71- Contract equipment oil and gas coalescing filter separator modification to achieve large processing capacity design measures for secondary coalescing and separation internal parts

Oil and gas coalescing filter separators are often arranged in a horizontal structure. Why are horizontal structures often used? The oil and gas coalescing filter separator requires a two-stage coalescing chamber. The first stage often uses coalescing filter element internals, and the coalescing filter element needs to be replaced and maintained regularly or irregularly. For the convenience of filter element replacement and maintenance, oil and gas coalescing filter separators are mostly arranged horizontally.

This post was last edited by luoli519 on 2017-1-6 19:46 In the past two years, the frequency of gas-liquid separators designed with too small an inner diameter has gradually increased, and the trends at home and abroad are similar. What factors caused it? One of the possible reasons is that the bidders designed the separator to be small in size due to the abnormal development needs of low-cost competition, so that the manufacturing cost is low, and the bidding cost has a competitive advantage. The second possible reason is that the bidder for equipment supply does not have the ability to complete the design of the precise dynamic separator system and roughly estimates the size and cost of the bidding equipment based on experience. The third possible reason is that the owner or design institute did not strictly control the technology during the bidding process for various reasons.

For example, a domestic equipment company participated in the bid for oil and gas coalescing filter separator skids for foreign projects. Based on the main working conditions parameters such as working temperature of 55°C, working pressure of 1440 psi and natural gas processing capacity of 20MMSCFD, the inner diameter of the bidding equipment was only 12”, and the first-level cabin used coalescing filter elements and the second-level cabin used coalescing wire mesh internal parts to keep the bidding cost lower than competitors.

Due to the obvious price advantage of the bid and the bid document also sworn on the operating results, the owner awarded the oil and gas coalescing filter separator skid contract to the manufacturer. The manufacturing plant begins production of the casing and internal parts.

Halfway through the production of the casing and internal parts, the manufacturer received a "Notice from the Manufacturer to Stop Manufacturing" jointly issued by the owner and the design institute. The notice stated that after repeated calculations of the manufacturer's bid plan by the design institute and the owner, it was found that the size of the secondary wire mesh coalescing internal parts configured in the manufacturer's original bid plan was too small and could not meet the design specifications and technical requirements for dynamic separation under this working condition in the bidding document. The owner and the design institute require the manufacturer to revise the original plan and obtain approval from the owner and the design institute before continuing with subsequent manufacturing.

However, the manufacturing progress of the equipment casing has exceeded 90%. What to do? Considering that the manufacturing cost of the equipment casing far exceeds that of the internal parts, the manufacturer considered retaining the casing and replacing the secondary coalescing internal parts in order to achieve a result where the cost does not change significantly without delaying the delivery date.

How to change the secondary coalescing internal parts scheme? The original plan was based on low manufacturing cost considerations and used the lowest cost wire mesh inner parts. Now, after calculation by the owner and the design institute, it is found that the size of the secondary wire mesh internal parts is too small and cannot meet the design specifications for dynamic separation internal parts. However, the inner diameter of the separator housing has been determined, and 90% of the manufacturing progress has been completed. ； Increasing the size of the secondary screen will cause the secondary cabin parts to be larger than the inner diameter of the shell and cannot be installed!

The equipment manufacturing owner and the design institute proposed the use of blade-type secondary coalescing internal parts. The owner and the design institute suggested to the manufacturer that it find a professional blade coalescing technology company to provide technical solutions. The response received from equipment manufacturers, design institutes and owners is that the blade coalescing internal parts corresponding to the inner diameter of the casing cannot meet the technical specifications for dynamic separation under this working condition.

This post was last edited by luoli519 on 2023-9-28 12:55. After many twists and turns, under the recommendation of the design institute, the equipment manufacturer later approached Novel for help. On its precise dynamic calculation and design system platform, Novel used the existing working condition parameter group and the existing separator inner diameter as new configuration constraints. The calculation results did deny several conventional configuration methods of blade coalescing internals, but obtained two configuration methods that passed the design specifications of dynamic separation technology. It also issued a detailed "Dynamic Separation Engineering Process Calculation Book" to the design institute, the owner and the shell manufacturer, proving the reliability of the two new configuration methods. In the end, the design institute, owner and equipment manufacturer chose one of two reliable new configuration solutions. In addition, Novel uses its fifth-generation G50 patented feather blade separation technology internals to replace conventional blade internals, further improving separation reliability and operating flexibility.

It can be seen from the drawings of Building 11: 1). The fluid inlet adopts a simple baffle. ； 2). The inner diameter of the separator cylinder is 1500mm. ； 3) The gas-liquid separation internal parts adopt a simple wire mesh with a diameter similar to the inner diameter of the cylinder. ； 4) The distance between the upper surface of the wire mesh defoaming inner parts and the upper end of the cylinder is 300mm.