour and two immiscible liquids of
different densities (for example, vapour, water, and hydrocarbon).
Vane-Type Mist Eliminator Zig-zag baffles which are used for removing entrained liquid
droplets from a vapor stream. Spacing between the baffles, turning
angles and number of passes are designed to satisfy specific
removal requirements.
Vapor-Liquid Separator A vessel used to separate a mixed-phase stream into vapour and
liquid phases.

8.39