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Process Design Calculations Client: Southern Petroleum Construction J.S Company (Alpha-ECC) Project: Thai Binh – Ham Rong Gas Distribution and Gathering System Project, Block 102 & 106 – Phase 1 Vessel Name: HP Separator Separator Vessel Tag: V-401 V-401
Process Internals Overview ................................................................ 3
3.
Process Description ............................................................................ 4
3.1 Evenflow HE Inlet Device................................................................. 4 3.2 Mesh Pad Demister ......................................................................... 5 3.3 Distribution Baffles .......................................................................... 6 4. Process Flow Information ................................................................... 7 5.
8.1 Evenflow HE ................................................................................. 10 8.2 Perforated Distribution Baffles ....................................................... 10 8.3 Mesh Pad Demister ....................................................................... 10 8.4 Weir Plate..................................................................................... 11 8.5 Accessibility .................................................................................. 12 9. Process Guarantee ........................................................................... 13 10. Detailed Vessel Sizing Sheet ............................................................. 14
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
1. Introduction This document is intended to describe the process design for the HP Separator V-401.
2. Process Internals Overview The following process internals have been selected in the process design for this vessel. Evenflow HE Perforated Distribution Baffles Mesh Pad Demister Weir Plate (design only)
Notes: 1. 2. 3. 4. 5.
Material of construction: Type 316 / 316L stainless steel. Material of construction for bolting and nuts: Type 316 stainless steel Material of gaskets: Expanded PTFE. No welding to the vessel wall is permitted for the installation of the internals. Material certificates shall be in accordance with EN 10204 3.1 for base material with the exception of bolting and gaskets that are to be in accordance with EN 10204 2.1. 6. All internals in FMC supply will be pi ckled and passivated. 7. All items in FMC supply will be made remo vable through the vessel manway. Client scope of work
Welded supports inside vessel for fixation of the internals Outlet Gas Box Inlet Bend Weir Plate Vortex Breakers Installation of internals (under FMC supervision)
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
3. Process Description Further details of the internals are given below:
3.1 Evenflow HE Inlet Device With over 1500 units sold since 1996, the proprietary Evenflow HE Inlet Device is a well proven technology. Developed with the benefit of extensive in-house testing, the design has been continually optimized with the CFD and the benefit of decades of field experience. The Evenflow HE Inlet device receives the incoming process stream diverting the fluids through the distribution vanes. In spreading the high momentum flow over a wider area filling the cross sectional area of the vessel, significantly reduces the momentum of the fluid entering the separator inlet zone. The Evenflow HE inlet device has two key benefits to improve separation. Firstly, by dissipating the momentum as early as possible in the inlet zone, reduces turbulence in the inlet zone and downstream in the vessel. Secondly, creating an even distribution of the inlet stream utilizes the full vessel volume improving residence time. The design of the Evenflow achieves these improvements in the inlet zone without impacting or breaking up liquid droplets. This reduces the presence of small entrained oil droplets carried over to downstream demisting device and reduces gas entrainment in the liquid phase. The Evenflow HE inlet device has been developed and refined extensively through the combined findings of CFD simulation and successful case studies and has been applied to a wide range of applications for horizontal and vertical separators. Replacing an existing inlet device with an Evenflow HE can enable the existing process vessel to effectively handle the higher inlet momentums and changed production profile ensuring economical process performance for future flow rates. Key benefits: Robust technology applied over decades Proven performance optimized by CFD Robust design with mechanical strength verified by FEA Resistant to fouling and blocking Effectively dissipates inlet momentum Maximizes gravity separation Evenly distributes fluid flow to utilize full vessel volume.
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
3.2 Mesh Pad Demister The mesh pad demister is a well-established design for dealing with liquid droplets entrained in the gas phase. This type of demister is characterized by a very low pressure drop and high contact area for fine liquid droplets. A lattice is woven from fine wire creating a mesh and supported within an open frame for mechanical strength. The mesh provides a high net free area with a high surface area for contact with fine liquid droplets. As the droplets make contact with the mesh, they coalesce and grow in size. As the droplets coalesce and grow, a critical mass is reached when they fall under gravity from the bottom of the mesh. The mesh can be mounted horizontally or vertically in two or three phase separators. In Summary, Mesh Pad demisters are: Resistant to erosion and degradation Highly efficient, with a wide turn down and operating range Robust technology applied over decades Proven performance optimized by CFD Robust design with mechanical strength verified by FEA Low cost and weight
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
3.3 Distribution Baffles Perforated baffles are positioned in horizontal separators to achieve a number of process benefits: The effects of high inlet momentum of incoming fluids are contained within the inlet zone Distribute pressure drop across the vessel diameter creating plug flow Resulting pressure drop promotes gas break out earlier in the separation zone. Reduces impact of fluid volume surges from fluctuating process conditions. Creates calm separation conditions to maximize the volume in the downstream quiescent zone. Reduce gas layer velocities, allowing for drop out of liquid droplets. In floating applications, correct placement of baffles provides effective sloshing mitigation
The inlet momentum of multiphase fluid entering a separator vessel must be effectively contained within the inlet zone while minimizing turbulence and shearing. Most of the momentum will be dispersed by the inlet device ensuring good distribution of fluid flow across the inlet zone. When fluctuating flow is experienced, changing velocities, phase ratios and slugging has the potential to agitate the inlet zone. Baffles positioned downstream of the inlet device serve to contain surges within the separator inlet zone. Perforated baffles are designed with an open area between 20-40% creating the desired level of pressure drop. By creating the pressure drop across the width of the vessel provides two direct benefits to separation efficiency: 1. Ensuring plug flow. Using the full width of the vessel prevents jetting or short cutting downstream towards the outlet nozzles 2. Gas phase hold up. Reduce gas phase velocity and liquid droplet entrainment towards the downstream demisting devices. The mechanical design of FMC Separation Systems perforated baffles is characterized by a distinctive conical arrangement. Significant strength improvements are gained and large support beams removed. Ease of fabrication and installation is improved with cost reductions over flat baffle designs.
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
4. Process Flow Information 1) The proposed design is based on the following process data from Doc. No. 135355-04-DAS-04-019 rev.C2 dated 14-04-14. Process Data
Operating Conditions Temperature Pressure Gas Flow Molecular weight Density Viscosity HC Liquid Flow Density Viscosity Gas / Oil Interfacial Tension Water Flow Density Viscosity Gas / Water Interfacial Tension
2) Additional Process Data from: 135355-01-REP-06-001_Process Simulation Report_Rev C0 and 135355-01-REP-06004-FlowAssuranceStudyReport-C0 Operating Conditions Temperature Pressure Gas Flow Molecular weight* Viscosity* HC Liquid Flow Density* Viscosity* Gas / Oil Interfacial Tension* Water Flow Density* Viscosity* Gas / Water Interfacial Tension* Operating Conditions Temperature Pressure Gas Flow Molecular weight* Viscosity* HC Liquid Flow Density* Viscosity* Gas / Oil Interfacial Tension* Water Flow Density* Viscosity* Gas / Oil Interfacial Tension*
Units °C kPa-a
Case 1 36.52 1501
Case 2 5.37 3407
Case 3 5.4 3391
Case 4 34.72 1501
Case 5 6.62 3321
MMSCFD cP
20.00 20 0.013
20.00 20 0.013
20.00 20 0.013
28.80 20 0.013
28.80 20 0.013
m³/d kg/m³ cP dyne/cm
18.17 600 0.5 20
31.5 600 0.5 20
21.59 600 0.5 20
17.9 600 0.5 20
56.5 600 0.5 20
m³/d kg/m³ cP dyne/cm
5.49 1000 0.5 70
5.5 1000 0.5 70
30.04 1000 0.5 70
33.47 1000 0.5 70
8.7 1000 0.5 70
Units °C kPa-a
Case 6 6.6 3251
Case 7 29.01 1501
Case 8 5.05 1751
Case 9 5.54 1881
MMSCFD cP
28.80 20 0.013
53.40 20 0.013
53.40 20 0.013
53.40 20 0.013
m³/d kg/m³ cP dyne/cm
33.7 600 0.5 20
22.83 600 0.5 20
58.2 600 0.5 20
55.1 600 0.5 20
m³/d kg/m³ cP dyne/cm
37.7 1000 0.5 70
68.29 1000 0.5 70
44.03 1000 0.5 70
68 1000 0.5 70
(*) These values were assumed and client is requested to confirm on these.
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
5. Vessel Summary Number of vessels Horizontal or Vertical Vessel internal diameter (mm) Tan to Tan Length (mm) Head type
1 Horizontal 3800 9000 Elliptical
6. Nozzle Schedule Nozzle N1 N3 N12
Size (“)/ID (mm) 18” / 387.4 mm 12” / 298.1 mm 3” / 47.8 mm
Location +1800 mm +8700 mm +7300 mm
N13
2” / 38.2 mm
+8800 mm
M1
24” / 531.8 mm
M2
24” / 531.8 mm
1 1 1 1
On upstream head +6950 mm 1 on top of vessel
Description Inlet Fluid Gas Outlet Liquid Outlet Condensate Outlet Manway
Notes Inlet Bend Gas Box Vortex Breaker Vortex Breaker
Manway
1. Location is taken from upstream tan line of vessel
7. Liquid Levels Level HHLL HLL NLL LLL LLLL Weir HIL NIL LIL LLIL
8. Internal Details 8.1 Evenflow HE Vane Type Inlet Device Type Vane Radius (mm) Number of Vane Ladders per Side Number of Vanes per Vane Ladder Min. Evenflow Centre Line Elevation 1
Evenflow HE 150 1 6 +3342
1. Elevation is taken from bottom of vessel
8.2 Perforated Distribution Baffles Perforated Distribution Baffles Full or Part Diameter Baffle Height of Part Diameter Baffle (mm) Perforation (% Net Free Area) Diameter holes (mm) Location of baffle (mm)1
#1 Full 1 3100 36 30 2200
#2 Full 1 3100 21 30 2700
1. Full diameter baffle with cut-outs 2. Location is taken from upstream tan line of vessel
8.3 Mesh Pad Demister Mesh Pad Demister Type Mesh Thickness (mm) Mesh Bottom Elevation (mm)1 Location of Mesh (mm) 2
412 150 3050 7700
1. Elevation is taken from bottom of vessel 2. Location is taken from upstream tan line of vessel
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
8.4 Weir Plate Weir Plate 1
Height of Weir (mm) Location of Weir (mm)2
620 7500
1. Elevation is taken from bottom of vessel 2. Location is taken from upstream tan line of vessel
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
8.5 Accessibility All internals are installable and removable via the manway. Client is requested to inform FMC about the available space around the separator and accessibility to the manway. Obstructions near the vessel and manway must be clearly indicated prior to design. This in order to prevent that parts of the internals will not be able to enter the vessel.
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
9. Process Guarantee Based on the equipment being stored, erected and operated in accordance with FMC instructions we guarantee the following. Liquid Entrainment in Gas The overall liquid carryover at high-high liquid level, neglecting the effect of condensation across the vessel due to pressure drop, will not exceed 1% vol. The liquid droplet removal shall equal or exceed 99% of droplets greater than 100 microns. Water Entrainment in Oil The amount of free water entrained in the oil will not exceed 1% v/v. This does not apply to water absorbed in the oil nor that contained in an emulsion. Oil Entrainment in Water The amount of free oil entrained in the water will not exceed 2000 ppm v/v. This does not apply to oil absorbed in the water nor that contained in an emulsion.
In order to confirm the above Process Guarantee and to assure that the internals design is adequate, the following upstream piping requirements apply: 1. The same ID as the inlet nozzle ID; 2. Straight pipe length of 10 times the inlet nozzle ID with no major disturbances or pressure drops within this straight pipe run; 3. All bends within 10D of the inlet nozzle in the vertical plane. Bends in horizontal plane shall be avoided. If the upstream piping does not match the above requirements client is expected to provide the actual layout for our further evaluation.
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FMC Project No.: FMC Doc. No. : Revision :
P14-04027 P14-04027-PDC 1
10. Detailed Vessel Sizing Sheet 1) Key Design Summary Tan to Weir Length 7500 Parameters Inlet nozzle momentum (ρv2) Overall maximum pressure drop Gas k-factor at HHLL Gas outlet nozzle momentum HC Liquid Residence time (NIL – NLL) Oil outlet velocity Water Residence time (BV – NIL) Water outlet velocity
mm Units kg/ms2 mbar
Case 1 1202 16
Case 2 138 2
Case 3 828 11
m/s kg/ms2
0.09 3352
0.031 369
0.073 2216
min m/s
351.2 0.173
113.2 0.538
130.3 0.467
min m/s
538.5 0.093
912.4 0.055
190.9 0.262
Liquid Level Settings
Interval
Level
Level (mm)
HLL to HHLL NLL to HLL LLL to NLL LLLL to LLL Liquid outlet to LLLL HIL to Weir NIL to HIL LIL to NIL LLIL to LIL BV to LLIL
2) Key Design Summary Tan to Weir Length 7500 Parameters Inlet nozzle momentum (ρv2) Overall maximum pressure drop Gas k-factor at HHLL Gas outlet nozzle momentum HC Liquid Residence time (NIL – NLL) Oil outlet velocity Water Residence time (BV – NIL) Water outlet velocity
mm Units kg/ms2 mbar
Case 1 196 3
Case 2 79 1
Case 3 82 1
Case 4 415 5
Case 5 170 2
m/s kg/ms2
0.038 539
0.025 214
0.025 215
0.055 1111
0.036 456
min m/s
331 0.184
191 0.319
278.6 0.218
336 0.181
106.5 0.572
min m/s
1408.6 0.035
1406 0.036
257.4 0.194
231 0.216
888.9 0.056
Liquid Level Settings
Interval HLL to HHLL NLL to HLL LLL to NLL LLLL to LLL Liquid outlet to LLLL HIL to Weir NIL to HIL LIL to NIL LLIL to LIL BV to LLIL
Key Design Summary Tan to Weir Length 7500 Parameters Inlet nozzle momentum (ρv2) Overall maximum pressure drop Gas k-factor at HHLL Gas outlet nozzle momentum HC Liquid Residence time (NIL – NLL) Oil outlet velocity Water Residence time (BV – NIL) Water outlet velocity
mm Units kg/ms2 mbar
Case 1 178 2
Case 2 1401 18
Case 3 1104 14
Case 4 1046 14
m/s kg/ms2
0.036 466
0.101 3750
0.09 2959
0.087 2760
min m/s
178.5 0.341
263.5 0.231
103.4 0.589
109.2 0.558
min m/s
205.1 0.244
113.2 0.441
175.6 0.284
113.7 0.439
Liquid Level Settings
Interval
Level
Level (mm)
HLL to HHLL NLL to HLL LLL to NLL LLLL to LLL Liquid outlet to LLLL HIL to Weir NIL to HIL LIL to NIL LLIL to LIL BV to LLIL