Introduction to CDS

•Introduction to CDS
•Products and Services
üSeparator Design
üInlet Devices
üMist Eliminators
üSand Jet Systems
üInline Degasser and Deliquidizer
üCFD Modeling (Computational Fluid Dynamics)
•New Technologies from R&D
üHydrocyclones
•Applications

Separation/Mass Transfer/Heat Transfer

 CDS Norge
20% of Turnover on R&D
Parent Company

CDS Engineering •New Hardware

CDS Separation •Improve Existing
Technologies CDS Abu Dhabi

CDS Engineering
Asia Pacific

Separation/Mass Transfer/Heat Transfer

CDS Known by the company we keep

BP Husky Energy Petrobras

British Gas Korea National PDVSA
ChevronTexaco Oil
Qatar
CNOOC Lukoil
Shell
ConocoPhillips Ludin
Statoil
EnCana Norsk Hydro
Unocal
ExxonMobil Pemex
Woodside

For the complete list, browse our CD for the

Hardware Reference List, and Design Study Reference

Separation/Mass Transfer/Heat Transfer

 CDS Known by the company we keep
BP Holstein, Marlin, Schiehallion, Thunderhorse, Vallhal British Gas
ChevronTexaco Benchamas, Sanha Condensate CNOOC Penglai
ConocoPhillips Bayu Undan, Belanak, Ekofisk, Magnolia, West Natuna
EnCana Terra Nova ExxonMobil DianaHoover, Hibernia, Kizomba,
Sable Husky Energy White Rose Korea National Oil Donghae
Lukoil (Russia) Karachaganak Lundin Norsk Hydro VigDis
Pemex Dos Bocas Petrobras P-35 PDVSA Qatar Al Shaheen
Shell Auger, Bonga, Cawthorne, Enchalada, Malampaya, Nakika, Salsa
Statoil Asgard, Gullfacs, Kristin, Sleipner, Statfjord Unocal North Pailin
Woodside Goodwin
The Hardware Reference List, and Design Study Reference are on our CD

Separation/Mass Transfer/Heat Transfer

 Introduction
Hardware

1 Internals (2/3 phase separators, contactors)

2 Complete separators

Process services

3 Design
4 Computational fluid dynamics modelling (CFD)
5 Debottlenecking

Separation/Mass Transfer/Heat Transfer

 Separator de-bottlenecking
4 Step Process

1. Separator diagnosis: Rad. tracer, gamma scan

2. Analysis / evaluation: Simulation tools (CFD & G/L
& L/L interface modelling)
3. Upgrade strategy: Selection of retrofit internals -
possibly development of new
internals
4. Installation: Ensure installation is possible
(through manway, no welding
required etc.)

Separation/Mass Transfer/Heat Transfer

 Computational Fluid Dynamics
Design and Troubleshooting

Cyclones

Horizontal
Flowing Vane
Packs Mesh
Pad

Evenflow
Half Pipe vane inlet
Inlet
Excellent
Separation
Poor Performance
Separation
Performance

Separation/Mass Transfer/Heat Transfer

Separator Design
3. Outlet
1. Inlet 2. Gravity

? ? ?

•Lower Velocities •Separate large drops

•Bulk Gas/Liquid •Coalesce small drops
Separation •Small Drop Removal
•Break Foam
•Straighten Out the Flows •Prevent Short Circuiting
•Break Foam
•Prevent Short Circuiting
•Prevent Drop Shatter
•Prevent Foam

Separation/Mass Transfer/Heat Transfer

 Separation Devices

Demisters
Inlet Cyclones Evenflow HE

SolidsRemoval Deliquidiser

Perforated Baffle
Degasser

Separation/Mass Transfer/Heat Transfer

 Inlet Devices – Application
Why Use Inlet Devices?
Reverse Vane
Impact Pipe Cyclones
Open Pipe Plates Spreader

Increasing Flow Rates

Leads to More Problems

Short Circuiting – Droplet Shatter - Foam

Separation/Mass Transfer/Heat Transfer

 Evenflow HE
•High Inlet Momentum
•Bulk Gas/Liquid Separation
•Flow Distribution in Vertical Vessels

Separation/Mass Transfer/Heat Transfer

 CDS Inlet Cyclones

•High inlet momentum

•De-foaming characteristics
•Liquid-liquid coalescing
•Bulk Gas-Liquid Separation

Separation/Mass Transfer/Heat Transfer

Stationary turbine blades, not
tangential inlet providing spin,
Inlet Cyclones
resulting in lower shear

CFD used in design to

compare to
measurements

Separation/Mass Transfer/Heat Transfer

 800 mm Inlet Cyclones 300 mm

Replaced competitor’s
6 cyclones

Separation/Mass Transfer/Heat Transfer

 Inlet Cyclones

Sub Sea Separator

Pre-separator for multi-phase meter

Inlet for vessel

design for floater

Gasunie Scrubber

Separation/Mass Transfer/Heat Transfer

 Mist Eliminators
Why Use Demisters?
Empty Mesh Vanes Cyclones

No
Pocket

Single

Gravity Pocket
Impact
Coalescense Coalescense Centrifugal
Gravity Impact
Double
Pocket Coalescense

Increasing Flow Rates Leads to More Entrainment and Smaller Drops

Separation/Mass Transfer/Heat Transfer

 Selecting a Demister

Drop Size Gas Rate DP Fouling

Removal
Large ~150 microns Low Low Low

Small ~10 microns Medium Low High

Medium ~40 microns High Low Low

Small ~10 microns Highest High Low

Separation/Mass Transfer/Heat Transfer

 Restrictions of vane packs

Principle of operation / vane type demister:

Vd
Fc Vg
, lo
Fd ca
l

R
Vg

G/L PHENOMENA IN VANE DEMISTER

Separation/Mass Transfer/Heat Transfer

 Operating envelope vane packs

Principle of operation / vane type demister:

5
v max
V 4
(m/s) v min (20 microns)

3 v min (35 microns)

v min (70 microns)
2

0
1 10 100
gas density (kg/m3)

Separation/Mass Transfer/Heat Transfer

 Operating envelope Spira-flow

Principle of operation / Spiraflow cyclone :

250
Throughput / cyclone (Am3/hr)

200

v max
150
v min (12 micr)
v min (15 micr)
100
v min (20 micr)

50

0
1 10 100
gas density (kg/m3)

Separation/Mass Transfer/Heat Transfer

 Results of High Pressure Testing
Efficiency Comparison of the Vane Pack and the 1st and 2nd
Generation Axial Flow Cyclone at 38 barg
100.0

95.0
2nd
Generation
90.0 Cyclone
Efficiency [%]

85.0

1st Generation
Cyclone
80.0
Vane Pack
75.0

70.0
Liquid was TEG
65.0
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0

Flow Index

Separation/Mass Transfer/Heat Transfer

Spira-Flow Demisting Cyclones

•Small Drop Removal Efficiency at High Pressures

•Higher capacity
•More compact vessels
•Greater flexibility in upgrading existing vessels
•Scrubber Example
•(100 MMSCFD, 600 psig, 40 kg/m3 gas, 550 kg/m3 liquid)
•Mesh 1.6 m ID
•Vanes 1.3 m ID
•Cyclones 1.1 m ID or 0.7 m ID with body flange

Separation/Mass Transfer/Heat Transfer

 Types of Cyclones

Reverse flow Non recycle axial Spira-Flow

flow 2nd Generation Recycle
Axial Flow Cyclone
1st Generation Axial
Flow Cyclone

Separation/Mass Transfer/Heat Transfer

 Spira-flow cyclone
Track record:
Approx. 450 references in separator revamp / upgrade
applications and/or downsized separator designs.

Separation/Mass Transfer/Heat Transfer

 Demisting cyclone
Types of applications:
x

Downhole

Separation/Mass Transfer/Heat Transfer

 CDS Sand Removal System For Production Separators

CDS Sand Jetting Technology:

• Based on extensive R&D

and testing
• Studies on design and operation
• Defined procedure for designing systems
• Method is well proven and widely used

Separation/Mass Transfer/Heat Transfer

 CDS Sand Removal System For Production Separators

Design procedure was developed with special

consideration of the following factors:

• Efficient sand removal

• Minimum use of wash water
• Minimum mixing of the solids and fluids
within the vessel
• Wash time to be kept as low as possible
• Minimum abrasion of the vessel wall and lining
• Minimum number of vessel penetrations
• Keep the system simple, reliable and safe

Separation/Mass Transfer/Heat Transfer

 CDS Sand Removal System For Production Separators

Important factors in designing

the jet water system for optimum
distribution of the jet water flux
• Optimum number of nozzles
• Optimum nozzle spacing
• Optimum nozzle type including spray angle and orientation
• Sufficient size wash jets to penetrate next tier or centre line
• Spaced sufficiently close together to interact laterally

Separation/Mass Transfer/Heat Transfer

 CDS Sand Removal System For Production Separators

CDS Sand Jetting

• The CDS system is based on
extensive research and experience
• Critical Factors are defined
and considered in the design
• Engineered to vessel and
process conditions
• Experience proven

Separation/Mass Transfer/Heat Transfer

 Inline Bulk Degasser
Remove Gas
Outside of Pipe

Stationary Stationary
turbine with turbine
opposite spin

Developed by CDS & Statoil - patented by Statoil

Separation/Mass Transfer/Heat Transfer

 18” Degasser
(Factory Acceptance Test)
380,000 BPD
3.5 MMSCFD
Gas-fraction: up to 50%
Efficiency: > 90%
Turndown: 40%

Separation/Mass Transfer/Heat Transfer

 Sleipner 14” deliquidiser

Gas: 200 mmscfd Operating Press: 800 psi

Liquid: 4,500 bpd Max Press drop: 8 psi

Separation/Mass Transfer/Heat Transfer

 Axial hydrocyclone for L/L separation
Prototype testing: In Development

Will be
Axial inlet offered as
liners
flow

Development objective:
Stationary turbine - high capacity
creates spin, not
tangential inlet
- wide O/W range,
- variable O/W range

Separation/Mass Transfer/Heat Transfer

 Applications
ØCFD (Sloshing)
ØDebottlenecking
ØFoaming (Inlet and outlet cyclones)
ØLiquid-liquid separation (Inlet cyclones)
ØCarryover (External demisting cyclones)
ØVibrations (Inline degasser)
ØTwo to Three Phase Separator Conversion

Separation/Mass Transfer/Heat Transfer

 Applications

CFD – Slosh Mitigation

Client Original
Design

CDS Final Design

Separation/Mass Transfer/Heat Transfer

 Applications
ØCFD (Scrubber Design, Carryover, and Sloshing)

ØDebottlenecking
ØFoaming (Inlet and outlet cyclones)
ØLiquid-liquid separation (Inlet cyclones)
ØCarryover (External demisting cyclones)
ØVibrations (Inline degasser)
ØTwo to Three Phase Separator Conversion

Separation/Mass Transfer/Heat Transfer

 System de-bottlenecking/Optimization

Example:
Tie-in of satellite field requires 60% increase of gas
processing capacity: possible with existing vessels ?

YES, Main actions:

• 1 st separator
New internals
• Dehydrator scrubber
New internals
• Glycol contactor
New high cap. cyclonic trays
New mist-elimination internals

Separation/Mass Transfer/Heat Transfer

 Applications
ØCFD (Scrubber Design, Carryover, and Sloshing)
ØDebottlenecking

ØFoaming (Inlet and outlet cyclones)

ØLiquid-liquid separation (Inlet cyclones)
ØCarryover (External demisting cyclones)
ØVibrations (Inline degasser)
ØTwo to Three Phase Separator Conversion

Separation/Mass Transfer/Heat Transfer

 Foaming
HP Header 2nd Stage FGC 1st Stage FGC

HP IP FWKO
Wells

2nd Stage VRU

Degas BOT Sales

Separation/Mass Transfer/Heat Transfer

 Foaming Problem

• Liquid Carryover: metering, flooding, asphaltene deposits

• Gas Carryunder: metering,compression capacity
• Level Control

• 2-Phase Separator with 1Min. Retention Time

• Competitors Inlet Cyclones & Vane Packs
• Requires High Chemical Defoamer Rates

• Cost for 150,000 BOPD ⇒ 2.9 MM$/year

Separation/Mass Transfer/Heat Transfer

 Foaming

Separation/Mass Transfer/Heat Transfer

 Foaming

Solution: Upgrade 4 Vessels

• CDS Hi G Inlet cyclones

• CDS Spiraflow demisting cyclones
• Reduce Chemical Defoamer by 50 %

• 1.5 MM$ Savings per year

Separation/Mass Transfer/Heat Transfer

 Applications
ØCFD (Scrubber Design, Carryover, and Sloshing)
ØDebottlenecking
ØFoaming (Inlet and outlet cyclones)

ØLiquid-liquid separation (Inlet cyclones)

ØCarryover (External demisting cyclones)
ØVibrations (Inline degasser)
ØTwo to Three Phase Separator Conversion

Separation/Mass Transfer/Heat Transfer

 Applications

Liquid-Liquid Separation

•North Sea Platform

•High inlet momentums
•Deflector plate in Test Separator
•Pall Ring box in Production Separator
•Test: 10-15% BS&W, 200 PPM+ O in W
Client desire
•Prod: 20%, 400 PPM+ O in W to improve

Separation/Mass Transfer/Heat Transfer

 Applications

CDS Results: Test Separator Design Competition

100
14 Upset 90
Deflector
12 80

Oil-in-Water [ppm]
70
10
% water in oil

60
8
50
Upset Overboard Limit
6 40

30
4
20
2
Inlet Cyclone 10

0 0
5000 15000 25000 35000 45000 55000 65000

Inlet momentum [kg/ms²]

Separation/Mass Transfer/Heat Transfer

 Applications

Liquid-Liquid Separation
Bottom Line
Test: 10-15% BS&W => 6%
200 ppm O-in-W => 20 ppm
(Selected over competitor to upgrade production vessel)
Prod: 20% BS&W => 6%
400ppm+ O-in-W => less than 200 ppm

Separation/Mass Transfer/Heat Transfer

 Inlet Cyclones

Results attributed to
low shear design
especially in liquid
outlet

Separation/Mass Transfer/Heat Transfer

 Applications
ØCFD (Scrubber Design, Carryover, and Sloshing)
ØDebottlenecking
ØFoaming (Inlet and outlet cyclones)
ØLiquid-liquid separation (Inlet cyclones)

ØCarryover (External demisting cyclones)

ØVibrations (Inline degasser)
ØTwo to Three Phase Separator Conversion

Separation/Mass Transfer/Heat Transfer

 Applications

Liquid Carryover

Scrubber

17 mile tie
back 2-phase
Subsea separator

Separation/Mass Transfer/Heat Transfer

 Applications

Liquid Carryover

Original Design:
HP Vessel: 59” ID x 20’ SS
Inlet: 8 10” Basic Inlet Cyclone tubes
Outlet: Vane Pack

Separation/Mass Transfer/Heat Transfer

 Applications

Liquid Carryover

•Well Startup => Carryover => Flooding

•Long startup times ~ 10 hours
•Higher Gas Capacity Also Desired
•Problem: Small Vessels; retrofit impossible internally

Separation/Mass Transfer/Heat Transfer

 Applications
Liquid Carryover

•Solution: External inline demister

External inline mist
eliminator

Well Startup
reduced from 10
to 2 hrs

Liquid drain fed

downstream of dump valve

Separation/Mass Transfer/Heat Transfer

 Applications

Liquid Carryover

Separation/Mass Transfer/Heat Transfer

 Applications
ØCFD (Scrubber Design, Carryover, and Sloshing)
ØDebottlenecking
ØFoaming (Inlet and outlet cyclones)
ØLiquid-liquid separation (Inlet cyclones)
ØCarryover (External demisting cyclones)

ØVibrations (Inline degasser)

ØTwo to Three Phase Separator Conversion

Separation/Mass Transfer/Heat Transfer

 Applications

Vibrations

Flow to
Vibration degassing drum

found in this 20 m
line

Flow from
hydrocyclones

Gas evolving due to

pressure drop causing
slugging
Separation/Mass Transfer/Heat Transfer
 Applications

Vibrations
Bulk Degasser - Solution

Flow to
Client 1. Flare 2. Recompression
degassing drum

qualified, 20 m
Gas outlet
installation line

this quarter Water flow

50,000 m³/d

GWR = 1 to 2
Flow from
hydrocyclones Degasser
Cyclone

Separation/Mass Transfer/Heat Transfer

 Applications
ØCFD (Carryover, and Sloshing)
ØDebottlenecking
ØFoaming (Inlet and outlet cyclones)
ØLiquid-liquid separation (Inlet cyclones)
ØCarryover (External demisting cyclones)
ØVibrations (Inline degasser)

ØTwo to Three Phase Separator Conversion

Separation/Mass Transfer/Heat Transfer

 System De-bottlenecking/Optimization
Example: Modification of 2/3-Phase to 3-Phase

Normal Liquid Level

New water
Raise Weir nozzle in
Inlet Diverter manway so no
vessel work

Normal Liquid Level

Normal Interface Level

Perforated
Distribution
Baffles

Separation/Mass Transfer/Heat Transfer

 System De-bottlenecking/Optimization
Example: Planned Modification of Slug Catcher (2-phase) to 3-Phase

Normal Liquid Level

Inlet Diverter

Perforated Plate packs

Distribution Standpipe
Baffles

Separation/Mass Transfer/Heat Transfer

 CDS Information: CD contents
Hardware References
BP US Holstein Vessel sizing and motion studies Production separators 2001
Shell E&P US Auger Modelling of inlet flow Flare scrubber 2001
Shell E&P US Nakika Vessel Sizing and motion studies Production vessels 2000
Phillips US Trinidad Atlantic LNG Modelling of inlet flow Heavies Removal Column 2000
Class: Class presentation Phillips US
Shell E&P US
Tyonek
Ursa
Modelling of new inlet flow
Vessel capacities
Production and test separators
HP and IP separators
1999
1999
Statoil, Sleipner T Modelling and design Inlet Separator Inlet Cyclones 2000
Norway
Info Pack: General information, optimization/de-bottlenecking, hardware, R&D, design philosophy.
Statoil,
Norway
Sleipner T Modelling and design Gycol Filter Coalescer 2000

Statoil, Sleipner T Modelling and design Expander Outlet Separator 2000

Norway
AFS 2000 Cyclone Tech Paper: Cyclonic internals/applications
UMOE,
Norway
Gullfaks C Modelling instrument protection KO Drum 1999

Statoil, Gullfaks C Motion analysis Flare Drum 1999

Norway
AFS 2001 Scrubber Design Paper: Design of cyclonic internals and scrubbers using CFD
Statoil,
Norway
Gullfaks C Modelling distribution chamber Glycol Contactor 1999

Statoil, Gullfaks C Modelling Dehydration Scrubber 1999

Norway
AFS 2002 Gasunie Scrubber Paper: Description and design of cyclonic scrubber
Statoil,
Norway
Gullfaks C Modelling and design Inlet Separator 1999

Statoil, Sleipner A Modelling performance Scrubber 1999

Norway

SPE 1999 Mars Retrofit Paper: Retrofits on Mars TLP resulting in 50% defoamer reduction
Statoil,
Norway
Statfjord C Modelling performance Inlet Separator CD2001 1999

Statoil, Sleipner T Troubleshooting Scrubber 1999

Norway

SPE 2002 New Technology paper: Cyclonic internals, inline separation, CFD/applications
CDS Engineering BV Sonsbeekweg 26 For our Oslo and Houston
Inlet Cyclones: Technical presentation about inlet cyclones
Fax (int +) 31 26 3531719
Tel (int +) 31 26 3531700
6814 BC Arnhem
The Netherlands
based offices please
contact CDS Engineering

Presentation: General introduction to CDS products and services Certificate No: 652134

Photos of Internals: Various pictures of internals

Video Clips: CFD Sloshing movies showing benefits of baffles, difference between half pipe/ vane type inlet.
Input Form: Data input form.
Spanish Brochure: CDS Brochure in Spanish
Separation/Mass Transfer/Heat Transfer
References: Hardware Reference List., Design Studies