three phase separator vessel for crude oil separation

Project Title

three phase separator vessel for crude oil separation

Project Area of Specialization Mechanical EngineeringProject Summary

PROJECT SUMMARY

The project is about the designing and optimization of a 3-phase separator vessel for the separation of crude oil. With the fluid properties of the crude oil that is extracted from the ground as input, a 3-phase separator vessel will be designed to give the desired outputs of gas, water and oil. The project will go through the process designing phase and then the mechanical design phase where the vessel specifications will be calculated for a safer and efficient performance. The project will also deal with the optimization of the vessel design to reduce the cost of fabrication while keeping the performance up to the mark.

Software ASPEN HYSYS will be used to test the process designing phase of the vessel, along with solidworks and ANSYS for the mechanical designing.

Project Objectives

• Process designing:

1. Literature review on the 3 phase separator vessel
2. Using the nozzle and operating conditions provided find the vessel dimensions
3. Material specifications required to carry out the required process.

• ASPEN HYSYS for process design cross check:

1. Using the software to cross check our results from the theoretical calculations in order to correct the mistakes.

• Mechanical design ASME BPVC- SECTION 1:

1. Vessel wall thickness calculations
2. vessel head designing and calculations
3. nozzle specifications
4. nozzle reinforcement calculations, using ASME BPVC section VIII

• Mechanical design ASME BPVC- SECTION 2:

1. Saddle designing according to the weight of the vessel
2. support rings if required
3. Joints and vessel connection
4. Demister specifications and designing.

• Model designing on solidworks:

1. 3d modeling for the design
2. cost analysis of the model

• Model cost estimation and reduction using parametrization:

1. Literature review and theoretical testing.
2. Ways to reduce the model cost without compromising the design efficiency and strength
3. Ways to enhance the strength of the vessel and reduce the cost (weld tests and material test)
4. More effective way to carry out similar process?

• Structural analysis on ANSYS workbench:

1. Analysis on the model structure to understand the relation between the theoretical and analytical calculations made.
2. To understand the effects of pressure and weight on the vessel structure and saddle.

• Report finalization:

Compiling the report for the project

Project Implementation Method

PROJECT IMPLEMENTATION METHOD

Process designing: for the process designing phase, first we will do literature review on the methods of calculating the vessel dimensions with help of the input and output nozzle parameters provided. Then using those formula and methods we will calculate the material thickness required for the vessel, the diameter and the length of the vessel. Based on these parameters the mechanical design on the vessel will be made using ASME standards

ASPEN HYSYS for process design cross check:using the software, the process design phase will be cross checked in order to make sure that the parameters obtained manually are valid.

Mechanical design ASME BPVC:  after obtaining the diameter and length for the vessel, ASME BPVC codes will be used to obtain the mechanical parameters and design specifications for components mentioned in the objectives.

Model designing on solidworks and ANSYS analysis: taking into account the mechanical specifications the model will be designed on solidworks and then tested in ANSYS static structural for the mechanical strength of the model.

Model cost estimation and reduction using parametrization: for this chapter first a literature review will be conducted and then different materials will be tested for corrosion and weld strength. The materials will be tested in the laboratory. This method will be used to design a vessel with least cost at the same efficiency.

Benefits of the Project

1. a better optimized model for a 3-phase seperator vessel for the seperation of crude oil that can be used in petroleum industries.
2. understanding of the best materials for the manufacturing of the vessel.
3. lower budgets for companies when installing or manufacturing seperators.
4. economic benifit for the country and pakistan's own capability for manufacturing cheap vessels that can be exported to other countries

Technical Details of Final Deliverable

1. complete process and mechanical design report.
2. model design in aspen hysys
3. model on solidworks along with the structural analysis
4. details of the cost reduction results and how much has the cost been reduced comparitively

Final Deliverable of the Project Software SystemCore Industry PetroleumOther Industries Manufacturing Core Technology OthersOther TechnologiesSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	68500
ASPEN HYSYS lisence mini package	Equipment	1	35000	35000
laboratory cost	Equipment	2	15000	30000
material cost	Equipment	5	500	2500
printing cost	Miscellaneous	1	1000	1000