8/20/2019 Spt High Efficiency Phase Separation Internals Brochure http://slidepdf.com/reader/full/spt-high-efficiency-phase-separation-internals-brochure 1/8 High-Efficiency Phase Separation Internals Compact and robust for efficient phase separation
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High-Efficiency Phase Separation InternalsCompact and robust for efficient phase separation
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Cameron has a continuous
focus on the development
of robust, high-efficiency phaseseparation internals. Cameron’s
phase separation internals are
designed to meet the most
stringent demands for separation
performance in a compact space.
The documented high
separation performance of the
internals reduces the risk of
operation, ensures that minimal
maintenance of downstream
equipment is needed and boasts
low life cycle cost. The high-
efficiency phase separation
internals will reduce the need
for chemicals as defoamers and
demulsifiers. High-efficiency
phase separation internals also
can help capture the valuable
liquid in a gas stream prior to the
transport.
They also are valuable for
retrofits of existing vessels to
achieve increased capacity or to
ensure separation for existing
vessels. It also is a key element
in robust compact systems when
the pressure is high or the space
is limited.
One of 16 Ormen Lange receiving
scrubbers delivered by Cameron is
assembled at the shop.
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APPLICATIONS
The high-efficiency phase separation internals are
used in phase separators for separation of oil, gas,sand and water. These applications include:
• Scrubber vessels
• Two-phase separators
• Three-phase separators
• Free-water knockout drums
• Flare knockout drums
• Contactor towers
• Slug catchers
WHY HIGH-EFFICIENCYPHASE SEPARATION INTERNALS?
High-efficiency phase separation internals reduce
the size and weight of the pressure vessel, reduce
the footprint and reduce the need for floor space,
thereby lowering the overall cost.
During operation, high-efficiency phase separation
internals protect the process system from
contamination. They also reduce the operating cost
of maintenance to the process system related to:
• Chemical usage (i.e., defoamers and demulsiers)
• Compressor breakdown
• Compressor wear on intake valves
• Fouling of downstream heat exchangers
• Pump cavitation from free gas in the liquid
• Hydrocarbon contamination
• Wear of valve trimming
• Limited capacity of the existing vessels
The high-efciency phase separation system helps
protect the process plant from potentially unsafe
situations during maintenance/replacement of
process equipment and the risk associated with
compressor breakdowns. The high- efciency phase
separation internals capture the free liquid in the
gas stream, ensuring minimum loss of valuable
liquid hydrocarbons or glycols.
P R O D U C T P O R T F O L I O
Two- and three-phaseseparators
Compact three-phaseseparators
Compact two-phaseseparators
Effic ient two-stage scrubbers Compact two- stage scrubbers
Compact in-line scrubber vessels
InletStream
WhirlyjigGas Recycled
GasOutlet
Liquid and solidscollected in sump
Liquid and solidsspun to wall
Liquid and solidsdrawn through opening
O
I L
G
A
S
Unique dehydration design
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IN-VESSEL SEPARATION
Operators are continuously looking for more efcient and
compact separation systems to reduce the overall costs. This
drives the development of high-efciency phase separation
internals. Cameron’s answer to this challenge is to:
• Use centrifugal, capillary or electrostatic forces rather
than just gravity forces to decrease separation time
• Reduce separation distances within the separator vessel
by using structured packing or plate packs
• Ensure that the intended separator volumes are fully
utilized by using perforated plates in separators and
mesh pads in scrubbers
As an alternative to
in-line separation,
Cameron suggests
the use of in-vessel
separation. In-vessel
compact separation
allows you to utilize
separation volume
more efciently than
traditional gravity
separation vessels.
CONSEPT AXIAL CYCLONIC INLET (ACI®)
Applications:
• High-efciency centrifugal inlet device for scrubbers
• Bulk separation vessel to be installed as an inlet in scrubbers
• Ideal for high-pressure applications and compact vessels
• Ideal for retrots to increase gas load or separation
performance
• Well-suited for retrots using only cold work
• Proven efciency by third party in real uid systems
• Removes more than 90% of the liquid already in the
vessel inlet at k values up to 0.5 m/s
Axial ow cyclones are highly efcient for removing small
amounts of liquid from a gas stream. The axial ow cyclones
have close to 100% efciency at a wide range of ow rates,
Advantages of In-Vessel Separation
• No new tags in the process systems
• No added regulation to the system
• No dirty streams that need additional
treatment
• No added blowdown volumes
• No added size or weight
• No need for hot work during installation
L A T E S T G E N E R A T I O N I N L E T D E V I C E
Spin generated through
modified spin element core
Gas flow distribution
Droplet tracking D = 10 μm
The axial cyclonic inlet (ACI) is a compact separator for bulk
separation of liquid that fits inside the scrubber vessel,considerably increasing the acceptable gas.
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but generally efciency degrades when the gas rate and/or
pressure increases.
The efciency of the axial ow cyclones is important inorder to achieve very stringent separator performance of
0.1 gal/MMcf that typically is required.
The latest generation of axial ow cyclones reduces the
liquid carryover with a factor of 10 by incorporating a new
element in the existing cyclone. The increased separation
efciency allows vessels to be more compact, which is
desirable for high-pressure and subsea applications.
CONSEPT INLET VANE DIFFUSERS (IVD®)
Applications:
• Vane inlet used in separators and scrubbers
• Well-suited for retrots using only cold work
• Cold work installation
• Well-suited for high-pressure applications
• Patented proled vanes ensure good hydraulic
performance and stable ow in the inlet section
• Double vanes enhance liquid separation inside the
vane inlet• Proven efciency by third party in real uid systems
The inlet vane diffuser is an inlet device for the separator,
consisting of multiple dual-plate vanes which are designed
to effectively distribute gas and liquid. These vanes
are designed to avoid any liquid carryover with gas by
providing gradual bend and enough surface area for
liquid to separate from gas.
These vanes are more efcient compared to single plate
vanes, which are a 90-degree bend and can potentially
carryover excess liquid with gas. Installing an IVD on
the inlet section of the separator can distribute gas and
liquid uniformly to decrease the required residence time
for the separator, while maintaining the required
separation efficiency.
CONSEPT DEMISTING CYCLONES (DC®
)Applications:
• Highly efcient cyclonic demister
• Ideally suited for scrubbers, separators and contactor
towers
• High efciency at high pressures and low surface
tensions
• Proven efciency by third party in real uid systems
• Compact solution well-suited for retrots
• No scaling effects in different sized vessels
• Relatively open with little chance of plugging
• Sand draining design of cyclone
to avoid solid accumulation
Demisting cyclones are
compact cartridges of mini-
cyclones designed to remove
liquids from gas. Each cyclone is
designed with internals which
set uids into centrifugal motion
to separate liquid from gas. Several ofthese cyclones are combined and installed on the gas
outlet of the separator.
Demisting cyclones provide higher K-value compared to
standard demisters or a mesh pad. These cyclones, in
combination with other internals, can increase separation
efciency of the separator to 99.99% removal of 10 micron
or larger liquid droplets or 0.1 gal/mmscf liquid carryover.CONSEPT IVD for a flare KO drum assembled in a shop
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CAMERON’S PORTA-TEST REVOLUTION
• Cyclonic inlet
• Highly efcient inlet device for two- and three-phaseseparators
• Reduces foam in vessel by separating gas and liquids
before inlet momentum reduction
• Can handle high inlet momentum in vessels
• No scaling effects by using multiple tubes
• Special design for two- and three-phase vessels
• Mechanical robust solution, optimized with FEM
Cameron’s PORTA-TEST REVOLUTION® is a unique
separator inlet device used to eliminate foam and improve
uid management within the separator.
A PORTA-TEST REVOLUTION may either be connected
directly to the inlet nozzle during fabrication, or it may
be installed as a retrot through a manway. It is suitable
for use in both vertical and horizontal vessels. With over
500 installations worldwide, we have the experience and
expertise to optimize your separator performance.
CONTACTOR VESSELS WITH DEMISTER
INTEGRATED IN CHIMNEY TRAY
Cameron’s unique contactor design has a built-in inlet
and outlet gas scrubbing system which can potentially
eliminate the requirement of scrubbers upstream and
downstream of the contactor.
The inlet section of the contactor can be equipped with
IVD, which provides uniform distribution of the gas and
removes any entrained liquids. Outlet
section of the gas, from the top of the
contactor tower, has DC as the demisting
section, increasing the overall separation
efciency and reducing the solvent losses
with outlet gas. The demister for the
hydrocarbon scrubber is tted inside the
chimney tray to save space. The pressure
drop through these devices is much less
than individual scrubbers, providing
overall CAPEX and OPEX savings.
ROBUST THREE-PHASE SEPARATIONWITH MECHANICAL COALESCENCE
Cameron’s three-phase separator is designed with various
internals for uid inlet, gas outlet and liquid outlet to
provide higher separation efciency while potentially
decreasing the overall size of the vessel by reducing
the overall required residence time. These three-phase
separators are designed to handle oil, gas, produced
water and solids. To improve the separation performance,
Cameron uses its high-efciency separator internals (i.e.,IVD, DC, PORTA-TEST REVOLUTION), vortex breakers or
PERFORMAX® structured packing/plate packs to ensure
mechanical coalescence and improved separation.
VERIFICATION
Verication of the separation performance at real ow
conditions using real fluids is essential for utilizing the
high-efficiency phase separation internals to their full
potential.
PORTA-TEST REVOLUTION as installed in a three-phase separator.
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The CONSEPT high-efciency phase separation internals,
for removal of liquid from a gas stream, have been tested
with real uids at high pressures. The demister sections
have been tested for liquid and gas mixtures operating
close to the critical point with interfacial tension between
gas and oil as low as 2.2 dyne/cm.
A Cameron-designed scrubber is used at Ormen Lange
Pilot, which is verication of a full-size subsea compressor
station in an onshore pit.
Based on the testing, a model for predicting the separation
performance is developed. The separation performance is
estimated based on:
• Pressure
• Liquid and gas densities
• Liquid and gas ow rates
• Viscosity
• Interfacial tension
The efciency models allow Cameron to accurately predict
the actual liquid carryover in real conditions and optimize
the vessel size based on the customer requirements for
vessel performance.
COMPUTATIONAL FLUID DYNAMICS (CFD) MODELING
Applications:
CFD is used by Cameron to:
• Verify the ow in the vessel
• Check volume utilization of vessel volume
• Detect any maldistribution in the inlet pipes
• Examine the effect of ow dynamics or slugging
• Examine the effect of separator motion and sloshing
of uids inside the vessel
• Estimate forces acting on internals in the vessel
• Predict separation performance
• Enhance product development
Computational uid dynamics (CFD) is an important and
integral part of high-efficiency phase separation internals
implementation. The CFD calculations assure proper
working of internals as designed, as well as their optimal
implementation. Cameron has extensive experience and
dedicated support staff for CFD. Every delivery of the
internals is veried with CFD.
Turbulent structures in a vanepack as simulated
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©2013 Cameron | ACI, DC, IVD, PEFORMAX and PORTA-TEST REVOLUTION are registered trademarks of Cameron. | C ME 1.5M 12/ 13 AD01091P
HSE Policy StatementAt Cameron, we are committed ethically, financially and personally to aworking environment where no one gets hurt and nothing gets harmed.
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