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When utilising the ZSQ® Inlet Device, the flow must be straightened to remove the spiral action vorticity from the flow. This is achieved by the inclusion of the ZSB Straightening Baffle containing our proprietary ZPC Vanes integrated on the downstream face of the baffle.

This combination first takes out the spiral component of the ZSQ® Inlet Device, directing the flow down the vessel whilst the use of the integrated ZPC Vanes, provides further fluidic processing and flow distribution. Its fluidic control effect is to divert gas and oil droplets upwards, thus extracting the lighter elements.

At the same time, by virtue of the compartmental effect, created by this baffle arrangement, a re-circulation effect has been set up to allow fine droplets longer residence time to coalesce, before moving forwards or upwards.

Where enhanced oil recovery or an arduous guarantee is required to be met, we can also include our proprietary horizontal ZPC Ultra-calm Skimming Zone, within the separator; the purpose being to provide a very "calm" oil zone, where the oil builds up and overflows the weir, with much less water overflow than in conventional designs.

The ZPC Vanes are installed immediately upstream of the weir and positioned close to the top of the weir. The liquid flows up through the vanes and droplets are directed to the liquid/gas interface, in a "calm" area above the baffle giving an extremely high degree of separation.

Applications of ZSB / ZPC Straightening Baffles:

  • Ideal for degassing and enhanced oil recovery systems
  • Distribute and calm the fluids
  • Do not suffer from fouling or blockage
  • Handle slugs and surges
  • Enhance interface level control
  • Provide minimal pressure drop
  • Enhance gas distribution on any downstream equipment
  • Reduce or eliminate re-entrainment of liquid from the liquid surface
  • Increase gas / liquid separation efficiency, where applicable
  • Enhance liquid distribution on any downstream equipment
  • Reduce turbulence and re-circulation within the liquid section, promoting gravity separation
  • Increase liquid / liquid separation efficiency
  • Provide a wide operational range with 100% turndown
  • Easy to install in both new and existing separators
  • No moving parts so no maintenance (for clean duties)
  • Reduce surface waves and sloshing effects.

Applications of ZSB / ZPC Straightening Baffles:

  • Produced Water Degassers
  • Surge Vessels
  • Skimmer Vessels
  • Enhanced Oil Recovery Systems
  • Floating Production Units (FPUs).

Case Studies

Motion Control on an FPSO

The upstream piping (or isometrics) will always dictate the condition of the flow entering the vessel. Special care should therefore be taken when designing the piping in a gas production system to minimize the risk of maldistribution and avoid the droplet shatter that could reduce the performance of the downstream separation internals. By modelling the isometrics with CFD, maldistribution can be reduced and the size of any droplets entering the separator can be predicted. This is useful for troubleshooting existing vessels and optimising the design of the process internals.

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