RU2751071C2 - Modernization method of gas separation device and gas separator - Google Patents

Abstract

FIELD: technological processes.

SUBSTANCE: invention relates to gas vertical separators intended for cleaning of gas flow from solid impurities contained therein and drop fluid. Gas separation device modernization method consists in dismantling the separator housing bottom; removed from the separator inner space through the formed opening dismounted structural elements located inside the separator housing; separating device is placed into separator inner space in form of assembled process module – cartridge; fixing it by means of bearing plate, placing it above inlet branch pipe; bottom is mounted on separator casing. Essence of gas separator consists in that separation device is made in form of assembled process module-cartridge, containing set of elements, such as: shells; annular plates; detachable filtering nozzle; centrifugal separation elements; gas distributing device; separation nozzles, which together, in the form of a structure called a cartridge, are mounted in a gas separator housing.

EFFECT: considerable reduction of costs for performance of works on modernization of separation device; providing convenience of these works performance; high level of manufacturability of operation of carrying out said work, high efficiency of separation, high quality of cleaning gas, ease of maintenance, high reliability factor of separator operation during whole life cycle of separator housing (at least 20 years).

2 cl, 1 dwg

Description

SUBSTANCE: invention relates to gas vertical separators intended for cleaning a gas stream from solid impurities and droplet liquid containing therein. The invention can be used in technological operations for gas purification in various industries - oil, chemical, energy, gas, etc.

It is known that the estimated period of operation of the separator body, as a pressure vessel, is not less than twenty years. However, the low MTBF of separation devices, such as: nozzle, cyclone, coalescer, mesh drip tray, etc., necessitates regular preventive and repair work on their maintenance. The efficiency of the separation devices, as well as the organization of the separation process, significantly affect the quality of gas purification. It should be noted that a significant impact on the quality of gas purification is exerted by the deviation of the actual gas flow rate from the gas flow rate included in the design solution, which is used as an initial value in the design of the separator. The dynamics of changes in the gas consumption during the start-up of the apparatus and during the shutdown of its operation also affects the quality of gas purification.

Decrease in the efficiency and reliability of the separators leads to a decrease in the durability and service life of the compressor equipment. Not the best statistics on the MTBF of compressor equipment sets the task of creating separation devices, on the one hand, with increased productivity, technological flexibility, providing high quality gas purification even in transient operating modes of technological processes, on the other hand, with a high indicator of their maintainability and reliability. work.

These factors necessitate the creation of methods for the modernization of gas separation devices, gas separators, aimed at increasing the efficiency of separators while reducing operating costs for performing routine maintenance and repair work.

It is known that centrifugal sedimentation is one of the most effective ways to intensify the separation of the dispersed phase. Centrifugal separators, in comparison with shock-gravity separators, have a higher throughput, less metal consumption and have much smaller overall dimensions. Cleaning the gas flow from liquid and solid phases in centrifugal separators is carried out by centrifugal forces, which are formed by organizing the rotational movement of the gas flow.

A known separator for cleaning gas from impurities, including a separator body with gas inlet and outlet pipes, and located in it: a gas distribution device, a filter section made in the form of a plate with direct-flow centrifugal separation elements, while each centrifugal separation element of the filter section is equipped with a coalescing cartridge (RF patent No. 2472570, B01D 45/12, 01.20.2013).

The disadvantage of the specified separator for gas purification is - the complexity of the assembly of the structure of the separation devices inside its body, especially with the performance of welding; low level of maintainability; high operating costs associated with preventive maintenance of the separator.

A known separator for cleaning gases from mechanical impurities and liquids, including a cylindrical body, and installed in it: a pallet with a drain pipe and a cover, between which there is a package of louvered, radial, corrugated plates, with a variable height of the corrugations, increasing in the direction of the gas flow ( AS USSR No. 1634300, B01D 45/06, 03/15/91 g). The cover is made with a central hole and has a diameter equal to the diameter of the separator body, and the pallet is made with a diameter smaller than the body diameter, and forms with it an annular channel for the gas flow to pass. The size of the width of the corrugation bases is made with a decrease from the periphery to the center.

The disadvantage of this design is - the complexity of the assembly of corrugated plates, with a variable height of the corrugations in an annular louvered package; attachment of plates along the end to the lid and pallet; a low level of maintainability of the structure as a whole, since in the event of a parametric or functional failure of the plate pack, it is necessary to cut the separator body and re-mount the newly produced annular pack into it.

Methods for modernization and refurbishment of separation equipment are known. Known apparatus for cleaning gas from liquid and solid impurities (RF patent No. 2236282, B01D 45/06, 20.09.2004.), Containing: a housing with inlet and outlet fittings; a top cover connected to the outlet fitting; bottom with a drain pipe; standard hatch-manhole for installation / dismantling of louvered separation elements; welded rectangular frame with nests-niches, in which are fixed with the possibility of replacement, louvered packages in rectangular frames. The size of the rectangular frame of the separation package is unified and is determined by the possibility of transporting the separation package inside the body of the device for mounting / dismantling through the standard hatch of the device.

The disadvantage of this design of the apparatus is - restrictions on the implementation of renovations, mainly due to the replacement of louvre-type separation elements, since the limited dimensions of the standard hatch-manhole complicate the installation inside the case of highly efficient separation devices of a different type.

Closest to the claimed method of modernization of the separation device is the method of modernization (RF patent No. 2310497, B01D 45/12, B04C 5/00 20.11.2007.), In which: dismantle the structural elements inside the separator body; remove dismantled structural elements from the inner space of the separator through a manhole; a separation device is placed in the inner space of the separator; by means of fastening beams, the separation device is rigidly fixed to at least one supporting element of the separator.

The disadvantage of this method is the principle of extraction and placement of structural elements of separation devices through a manhole, the dimensions of which limit both the dimensions of the removed dismantled structural elements from the inner space of the separator and the separation devices placed in its inner space. This factor complicates the technology of both dismantling of structural elements of separation devices that cannot be repaired, since it becomes necessary to use gas cutting technological processes inside the body of the apparatus of these elements in order to adjust their dimensions to the dimensions of the manhole, and the technology of assembly and repair of structural elements of newly created separation devices. inside the body of the device.

The closest, in technical essence and the achieved result to the claimed gas separator, is a cylindrical, vertical, gas separator type manufactured by JSC Volgogradneftemash according to TU3683-015-00220575-2002, (Catalog of separation equipment, part II Gas separators according to TU 3683-015-00220575 -2002), including: vertically located body; elliptical bottoms; inlet, outlet, drain pipes; standard manhole hatch; separation device. At the same time, the separation device is made in the form of a set of nozzles mounted on a horizontal plate located in the upper part of the separator and an uncleaned gas inlet assembly fixed on a horizontal plate mounted on the separator support elements above the tangential gas inlet to the separator body.

The disadvantage of this separator is its low efficiency, due to the deterioration of the quality of gas purification with a decrease in the speed of its movement through the separation nozzles. The gas flow rate depends on the discharge pressure generated by the compressor stations and its flow rate, which depends on the daily flow rate of the gas field. The first value can be kept constant, with the exception of the time period for starting and stopping the compressor station. The second value depends on the period of operation of the field, the time of the year, etc., and may differ significantly from the amount of gas consumption included in the project. The value of the gas consumption value included in the design is used as the initial data in the calculation of the separators. The difference in the value of the design gas flow rate from the real value of its flow at a given time will determine the actual speed of gas movement through the nozzles, and hence the quality of gas purification. These factors determine the need for revision, and in some cases, modernization of the separation devices mounted inside the separator body.

The purpose of the invention "Method of modernization of the gas separation device" is:

- reducing the cost of performing work on the modernization of the separation device. These works include: dismantling of structural elements inside the separator body; removing them from the inner space of the separator body; work on transferring the newly created separation device from the outside to the inner space of the separator; installation of this device in the inner space of the separator;

- ensuring the convenience of carrying out these works;

- increasing the overall level of manufacturability of the above works.

The purpose of the invention of the device "Gas Separator" is:

- increasing the efficiency of separation, which ensures high quality of gas purification;

- increasing the indicator of manufacturability of maintenance of the separator and the reliability of its operation during operation during the entire life cycle of the separator body (at least 20 years).

The goal set for the method of modernization of the gas separation device has a solution, the essence of which is that the structural elements inside the separator body are dismantled; remove dismantled structural elements from the inner space of the separator through a manhole; a separation device is placed in the inner space of the separator; the separation device is rigidly fixed to at least one supporting element of the separator; according to the invention, the bottom of the separator body is dismantled; removed from the inner space of the separator, through the opening formed, the dismantled structural elements inside the separator body; a separation device is placed in the inner space of the separator, in the form of an assembled technological module-cartridge, it is fixed with a support plate, placing it above the inlet pipe; and mount the bottom on the separator body. It is important to note that the size of the opening area in the separator body, formed after dismantling the bottom, exceeds the size of the area of the standard hatch in the separator body, and only this factor makes it possible to place a separation device made in the form of an assembled technological cartridge-module into the inner space of the separator. In this case, the connection of the carrier plate of the assembled technological module of the cartridge with the supporting element of the separator can be made both detachable and non-detachable.

The goal set for the creation of a gas separator is solved with the help of a modernized gas separation device. The essence of the gas separator is that it contains a vertically located body; elliptical bottoms; inlet, outlet, drain pipes; standard manhole hatch; separator support elements; separation device; According to the invention, the separation device is made in the form of an assembled technological module-cartridge containing external and internal shells, oriented vertically and located coaxially, hermetically fastened to each other along the lower and upper edges of the inner shell by means of annular plates, while attached to the lower annular plate, a removable filter nozzle (for example, a mesh bag), the diameter of which is equal to the diameter of the inner shell, and holes are made in the upper annular plate, in which the cylinders of centrifugal separation elements (for example, cyclones) are hermetically fixed, the exhaust pipes of which are hermetically fixed in the holes made in the bearing plate, the diameter of which is equal to the inner diameter of the separator body, the bearing plate contains: a hatch-manhole, is based coaxially with the outer shell and is attached hermetically to its upper edge, and the tail sections of the exhaust pipes are hermetically fastened to the gas distribution devices at the ends branch pipes of which, with the help of a detachable connection, separation nozzles are hermetically mounted, for example, centrifugal direct-flow separation nozzles.

The essence of the claimed invention is illustrated by a drawing (Fig. 1), which shows a 3D model of a separation device - an assembled technological module-cartridge.

The method of modernization of the gas separation device is as follows: dismantle the bottom (item 1) from the separator body (item 2); dismantled structural elements (a set of nozzles mounted on a horizontal plate and a raw gas injection unit) are removed from the inner space of the separator through the formed opening; a separation device made in the form of an assembled technological module-cartridge is placed in the inner space of the separator; fasten its carrier plate (item 3) by means of a detachable (one-piece) connection with the separator support element (item 4) located above the gas inlet pipe into the separator body (item 5).

The technological process of modernization of the gas separator separation device, manufactured by JSC Volgogradneftemash according to TU3683-015-00220575-2002, will consist of the following operations:

- dismantle the upper bottom of the separator body;

- dismantle the structural elements inside the casing of the separator, namely, disconnect the first assembly unit from the supporting element of the separator - a horizontal plate with nozzles; the second assembly unit is disconnected from the supporting elements of the separator - the unit for introducing unclean gas mounted on a horizontal plate mounted on the supporting element of the separator located above the branch pipe for introducing gas into the body of the separator;

- removed from the inner space of the separator, through the formed opening, the dismantled structural elements inside the separator body;

- a separation device made in the form of an assembled technological module-cartridge is placed in the inner space of the separator, through the formed opening;

- a separation device is mounted, made in the form of an assembled technological module - a cartridge in the inner space of the separator by connecting its carrier plate (item 3) with the supporting elements of the separator (item 4), located above the gas inlet pipe into the separator body.

The technical result, from the implementation of the method of modernization of the gas separation device will allow:

- to minimize the cost of dismantling structural elements located inside the separator body, since the volume of work on gas cutting of structural elements inside the separator body should be reduced due to the fact that dismantled structural elements are removed from the inner space of the separator through the opening formed after dismantling the bottom of the separator body , the area of which exceeds the area of the standard hatch-manhole;

- to exclude welding work on assembling the separation device inside the separator body, since the separation device is made in the form of an assembled technological module-cartridge, which is placed through the opening formed after dismantling the bottom of the separator body into the inner space of the separator;

- to minimize the cost of installation work (welding inside the casing of the separator) to install the separation device inside the casing of the separator to the supporting element of the separator, since the separation device is made in the form of an assembled technological module-cartridge.

From the above, it follows that the claimed method of modernization of the gas separation device will ensure the achievement of the following technical result: a significant reduction in the cost of performing work on the modernization of the separation device; ensuring the convenience of carrying out these works; increasing the level of manufacturability of the operation of dismantling the structural elements inside the separator body and mounting the newly created separation device in the separator's inner space. This is achieved due to the fact that the bottom is dismantled from the separator body, removed from the inner space of the separator, through the formed opening, the dismantled structural elements located inside the separator body are placed in the inner space of the separator, a separation device made in the form of an assembled technological module - a cartridge, is fixed with using a carrier plate, placing it above the inlet pipe, and the bottom is mounted on the separator body.

The gas separator consists of the following main elements: a vertically located body (pos. 2), elliptical bottoms (pos. 1), an inlet tangentially located branch pipe (pos. 5), an outlet (pos. 6), drain pipes, a supporting element of the separator (pos. 4), a standard hatch-manhole (pos. 7), a separation device in the form of an assembled technological cartridge-module shown in Fig. 1. The separation device contains external (pos. 8) and internal (pos. 9) shells, oriented vertically and located coaxially, hermetically fastened to each other along the lower and upper edges of the inner shell by means of annular plates (pos. 10, 11), in this case, a removable filter nozzle (pos. 12) is attached to the lower annular plate (pos. 10), (for example, a mesh bag), the diameter of which is equal to the diameter of the inner shell (pos. 9), and in the upper annular plate (pos. 11) holes are made in which cylinders (item 13) of centrifugal separation elements (for example, cyclones) are hermetically fixed, the exhaust pipes (item 14) of which are hermetically fixed in the holes made in the base plate (item 3), the diameter of which is equal to the inner diameter of the cage body (item 2). The carrier plate contains: a manhole (pos. 15), is based coaxially with the outer shell and is sealed to its upper edge, and the tail sections of the exhaust pipes are hermetically fastened to the gas distribution devices (pos. 16), on the end pipes of which, using a detachable the connections are hermetically mounted separating (filtering) nozzles (pos. 17).

The claimed technical result of the gas separator - improving the quality of gas purification, is achieved due to the fact that the separation element, made in the form of an assembled technological module of the cartridge, provides a high organization of the gas purification process. At the initial stage, of great importance for the gas purification process is a removable filter nozzle (pos. 12.), the main purpose of which is to remove large particles from the gas flow in the form of gels of hydrocarbon origin. This technical solution will make it possible to increase the inter-regulation period of operation of the separation nozzles, which are responsible for the final gas purification. Then the gas is cleaned using centrifugal separation elements (item 13) (for example, cyclones), then at the final stage with separation or filtering nozzles (item 17). At the same time, gas distribution devices (pos. 16) provide the calculated ratios of the values of the gas flow rates through centrifugal separation elements and separation filtering nozzles that carry out the final gas purification. This makes it possible to increase the efficiency of gas purification separately, both with centrifugal separation elements and with separation (filtering) nozzles that carry out the final gas purification.

The claimed technical result - ease of maintenance of the assembled technological module-cartridge, is achieved due to the presence of a hatch - manhole (item 15) located in the carrier plate and due to the detachable connection of the gas distribution device (item 16) with separation nozzles (item 17). This simplifies the procedure for monitoring the condition of the separation nozzles and their replacement.

The gas separator works as follows. The gas flow to be cleaned is fed into the separator body (item 2) tangentially directed through the inlet pipe (item 5). At the same time, in the case of a salvo discharge of liquid, it immediately settles in the bottom of the separator bypassing the cartridge. Further, the gas enters through a removable separation nozzle (item 12) into the inner cavity of the inner shell of the cartridge (item 9) and then, is directed into the cylinders of centrifugal separation elements (item 13). High quality gas purification is ensured due to the action of centrifugal and gravitational forces on mechanical particles and dropping liquid, taking into account the change in the direction of gas movement to the opposite. Then, the gas enters the gas distribution device (item 16), which reduces the speed of gas movement through a separate separation nozzle, due to the distribution of the gas flow between them. At the same time, the speed of gas movement through the separation nozzles sharply decreases, this determines the high quality of gas purification and a long service life of the separation nozzles.

So, the claimed invention - "a method of modernization of a gas separation device" allows you to reduce the cost of performing work on the modernization of gas separation devices; operating costs for performing preventive maintenance of the separator; increase the level of manufacturability of the above-mentioned works. The technical result, provided by a gas separator, in which the separation device is made in the form of a complete technological module-cartridge, - increasing the separation efficiency - determines the high quality of gas purification, ease of maintenance, and a high indicator of the reliability of the separator during operation during the entire life cycle of the separator body ( at least 20 years).

Claims (2)

1. The method of modernization of the gas separation device, in which: dismantle the structural elements inside the separator body; remove dismantled structural elements from the inner space of the separator; a separation device is placed in the inner space of the separator; the separation device is fixed to at least one supporting element of the separator, characterized in that: the bottom is dismantled from the separator body; removed from the inner space of the separator, through the formed opening, the dismantled structural elements inside the separator body; a separation device made in the form of an assembled technological module-cartridge is placed in the inner space of the separator; fix it with a support plate, placing it above the inlet pipe, and mount the bottom on the separator body. 2. A gas separator, comprising: a vertically located body; elliptical bottoms; an inlet pipe located tangentially with respect to the separator body; outlet, drain pipes; standard manhole hatch; supporting elements of the separator, a separation device, characterized in that the separation device is made in the form of an assembled technological module-cartridge containing outer and inner shells, oriented vertically and arranged coaxially, hermetically fastened to each other along the lower and upper edges of the inner shell by means of annular plates, at the same time, a removable filter nozzle (for example, a mesh bag) is attached to the lower annular plate, the diameter of which is equal to the diameter of the inner shell, and holes are made in the upper annular plate in which the cylinders of centrifugal separation elements (for example, cyclones) are hermetically fixed, the exhaust pipes of which are hermetically are fixed in the holes made in the carrier plate, the diameter of which is equal to the inner diameter of the separator body, the carrier plate contains: a hatch, is based coaxially with the outer shell and is sealed to its upper edge, and the tail sections of the exhaust pipes are hermetically fastened They are equipped with a gas distribution device, on the end pipes of which, by means of a detachable connection, the separation (filtering) nozzles are hermetically mounted.

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