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The document provides process design calculations for HP separators in a gas plant in Bangladesh. It details the selected internals, flow information, vessel sizing, and nozzle schedules.

The document is intended to describe the process design for HP separators (MBD-1000/1010/1020/1030) at the Bibiyana Gas Plant in Bangladesh.

The process internals selected include a CDS inlet cyclone, distribution baffles, drained meshpad agglomerator, Spiraflow, weir plate, and associated supports.

By Md Aktaruzzaman at 3:58 pm, Jun 12, 2014

Process Design Calculations


Client: Chevron Bangladesh Block Twelve, Ltd.
Project: Bibiyana
Vessel Name: HP Separators
Vessel Tag: MBD-1000/ 1010/ 1020/ 1030

Rev. No.

Description of Revision

First Issue for Approval

Prepared
By
Date

PS

Checked / Approved
By
Date

28-Apr-2014

RB

6-May-2014

FMC Separation Systems B.V.


Delta 101
6825 MN Arnhem
The Netherlands
Tel: +31 26 7999 100
Fax: +31 26 7999 119

Client Order Number


Field / Platform
End User
Client Document Number
-

Standard Document Code: CWF-2.11


Revision Date: 02-Feb-2012

Bibiyana Gas Plant


Chevron Bangladesh
FMC Document Number
P12-11007-PDC

FMC Project No.


P12-11007

Rev. No.
1

No. of Pages
15

FMC Project No.:


FMC Doc. No. :
Revision :

P12-11007
P12-11007-PDC
1

Table of Contents
1.

Introduction ...................................................................................... 3

2.

Process Internals Overview................................................................. 3

3.

Process Description ............................................................................ 4

4.

3.1 CDS Inlet CycloneTM Inlet Device ................................................... 4


3.2 Distribution Baffles ....................................................................... 5
Process Flow Information ................................................................... 6

5.

Vessel Summary ................................................................................ 6

6.

Nozzle Schedule ................................................................................. 7

7.

Liquid Levels...................................................................................... 7

8.

Internal Details .................................................................................. 8

9.

8.1 CDS Inlet CycloneTM .................................................................... 8


8.2 Perforated Distribution Baffle(s) .................................................. 8
8.3 CDS Drained Meshpad AgglomeratorTM (Existing) ......................... 8
8.4 CDS SpiraflowTM (Existing) .......................................................... 8
8.5 Weir Plate (Existing) ................................................................... 8
8.6 Water Outlet Extension (Existing) ................................................ 9
8.7 Accessibility.............................................................................. 10
Process Guarantee ........................................................................... 11

10. Detailed Vessel Sizing Sheet ............................................................. 12

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1. Introduction
This document is intended to describe the process design for the HP Separators (MBD-1000/ 1010/
1020/ 1030).

2. Process Internals Overview


The following process internals have been selected in the process design for this vessel.

CDS Inlet CycloneTM (new) and associated supports


Full Diameter Perforated Distribution Baffle (new) and associated supports
Partial Diameter Perforated Distribution Baffle (existing)
CSD Drained Meshpad AgglomeratorTM (existing)
CDS SpiraflowTM (existing)
Weir Plate (existing)
Interface Bolting and Gaskets for new internals

Notes:
1.
2.
3.
4.

Material of construction: Type 316 / 316L 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.
5. All internals in FMC supply will be pickled and passivated.
6. All items in FMC supply will be made removable through the vessel manway.
Client scope of work

Installation of internals and associated supports


Preparation of vessel (removal of existing supports as per FMC demolition drawings)

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3. Process Description
Further details of the internals are given below:

3.1 CDS Inlet CycloneTM Inlet Device


Since its development in 1998, the CDS Inlet CycloneTM inlet device has been continually optimized
with the CFD and in-house testing. The cyclone is successfully applied in many projects and is the
first inlet cyclone technology used subsea. The inlet cyclone cluster is designed to have a wide
operating window; design, number and size of the cyclones depends on the process conditions.
The CDS Inlet CycloneTM absorbs the high inlet momentum of the incoming process stream
converting the inlet velocity into centrifugal force. The centrifugal force drives liquid and gas
separation within the cyclones. The separated liquid leaves the cyclone through the bottom section
submerged in the process liquid. The gas exits the cyclone through the top section. The cyclone is
designed for different gas-to-oil ratios with high flexibility in operating range.
The CDS Inlet CycloneTM is designed to minimize shear and break-up of liquid droplets.
Furthermore, pressure drops in the cyclones are balanced to prevent liquid carry over and gas
carry under. Liquid carry over from the cyclone should be avoided to prevent a too high liquid load
on the downstream demister; gas carry under should be avoided to prevent foam generation and
gas re-entrainment in the liquid phase.
In applications where foaming occurs, the CDS Inlet CycloneTM reduces foam generation as a result
of the applied centrifugal forces and high gas from liquid removal efficiency.
Key benefits:
Well established technology
Proven performance optimized by CFD
Robust design with mechanical strength verified by FEA
Resistant to fouling and blocking
Flexible operating envelope for all gas/liquid ratios
Effectively dissipates high inlet momentum
Low shear forces
Mitigation of foam generation
Improves separation performance of vessel

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3.2 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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4. Process Flow Information


The proposed design is based on the process data provided in document titled Exhibit A
Specification HPSI Package received on 2 January 2014.
Case 1

Case 2

Case 3

Case 4

1075.00
100.00

1075.00
100.00

1075.00
100.00

1075.00
100.00

225.0
17.2
3.12
0.014000

225.0
17.2
3.12
0.014000

225.0
17.2
3.12
0.013000

225.0
17.2
3.12
0.012000

1500.0
43.40
0.490

1500.0
43.40
0.490

1834.0
44.20
0.540

2205.3
44.80
0.580

250.0
63.20
0.850

250.0
63.20
0.850

306.4
63.20
0.850

368.3
63.20
0.850

Environment
Pressure (psig)
Temperature (F)
Gas
Flow rate (MMSCFD)
MW
Density (lb/ft)
Viscosity (cP)
Oil
Flow rate (bbl/d)
Density (lb/ft)
Viscosity (cP)
Water
Flow rate (bbl/d)
Density (lb/ft)
Viscosity (cP)

5. Vessel Summary
Number of vessels
Horizontal or Vertical
Vessel internal diameter (mm /ft)
Tan to Tan Length (mm/ ft)
Head type

Four (4)
Horizontal
2134 / 7
6198 / 20 4
Elliptical

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6. Nozzle Schedule
Location (mm/ ft)1
+ 965/ 3-2

+ 4776 / 15-8

Nozzle
A
B

Size ()/ID (mm)


12 / 289.05
12 / 289.05

4 / 97.28

4 / 97.28

+1575 / 5-2

Water Outlet

M1
M2

24/ 609.6
24 / 609.6

Downstream head

+ 2568 / 8-5

Manway
Manway

+ 4877 /

16-

Description
Inlet
Gas Outlet

Notes
Top Box
Gas Box (existing)

Oil Outlet

Vortex Breaker
(existing)
Water Outlet Extension
Vortex Breaker
(existing)

1. Location is taken from upstream tan line of vessel

7. Liquid Levels
Level
HHLL
HLL
NLL
LLL
LLLL
Weir
HIL
NIL
LIL
LLIL

Elevation1
(mm)
1016
914
813
762
610
610
457
381
178
102

1. From bottom of vessel

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8. Internal Details
8.1 CDS Inlet CycloneTM
Inlet Cyclone
Number of Cyclones
Cyclone Internal Diameter (mm)
Cyclone Bottom Elevation (mm)1
Distributor Box Centreline elevation (mm)1
Inlet Arrangement

Four (4)
500 / 150
245
1700
Top Box

1. Elevation is taken from bottom of vessel

8.2 Perforated Distribution Baffle(s)


Perforated Distribution Baffle(s)
Full or Part Diameter Baffle
Height of Part Diameter Baffle (mm)
Perforation (% Net Free Area)
Diameter holes (mm)
Location of baffle (mm)1
Type of baffle
Note

1.
2.

#1
Full
2134
36
30
1865 mm
Flat
New baffle

#2
Part
1116
21
30
2065 mm
Flat
Existing baffle to be
shifted downstream to
the new location2

Location is taken from upstream tan line of vessel


The existing baffle to be re-used with modification to allow for the water outlet extension pipe to pass through

8.3 CDS Drained Meshpad AgglomeratorTM (Existing)


Mesh Pad Agglomerator (Horizontal Vessel)
Existing (no modifications are required)

8.4 CDS SpiraflowTM (Existing)


Spiraflow 80 Cyclone Deck
Existing (no modifications are required)
1. Elevation is taken from bottom tan line of vessel

8.5 Weir Plate (Existing)


Weir Plate
Existing (no modifications are required)

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8.6 Water Outlet Extension (Existing)


Water Outlet Extension
Existing (no modifications are required)

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8.7 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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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 0.1 USG/MMSCF.

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10. Detailed Vessel Sizing Sheet


Case number : 1
Case title : Case 1
Including head volume : y
Process summary
Oil
Pressure =
1075.00 psig
Temperature =
100.0 F

Flow :
Density :
Viscosity :
Surface tension :

1500.0
43.40
0.490
20.00

Water
bbl/d
lb/ft
cP
dyne/cm

250.0
63.20
0.850
70.00

Gas
bbl/d
lb/ft
cP
dyne/cm

225.0 MMRft/d
3.12 lb/ft
0.014 cP

Vessel data
2 or 3 phase :
Internal diameter :
Tan to Tan length :
Hemi or 2:1 heads :
Split Flow? :
End or Central Inlet :
Maximum pitch :
Mist eliminator :
Cyclone or vane mist eliminator :
Vane type :
Sizing K factor :

3
2.134
6.198
E
N
C
0.00
Y
C
CDS 250
0.150

m/s

Minimum Tan to Tan Length :


Total vessel volume :
Bottom of cyclone elevation :
Max liquid level under cyclones :

4.230
24.70
1544
1016

m
m
mm
mm

m
m
(H/E)

(c/v)

Inlet Cyclone :
Mesh Agglomerator :
Mesh thickness :
Coalescer Plate Pack :
Plate Spacing :
Plate Angle :
Plate Length :
Weir Plate :
Tan to Weir Length :
Liquid separating length :
Gas separating length :

Y
Y
0.100
N
0.010
45
1.000
Y
4.305
4.198
4.198

Actual drainage head :


Required drainage head :
Mesh lower elevation :

528 mm
444 mm
1.016 m

m
m

m
m
m
m

Nozzle Table

Fluid Inlet
Mesh Coalescer
Spira-flow 80 cyclones
Gas Outlet
Oil Outlet
Water Outlet

N.B
(in)

I.D
(m)

Minimum I.D
(m)

Velocity
(m/s)

rho-v
(kg/ms)

Pressure drop
(mbar)

12

0.289

0.285

16.37
0.56

13950
16

21% NFA
12
4
4

0.289
0.097
0.097

0.310
0.051
0.021

16.32
0.37
0.06

13315

140
3
54
40

'K' value

0.157

Volume between
levels
(m)

Residence
time
(mins)

1.52
1.48
3.83
0.74
2.11
1.85

9.19
8.96
23.13
4.44
12.75
11.17

Liquid levels
Gas space above

HHLL

1.118
0.565

m
m/s

Level

Level
(m)

Vessel fill
(%)

HHLL
HLL
NLL
NLL
LLL
LLLL

1.016
0.914
0.813
0.813
0.762
0.610

47.6
42.8
38.1
38.1
35.7
28.6

Top of weir

0.610

28.6

1.32

47.74

HIL
NIL
NIL
LIL
LLIL

0.457
0.381
0.381
0.178
0.102

21.4
17.9
17.9
8.3
4.8

0.60
1.97
1.33
0.36
0.28

21.64
71.36
48.22
13.08
10.06

Axial velocity
(m/s)

0.003

0.001

Reynolds
Number

m/s

Interval
HLL to
NLL to
NLL to
LLL to
LLLL to
Liquid Outlet to

HHLL
HLL
NIL
NLL
LLL
LLLL

HIL to Top of weir


NIL to
BV to
LIL to
LLIL to
BV to

HIL
NIL
NIL
LIL
LLIL

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Case number : 2
Case title : Case 2
Including head volume : y
Process summary
Oil
Pressure =
1075.00 psig
Temperature =
100.0 F

Flow :
Density :
Viscosity :
Surface tension :

1500.0
43.40
0.490
20.00

Water
bbl/d
lb/ft
cP
dyne/cm

250.0
63.20
0.850
70.00

Gas
bbl/d
lb/ft
cP
dyne/cm

225.0 MMRft/d
3.12 lb/ft
0.014 cP

Vessel data
2 or 3 phase :
Internal diameter :
Tan to Tan length :
Hemi or 2:1 heads :
Split Flow? :
End or Central Inlet :
Maximum pitch :
Mist eliminator :
Cyclone or vane mist eliminator :
Vane type :
Sizing K factor :

3
2.134
6.198
E
N
C
0.00
Y
C
CDS 250
0.150

Minimum Tan to Tan Length :


Total vessel volume :
Bottom of cyclone elevation :
Max liquid level under cyclones :

4.230
24.70
1544
1016

m
m
(H/E)

(c/v)
m/s

Inlet Cyclone :
Mesh Agglomerator :
Mesh thickness :
Coalescer Plate Pack :
Plate Spacing :
Plate Angle :
Plate Length :
Weir Plate :
Tan to Weir Length :
Liquid separating length :
Gas separating length :

Y
Y
0.100
N
0.010
45
1.000
Y
4.305
4.198
4.198

Actual drainage head :


Required drainage head :
Mesh lower elevation :

528 mm
444 mm
1.016 m

m
m
mm
mm

m
m

m
m
m
m

Nozzle Table

Fluid Inlet
Mesh Coalescer
Spira-flow 80 cyclones
Gas Outlet
Oil Outlet
Water Outlet

N.B
(in)

I.D
(m)

Minimum I.D
(m)

Velocity
(m/s)

rho-v
(kg/ms)

Pressure drop
(mbar)

12

0.289

0.285

16.37
0.56

13950
16

21% NFA
12
4
4

0.289
0.097
0.097

0.310
0.051
0.021

16.32
0.37
0.06

13315

140
3
54
40

'K' value

0.157

Volume between
levels
(m)

Residence
time
(mins)

1.52
1.48
3.83
0.74
2.11
1.85

9.19
8.96
23.13
4.44
12.75
11.17

Liquid levels
Gas space above

HHLL

1.118
0.565

m
m/s

Level

Level
(m)

Vessel fill
(%)

HHLL
HLL
NLL
NLL
LLL
LLLL

1.016
0.914
0.813
0.813
0.762
0.610

47.6
42.8
38.1
38.1
35.7
28.6

Top of weir

0.610

28.6

1.32

47.74

HIL
NIL
NIL
LIL
LLIL

0.457
0.381
0.381
0.178
0.102

21.4
17.9
17.9
8.3
4.8

0.60
1.97
1.33
0.36
0.28

21.64
71.36
48.22
13.08
10.06

Axial velocity
(m/s)

0.003

0.001

Reynolds
Number

m/s

Interval
HLL to
NLL to
NLL to
LLL to
LLLL to
Liquid Outlet to

HHLL
HLL
NIL
NLL
LLL
LLLL

HIL to Top of weir


NIL to
BV to
LIL to
LLIL to
BV to

HIL
NIL
NIL
LIL
LLIL

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Case number : 3
Case title : Case 3
Including head volume : y
Process summary
Oil
Pressure =
1075.00 psig
Temperature =
100.0 F

Flow :
Density :
Viscosity :
Surface tension :

1834.0
44.20
0.540
20.00

Water
bbl/d
lb/ft
cP
dyne/cm

306.4
63.20
0.850
70.00

Gas
bbl/d
lb/ft
cP
dyne/cm

225.0 MMRft/d
3.12 lb/ft
0.013 cP

Vessel data
2 or 3 phase :
Internal diameter :
Tan to Tan length :
Hemi or 2:1 heads :
Split Flow? :
End or Central Inlet :
Maximum pitch :
Mist eliminator :
Cyclone or vane mist eliminator :
Vane type :
Sizing K factor :

3
2.134
6.198
E
N
C
0.00
Y
C
CDS 250
0.150

m/s

Minimum Tan to Tan Length :


Total vessel volume :
Bottom of cyclone elevation :
Max liquid level under cyclones :

4.230
24.70
1544
1016

m
m
mm
mm

m
m
(H/E)

(c/v)

Inlet Cyclone :
Mesh Agglomerator :
Mesh thickness :
Coalescer Plate Pack :
Plate Spacing :
Plate Angle :
Plate Length :
Weir Plate :
Tan to Weir Length :
Liquid separating length :
Gas separating length :

Y
Y
0.100
N
0.010
45
1.000
Y
4.305
4.198
4.198

Actual drainage head :


Required drainage head :
Mesh lower elevation :

528 mm
438 mm
1.016 m

m
m

m
m
m
m

Nozzle Table

Fluid Inlet
Mesh Coalescer
Spira-flow 80 cyclones
Gas Outlet
Oil Outlet
Water Outlet

N.B
(in)

I.D
(m)

Minimum I.D
(m)

Velocity
(m/s)

rho-v
(kg/ms)

Pressure drop
(mbar)

12

0.289

0.285

16.38
0.56

14103
16

21% NFA
12
4
4

0.289
0.097
0.097

0.310
0.051
0.021

16.32
0.45
0.08

13315

141
3
54
40

'K' value

0.156

Volume between
levels
(m)

Residence
time
(mins)

1.52
1.48
3.83
0.74
2.11
1.85

7.52
7.33
18.92
3.63
10.43
9.13

Liquid levels
Gas space above

HHLL

1.118
0.565

m
m/s

Level

Level
(m)

Vessel fill
(%)

HHLL
HLL
NLL
NLL
LLL
LLLL

1.016
0.914
0.813
0.813
0.762
0.610

47.6
42.8
38.1
38.1
35.7
28.6

Top of weir

0.610

28.6

1.32

38.95

HIL
NIL
NIL
LIL
LLIL

0.457
0.381
0.381
0.178
0.102

21.4
17.9
17.9
8.3
4.8

0.60
1.97
1.33
0.36
0.28

17.65
58.22
39.34
10.67
8.21

Axial velocity
(m/s)

0.004

0.001

Reynolds
Number

m/s

Interval
HLL to
NLL to
NLL to
LLL to
LLLL to
Liquid Outlet to

HHLL
HLL
NIL
NLL
LLL
LLLL

HIL to Top of weir


NIL to
BV to
LIL to
LLIL to
BV to

HIL
NIL
NIL
LIL
LLIL

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Case number : 4
Case title : Case 4
Including head volume : y
Process summary
Oil
Pressure =
1075.00 psig
Temperature =
100.0 F

Flow :
Density :
Viscosity :
Surface tension :

2205.3
44.80
0.580
20.00

Water
bbl/d
lb/ft
cP
dyne/cm

368.3
63.20
0.850
70.00

Gas
bbl/d
lb/ft
cP
dyne/cm

225.0 MMRft/d
3.12 lb/ft
0.012 cP

Vessel data
2 or 3 phase :
Internal diameter :
Tan to Tan length :
Hemi or 2:1 heads :
Split Flow? :
End or Central Inlet :
Maximum pitch :
Mist eliminator :
Cyclone or vane mist eliminator :
Vane type :
Sizing K factor :

3
2.134
6.198
E
N
C
0.00
Y
C
CDS 250
0.150

m/s

Minimum Tan to Tan Length :


Total vessel volume :
Bottom of cyclone elevation :
Max liquid level under cyclones :

4.230
24.70
1544
1016

m
m
mm
mm

m
m
(H/E)

(c/v)

Inlet Cyclone :
Mesh Agglomerator :
Mesh thickness :
Coalescer Plate Pack :
Plate Spacing :
Plate Angle :
Plate Length :
Weir Plate :
Tan to Weir Length :
Liquid separating length :
Gas separating length :

Y
Y
0.100
N
0.010
45
1.000
Y
4.305
4.198
4.198

Actual drainage head :


Required drainage head :
Mesh lower elevation :

528 mm
434 mm
1.016 m

m
m

m
m
m
m

Nozzle Table

Fluid Inlet
Mesh Coalescer
Spira-flow 80 cyclones
Gas Outlet
Oil Outlet
Water Outlet

N.B
(in)

I.D
(m)

Minimum I.D
(m)

Velocity
(m/s)

rho-v
(kg/ms)

Pressure drop
(mbar)

12

0.289

0.285

16.39
0.56

14273
16

21% NFA
12
4
4

0.289
0.097
0.097

0.310
0.051
0.021

16.32
0.55
0.09

13315

143
3
54
40

'K' value

0.155

Volume between
levels
(m)

Residence
time
(mins)

1.52
1.48
3.83
0.74
2.11
1.85

6.25
6.10
15.73
3.02
8.67
7.59

Liquid levels
Gas space above

HHLL

1.118
0.565

m
m/s

Level

Level
(m)

Vessel fill
(%)

HHLL
HLL
NLL
NLL
LLL
LLLL

1.016
0.914
0.813
0.813
0.762
0.610

47.6
42.8
38.1
38.1
35.7
28.6

Top of weir

0.610

28.6

1.32

32.40

HIL
NIL
NIL
LIL
LLIL

0.457
0.381
0.381
0.178
0.102

21.4
17.9
17.9
8.3
4.8

0.60
1.97
1.33
0.36
0.28

14.69
48.44
32.73
8.88
6.83

Axial velocity
(m/s)

0.005

0.002

Reynolds
Number

m/s

Interval
HLL to
NLL to
NLL to
LLL to
LLLL to
Liquid Outlet to

HHLL
HLL
NIL
NLL
LLL
LLLL

HIL to Top of weir


NIL to
BV to
LIL to
LLIL to
BV to

HIL
NIL
NIL
LIL
LLIL

Page 15 of 15

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