DS-SI-01 Rev 3 - hatltd.com

1 Separator DESIGN SHEETO verviewHAT supplies a large number of internals used in separation service from the various Alphaproduct of these have uses in other applications, but some have beendeveloped specifically for gas/liquid separation service in fields such as: OilfieldProduction (gas/oil/water)Separators (onshore, offshore and FPSO) Test Separators Free Water KO Drums Oil/Water Coalescers Compressor scrubbers Gas/Liquid KO Drums& Inlet ScrubbersInlet Devices:BID Bifurcator Inlet DistributorVID Vane Inlet DistributorCID Cyclone Inlet DistributorBP Perforated Baffle PlatesDefoaming Internals:FB-V Foam Breaker VanesFB-M Foam Breaker MatrixCoalescing Internals:FP Flat Plate PackSeparator DESIGN SHEETMP Matrix PackDM Dual MediaCoalescerDemisting Internals:DS/GP/HEWire Mesh DemistersVV/VHVane Mist EliminatorsSME Swirl Mist EliminatorsMCE Multi Cyclone ElementsDesanding Internals:SJ-HNSand JetH Spray SystemSJ-HTHydro TransportRemovalOther Devices.

2 VB Vortex BreakersSW Stilling WellsWF/WA Fixed/Adjustable WeirsSB Skimmer BoxesInlet 3 AlphaPLUS DESIGN SHEETM ultiVane Inlet DistributorTheAlphaPLUS VIDis a multi-vane inletdevice used in horizontal and verticalseparators where there is arequirementfor good flow distribution with minimumshear and pressure horizontal vessels the VID is suited toboth end entry as illustrated below, and topentry by means of an elbow directedtowards the of this devicecompared with simpler deflectors includereduced agitation and hence improved 2and 3 phase operational performance,more stable level control, and vertical vessel installations, usuallywhere there is a high gas flow relative tothe liquid flow, the VID provides excellentvapour distribution allowing a reducedheight to the mass transfer or misteli minator VID works bysmoothly dividingtheincoming flow intovarious segments usingan array of curved vanes to suit the overallgeometry of the inlet nozzle and distributorlength.

3 To achieve this effect the vanesstart withawidespacingandgraduallyreduce the gap, giving the unit itscharacteristic tapering design,AlphaPLUSVID units areinstalled in a wide range VID is usually constructed fromstainless steel and is designed to beinstalled in sections through a vesselmanway and assembled in the sizing the VID to match the inletnozzle, we recommend the fluid momentum v2is in the range of 6,000- 10, 3 AlphaPLUS DESIGN SHEETB ifurcatorInlet DistributorTheAlphaPLUSBIDis a simple, dual-vane inlet device used in horizontalseparators where there is a requirementfor reasonable flow distribution with lowshear and pressure horizontal vessels the BID is suited totop entry. Benefits of this device comparedwith simpler deflectors such as deflectorplates or dishes include reduced agitationand hence improved 2 and3 phaseoperational performance, more stable levelcontrol, and reduced slugging applications, usuallywhere there is a long incoming flowline, BID works by smoothly dividing theincoming flow intotwosegments usingcurved vanes to suit the overall geometryof the inlet nozzle.

4 The gas phase readilyseparates and disperses along the vessel,whilst the liquid phase velocity is reducedand the flow directedatthe vesselwallswhereit further disperses and falls into thebulk liquid layerat relatively low on well provenindustrydesigns,HAT sBID units are installed in a widerange of sizing the inlet nozzle for a BIDinstallation,werecommend thefluidmomentum v2does not significantlyexceed6, 3 AlphaPLUS DESIGN SHEETM odular ConstructionHAT s unique modular design means future changes are easily made shouldthe production profile change over time, or not be as CIDis a cyclonic inletdevice used in horizontal and some verticalseparators where there is a requirementfor high momentum dissipation, foamreduction and high in the 1960 s for thetreatment of foamy crude oil in productionequipment, early inlet cyclone devicessuffered from a range of mechanical andfluid instability problems, and were notwidely work continued, however, andthe design of the inlet cyclones evolvedover the next4 decadesfrom short, fat,single or dual cyclones into tall, thin, multicyclone arrangements.

5 The characteristicsofthesedevicesbecamebette runderstood,and reliableperformanceenvelopes were characteristic of the cyclones is theirhigh flow capacity, meaning that morethroughput is possible through any givensize MechanismThe primary purposeof theCIDinletcyclone is that of foam elimination inside crude oils exhibitmoderate or severe foaming tendency andthe traditional approach to these problemsis through a combination of oversizedequipment using foam breaking cyclones work on the principle ofenhancedgravityseparationbyacceleratin g any incoming foam tohigh g-force, when it breaks downinto separate liquid and gas oil/wateris flung to theperimeter of the cyclone tubes andf lows down them into the bulk liquidlayers, whilst the gas forms acentral vortex core and escapesthrough a top outlet hole into thegas are many factors to take intoaccountwhen designing thesedevices so please refer toHATforsizing to InstallManufactured as components thatfit through a standard manway,CIDinletcyclonescomprisespre-stif fened cylinders and manifolds,requiring only simple supports andassembly within the vessel toachieve a secure sfullinstallationguidelinestoensureproce ssInlet 3 AlphaPLUS DESIGN SHEET integrity is not compromised.

6 If required,we can also arrange to inspect equipmentprior to Performance RangeHATwill design the cyclone cluster to meetyour specific requirements, but the designenvelope of the whole separator usuallymeansthatperformancecanbeguarante ed all the way down to zeroturndown. In many cases there will be littleloss in performance also should anadditional 10-20% flow be required throughthe cyclones can beused at any operating pressure andtemperature likely to be sizing theCID to match the inletnozzle, we recommend the fluid momentum v2is in the range of10 ,000- 20, sometimes recommends the useof inlet weirs and flow distributor baffles,depending on the Life ConstructionStandard materials of construction arestainlesssteelgrade316forallcomponent s.

7 For very sour or corrosiveservice other materials such as Inconelcan be include both horizontal andvertical: Production Separators Free Water Knock-Outs Degassing Vessels Slug CatchersInlet 3 AlphaPLUS DESIGN SHEETP erforated Baffle PlatesA selectionofAlphaPLUSB affle Plates(BP)is available from HAT. These areavailable in a range of perforationsandstylesfor installation in horizontal or applications include: Calming the inlet zone in horizontalseparators Liquid flow redistribution in longvessels Surgesuppressioninvesselsinstalledinoffs horeFPSO applications Gasdistributionupstreamordownstream of mist eliminatorsThe flow distribution characteristic ofperforated baffles is well established, butmodern design tools such as CFD enabletoday s designers to tailor the baffle designto achieve optimum distribution by adjustingthe hole size, % open area, number ofbaffles(BP-1 single and BP-2 dual)

8 Andth eir overlap as illustrated are designedandmanufacturedtobeinstalledinse ctionsthrough a vessel manwayan d areeither self reinforced using webs on thepanels, or in larger vessels may beadditionallysupportedwithseparatestiff ening of the BP s is usually instainless steel and, thanks to the integralstiffening mentioned above, it is possible toutilise thicknesses as low as 2 or 3mm formany applications, reducingbothinstalledcost and 3 AlphaPLUS DESIGN SHEETC alculation of Pressure DropThe pressure drop across aBPperforated baffle may be estimated using thefollowing formula and application guidelines: P < 5mm liquidIneffective baffle P = 10 to50mm liquidFlowdistribution P > 100mm liquidSurgesuppression P (mm liquid) = P(kPa) L(kg/m3) . g (m/s2)and P =( L.)

9 Vin2) . 2. ( (t / d) + 3) . [(1070 .. / vin. d) + ]where L=Liquid density, kg/m3vin=Liquid bulk velocity before baffle, m/s =Fractional open area of bafflet=Baffle plate thickness, md=Hole diameter, m =Liquid kinematic viscosity,m2/s P=Pressure drop, kPaNote, the pressure drop across a dual baffle will be the sum of the two separatebaffle pressure 3 AlphaPLUS DESIGN SHEETOVERVIEWMuch work has been performed on the development of sand or sludge removal systems fromseparators over many years. However, no single sand jet system has evolved as clearlysuperior, rather there are a number of design features to choose fromdepending on thecharacteristics and nature of the problem. HAT tailor makes it s sand jetting systems based ona wide range of features as shown below, to ensure that the sand deposits can be fluidisedand hence drained satisfactorily in the most economic OFSAND REMOVAL SYSTEMHAT manufactures a comprehensive range ofAlphaPLUS standard and highperformancewash systemsas listed Types:SJ-HPPipe HeaderBasic design for low fouling or smallsystems, may or may not be fittedwith jet PerformanceTypes:SJ-HNNozzle Spray HeaderWell proven, conventional designwith directional pipes and specialistnozzles for improved Transportation SystemLatest generation design with vortexinduced fluidisation for improvedperformance.

10 HAT manufacturesthese systems for 3 AlphaPLUS DESIGN SHEETTypeBenefitsAlphaPLUS SJ-HNConventional Jet Nozzle SystemTwin jet headersare placed either side of thecentreline to provide maximum coverage. Theycan be split into several H sections (partitioned)each separately fed with jet water, and separatelydrained so that sand deposition and flushing canbe monitored and controlled at or above thecritical Fluidisation headers are fitted with an array of smallerarms fitted with fan-jet nozzles to fluidise andsweep the solids most central sand pan prevents sand settling onthe centreline and clogging the flushing out (sandremoval) of the sand area of the vessel isimportant for flushing purposes. It minimises jetwater use and prevents fluidised solids fromdissipating downstream.