Spt High Efficiency Phase Separation Internals Brochure

8/20/2019 Spt High Efficiency Phase Separation Internals Brochure

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High-Efficiency Phase Separation InternalsCompact and robust for efficient phase separation



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.



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.



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.



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



©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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Documents

Spt High Efficiency Phase Separation Internals Brochure