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 Prepared Checked / Approved

By Date By Date

1 First Issue for Approval PS 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 Bibiyana Gas Plant
End User Chevron Bangladesh

Client Document Number FMC Document Number FMC Project No. Rev. No. No. of Pages
- P12-11007-PDC P12-11007 1 15

Standard Document Code: CWF-2.11

Revision Date: 02-Feb-2012
 FMC Project No.: P12-11007
FMC Doc. No. : P12-11007-PDC
Revision : 1

Table of Contents

1. Introduction ...................................................................................... 3

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

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

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

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

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

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

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

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

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
9. 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. Material of construction: Type 316 / 316L stainless steel.

2. Material of gaskets: Expanded PTFE.
3. No welding to the vessel wall is permitted for the installation of the internals.
4. 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

Environment

Pressure (psig) 1075.00 1075.00 1075.00 1075.00

Temperature (°F) 100.00 100.00 100.00 100.00

Gas

Flow rate (MMSCFD) 225.0 225.0 225.0 225.0

MW 17.2 17.2 17.2 17.2
Density (lb/ft³) 3.12 3.12 3.12 3.12
Viscosity (cP) 0.014000 0.014000 0.013000 0.012000

Oil

Flow rate (bbl/d) 1500.0 1500.0 1834.0 2205.3

Density (lb/ft³) 43.40 43.40 44.20 44.80
Viscosity (cP) 0.490 0.490 0.540 0.580

Water

Flow rate (bbl/d) 250.0 250.0 306.4 368.3

Density (lb/ft³) 63.20 63.20 63.20 63.20
Viscosity (cP) 0.850 0.850 0.850 0.850

5. Vessel Summary

Number of vessels Four (4)

Horizontal or Vertical Horizontal
Vessel internal diameter (mm /ft) 2134 / 7’
Tan to Tan Length (mm/ ft) 6198 / 20’ – 4”
Head type Elliptical

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6. Nozzle Schedule

Nozzle Size (“)/ID (mm) Location (mm/ ft)1 Description Notes

A 12” / 289.05 + 965/ 3’-2” Inlet Top Box
ଵ
B 12” / 289.05 + 4776 / 15’-8 ” Gas Outlet Gas Box (existing)
ଷଶ
ଵ
C 4” / 97.28 + 4877 / 16’-ଷଶ” Oil Outlet Vortex Breaker
(existing)
D 4” / 97.28 +1575 / 5’-2” Water Outlet Water Outlet Extension
Vortex Breaker
(existing)
M1 24”/ 609.6 Downstream head Manway
ଷ
M2 24” / 609.6 + 2568 / 8’-5ଷଶ” Manway
1. Location is taken from upstream tan line of vessel

7. Liquid Levels

Level Elevation1
(mm)
HHLL 1016
HLL 914
NLL 813
LLL 762
LLLL 610
Weir 610
HIL 457
NIL 381
LIL 178
LLIL 102
1. From bottom of vessel

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8. Internal Details

8.1 CDS Inlet CycloneTM

Inlet Cyclone
Number of Cyclones Four (4)
Cyclone Internal Diameter (mm) 500 / 150
Cyclone Bottom Elevation (mm)1 245
Distributor Box Centreline elevation (mm)1 1700
Inlet Arrangement Top Box
1. Elevation is taken from bottom of vessel

8.2 Perforated Distribution Baffle(s)

Perforated Distribution Baffle(s) #1 #2

Full or Part Diameter Baffle Full Part
Height of Part Diameter Baffle (mm) 2134 1116
Perforation (% Net Free Area) 36 21
Diameter holes (mm) 30 30
Location of baffle (mm)1 1865 mm 2065 mm
Type of baffle Flat Flat
Note New baffle Existing baffle to be
shifted downstream to
the new location2
1.
Location is taken from upstream tan line of vessel
2.
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 Water Gas
Pressure =
1075.00 psig Flow : 1500.0 bbl/d 250.0 bbl/d 225.0 MMRft³/d
Temperature = Density : 43.40 lb/ft³ 63.20 lb/ft³ 3.12 lb/ft³
100.0 °F Viscosity : 0.490 cP 0.850 cP 0.014 cP
Surface tension : 20.00 dyne/cm 70.00 dyne/cm

Vessel data

2 or 3 phase : 3 Inlet Cyclone : Y

Internal diameter : 2.134 m Mesh Agglomerator : Y
Tan to Tan length : 6.198 m Mesh thickness : 0.100 m
Hemi or 2:1 heads : E (H/E) Coalescer Plate Pack : N
Split Flow? : N Plate Spacing : 0.010 m
End or Central Inlet : C Plate Angle : 45 °
Maximum pitch : 0.00 ° Plate Length : 1.000 m
Mist eliminator : Y Weir Plate : Y
Cyclone or vane mist eliminator : C (c/v) Tan to Weir Length : 4.305 m
Vane type : CDS 250 Liquid separating length : 4.198 m
Sizing K factor : 0.150 m/s Gas separating length : 4.198 m

Minimum Tan to Tan Length : 4.230 m Actual drainage head : 528 mm

Total vessel volume : 24.70 m³ Required drainage head : 444 mm
Bottom of cyclone elevation : 1544 mm Mesh lower elevation : 1.016 m
Max liquid level under cyclones : 1016 mm

Nozzle Table
N.B I.D Minimum I.D Velocity rho-v² Pressure drop
(in) (m) (m) (m/s) (kg/ms²) (mbar)

Fluid Inlet 12 0.289 0.285 16.37 13950 140

Mesh Coalescer 0.56 16 3
Spira-flow 80 cyclones 21% NFA 54
Gas Outlet 12 0.289 0.310 16.32 13315 40
Oil Outlet 4 0.097 0.051 0.37
Water Outlet 4 0.097 0.021 0.06

Liquid levels

Gas space above HHLL 1.118 m 'K' value 0.157 m/s

0.565 m/s
Volume between Residence
Level Level Vessel fill Axial velocity Reynolds levels time Interval
(m) (%) (m/s) Number (m³) (mins)

HHLL 1.016 47.6 1.52 9.19 HLL to HHLL

HLL 0.914 42.8 1.48 8.96 NLL to HLL
NLL 0.813 38.1 0.003 3.83 23.13 NLL to NIL
NLL 0.813 38.1 0.74 4.44 LLL to NLL
LLL 0.762 35.7 2.11 12.75 LLLL to LLL
LLLL 0.610 28.6 1.85 11.17 Liquid Outlet to LLLL
Top of weir 0.610 28.6 1.32 47.74 HIL to Top of weir
HIL 0.457 21.4 0.60 21.64 NIL to HIL
NIL 0.381 17.9 0.001 1.97 71.36 BV to NIL
NIL 0.381 17.9 1.33 48.22 LIL to NIL
LIL 0.178 8.3 0.36 13.08 LLIL to LIL
LLIL 0.102 4.8 0.28 10.06 BV to LLIL

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Case number : 2
Case title : Case 2
Including head volume : y

Process summary
Oil Water Gas
Pressure =
1075.00 psig Flow : 1500.0 bbl/d 250.0 bbl/d 225.0 MMRft³/d
Temperature = Density : 43.40 lb/ft³ 63.20 lb/ft³ 3.12 lb/ft³
100.0 °F Viscosity : 0.490 cP 0.850 cP 0.014 cP
Surface tension : 20.00 dyne/cm 70.00 dyne/cm
Vessel data

2 or 3 phase : 3 Inlet Cyclone : Y

Internal diameter : 2.134 m Mesh Agglomerator : Y
Tan to Tan length : 6.198 m Mesh thickness : 0.100 m
Hemi or 2:1 heads : E (H/E) Coalescer Plate Pack : N
Split Flow? : N Plate Spacing : 0.010 m
End or Central Inlet : C Plate Angle : 45 °
Maximum pitch : 0.00 ° Plate Length : 1.000 m
Mist eliminator : Y Weir Plate : Y
Cyclone or vane mist eliminator : C (c/v) Tan to Weir Length : 4.305 m
Vane type : CDS 250 Liquid separating length : 4.198 m
Sizing K factor : 0.150 m/s Gas separating length : 4.198 m

Minimum Tan to Tan Length : 4.230 m Actual drainage head : 528 mm

Total vessel volume : 24.70 m³ Required drainage head : 444 mm
Bottom of cyclone elevation : 1544 mm Mesh lower elevation : 1.016 m
Max liquid level under cyclones : 1016 mm

Nozzle Table
N.B I.D Minimum I.D Velocity rho-v² Pressure drop
(in) (m) (m) (m/s) (kg/ms²) (mbar)

Fluid Inlet 12 0.289 0.285 16.37 13950 140

Mesh Coalescer 0.56 16 3
Spira-flow 80 cyclones 21% NFA 54
Gas Outlet 12 0.289 0.310 16.32 13315 40
Oil Outlet 4 0.097 0.051 0.37
Water Outlet 4 0.097 0.021 0.06

Liquid levels

Gas space above HHLL 1.118 m 'K' value 0.157 m/s

0.565 m/s
Volume between Residence
Level Level Vessel fill Axial velocity Reynolds levels time Interval
(m) (%) (m/s) Number (m³) (mins)

HHLL 1.016 47.6 1.52 9.19 HLL to HHLL

HLL 0.914 42.8 1.48 8.96 NLL to HLL
NLL 0.813 38.1 0.003 3.83 23.13 NLL to NIL
NLL 0.813 38.1 0.74 4.44 LLL to NLL
LLL 0.762 35.7 2.11 12.75 LLLL to LLL
LLLL 0.610 28.6 1.85 11.17 Liquid Outlet to LLLL
Top of weir 0.610 28.6 1.32 47.74 HIL to Top of weir
HIL 0.457 21.4 0.60 21.64 NIL to HIL
NIL 0.381 17.9 0.001 1.97 71.36 BV to NIL
NIL 0.381 17.9 1.33 48.22 LIL to NIL
LIL 0.178 8.3 0.36 13.08 LLIL to LIL
LLIL 0.102 4.8 0.28 10.06 BV to LLIL

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Case number : 3
Case title : Case 3
Including head volume : y

Process summary
Oil Water Gas
Pressure =
1075.00 psig Flow : 1834.0 bbl/d 306.4 bbl/d 225.0 MMRft³/d
Temperature = Density : 44.20 lb/ft³ 63.20 lb/ft³ 3.12 lb/ft³
100.0 °F Viscosity : 0.540 cP 0.850 cP 0.013 cP
Surface tension : 20.00 dyne/cm 70.00 dyne/cm

Vessel data

2 or 3 phase : 3 Inlet Cyclone : Y

Internal diameter : 2.134 m Mesh Agglomerator : Y
Tan to Tan length : 6.198 m Mesh thickness : 0.100 m
Hemi or 2:1 heads : E (H/E) Coalescer Plate Pack : N
Split Flow? : N Plate Spacing : 0.010 m
End or Central Inlet : C Plate Angle : 45 °
Maximum pitch : 0.00 ° Plate Length : 1.000 m
Mist eliminator : Y Weir Plate : Y
Cyclone or vane mist eliminator : C (c/v) Tan to Weir Length : 4.305 m
Vane type : CDS 250 Liquid separating length : 4.198 m
Sizing K factor : 0.150 m/s Gas separating length : 4.198 m

Minimum Tan to Tan Length : 4.230 m Actual drainage head : 528 mm

Total vessel volume : 24.70 m³ Required drainage head : 438 mm
Bottom of cyclone elevation : 1544 mm Mesh lower elevation : 1.016 m
Max liquid level under cyclones : 1016 mm

Nozzle Table
N.B I.D Minimum I.D Velocity rho-v² Pressure drop
(in) (m) (m) (m/s) (kg/ms²) (mbar)

Fluid Inlet 12 0.289 0.285 16.38 14103 141

Mesh Coalescer 0.56 16 3
Spira-flow 80 cyclones 21% NFA 54
Gas Outlet 12 0.289 0.310 16.32 13315 40
Oil Outlet 4 0.097 0.051 0.45
Water Outlet 4 0.097 0.021 0.08

Liquid levels

Gas space above HHLL 1.118 m 'K' value 0.156 m/s

0.565 m/s
Volume between Residence
Level Level Vessel fill Axial velocity Reynolds levels time Interval
(m) (%) (m/s) Number (m³) (mins)

HHLL 1.016 47.6 1.52 7.52 HLL to HHLL

HLL 0.914 42.8 1.48 7.33 NLL to HLL
NLL 0.813 38.1 0.004 3.83 18.92 NLL to NIL
NLL 0.813 38.1 0.74 3.63 LLL to NLL
LLL 0.762 35.7 2.11 10.43 LLLL to LLL
LLLL 0.610 28.6 1.85 9.13 Liquid Outlet to LLLL
Top of weir 0.610 28.6 1.32 38.95 HIL to Top of weir
HIL 0.457 21.4 0.60 17.65 NIL to HIL
NIL 0.381 17.9 0.001 1.97 58.22 BV to NIL
NIL 0.381 17.9 1.33 39.34 LIL to NIL
LIL 0.178 8.3 0.36 10.67 LLIL to LIL
LLIL 0.102 4.8 0.28 8.21 BV to LLIL

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Case number : 4
Case title : Case 4
Including head volume : y

Process summary
Oil Water Gas
Pressure =
1075.00 psig Flow : 2205.3 bbl/d 368.3 bbl/d 225.0 MMRft³/d
Temperature = Density : 44.80 lb/ft³ 63.20 lb/ft³ 3.12 lb/ft³
100.0 °F Viscosity : 0.580 cP 0.850 cP 0.012 cP
Surface tension : 20.00 dyne/cm 70.00 dyne/cm

Vessel data

2 or 3 phase : 3 Inlet Cyclone : Y

Internal diameter : 2.134 m Mesh Agglomerator : Y
Tan to Tan length : 6.198 m Mesh thickness : 0.100 m
Hemi or 2:1 heads : E (H/E) Coalescer Plate Pack : N
Split Flow? : N Plate Spacing : 0.010 m
End or Central Inlet : C Plate Angle : 45 °
Maximum pitch : 0.00 ° Plate Length : 1.000 m
Mist eliminator : Y Weir Plate : Y
Cyclone or vane mist eliminator : C (c/v) Tan to Weir Length : 4.305 m
Vane type : CDS 250 Liquid separating length : 4.198 m
Sizing K factor : 0.150 m/s Gas separating length : 4.198 m

Minimum Tan to Tan Length : 4.230 m Actual drainage head : 528 mm

Total vessel volume : 24.70 m³ Required drainage head : 434 mm
Bottom of cyclone elevation : 1544 mm Mesh lower elevation : 1.016 m
Max liquid level under cyclones : 1016 mm

Nozzle Table
N.B I.D Minimum I.D Velocity rho-v² Pressure drop
(in) (m) (m) (m/s) (kg/ms²) (mbar)

Fluid Inlet 12 0.289 0.285 16.39 14273 143

Mesh Coalescer 0.56 16 3
Spira-flow 80 cyclones 21% NFA 54
Gas Outlet 12 0.289 0.310 16.32 13315 40
Oil Outlet 4 0.097 0.051 0.55
Water Outlet 4 0.097 0.021 0.09

Liquid levels

Gas space above HHLL 1.118 m 'K' value 0.155 m/s

0.565 m/s
Volume between Residence
Level Level Vessel fill Axial velocity Reynolds levels time Interval
(m) (%) (m/s) Number (m³) (mins)

HHLL 1.016 47.6 1.52 6.25 HLL to HHLL

HLL 0.914 42.8 1.48 6.10 NLL to HLL
NLL 0.813 38.1 0.005 3.83 15.73 NLL to NIL
NLL 0.813 38.1 0.74 3.02 LLL to NLL
LLL 0.762 35.7 2.11 8.67 LLLL to LLL
LLLL 0.610 28.6 1.85 7.59 Liquid Outlet to LLLL
Top of weir 0.610 28.6 1.32 32.40 HIL to Top of weir
HIL 0.457 21.4 0.60 14.69 NIL to HIL
NIL 0.381 17.9 0.002 1.97 48.44 BV to NIL
NIL 0.381 17.9 1.33 32.73 LIL to NIL
LIL 0.178 8.3 0.36 8.88 LLIL to LIL
LLIL 0.102 4.8 0.28 6.83 BV to LLIL

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