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Where there is a high solids loading, a waxy crude, or a chance of fouling, the ZVB® Calming Baffle is utilised, to enhance the flow distribution downstream of the inlet processing zone (typically consisting of an inlet device and a ZHB® Distribution Baffle) and to reduce the effects of any motion or waves on the liquid surface. Fitting the baffles within the vessel, in this way, controls and calms the liquid flow, thus maximising the effectiveness of the liquid/liquid separation process.

In most designs, the baffle will occupy the whole cross-sectional area of the vessel. This gives it an extremely important role in improving the gas distribution through the separator, helping to minimise mal-distribution effects on the downstream demisting equipment and maximising the efficiency of the gas/liquid separation process.

ZVB® Calming Baffles can be used in most separation duties and are particularly recommended for separators on Floating Production Units (FPUs).

Separators on FPUs are subjected to oscillatory motions and accelerations which cause surface waves and sloshing of the liquid phases inside the process vessels. Pitch motions are the most serious and, unless countered, cause longitudinal sloshing in the separator which can lead to mixing, overflow of the weirs, and mechanical damage to the internals.

ZVB® Calming Baffles are used within the separator to divide the flow regions into linked sections, introducing damping and reducing the amplitude of any surface waves.

Advantages of ZVB® Calming Baffles:

  • 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 from the liquid surface
  • Increase gas / liquid separation efficiency
  • Enhance liquid distribution on downstream equipment
  • Reduce turbulence and re-circulation within the liquid section, promoting gravity separation
  • Increase liquid / liquid separation efficiency
  • Wide operational range - typically, providing 100% turndown
  • Easy to install in both new and existing separators
  • No moving parts so no maintenance
  • Reduce surface waves and sloshing effects.

Applications of ZVB® Calming Baffles:

  • Production Separators
  • Test Separators
  • Slug Catchers
  • Flash Drums
  • Produced Water Degassers
  • Enhanced Oil Recovery Systems
  • Floating Production Units (FPUs).

Case Studies

Gas Scrubbers Flow Assurance

This is a before and after case study of a simple gas scrubber experiencing carryover problems. The original internals were an inlet deflector plate and a mesh pad only. These were replaced with a vane type inlet device and 48, 4G-FD® Demisting Cyclones.

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