Project Case Study
Desander Cyclone Package
Advanced Sand Separation
Automated Dual Unit
Operating & standby units with fully automated switchover for seamless operation and minimal downtime.
High Efficiency
Cyclone technology removes up to 99% of solids, protecting downstream equipment and enhancing process efficiency.
Cold‑Weather Ready
Insulated skid with electric trace heating ensures reliability in harsh climates and demonstrates commitment to innovation.
Overview
The Desander Cyclone Package project involved an advanced sand separation system for a client dealing with sand-laden flows in their process. Sand ingress was causing erosion and performance issues in downstream equipment, so the objective was to provide a solution that could continuously remove sand and protect the rest of the plant. The project needed to ensure minimal downtime and reliable operation even in harsh (cold-weather) conditions, all while keeping the client’s identity and specific project details confidential.
Solution
Kapwell delivered a dual-cyclone sand separation skid featuring two cyclone units configured in parallel (one operating and one standby). The system was fully automated to switch between the duty and standby cyclone without process interruption. This means when one unit required maintenance or reached capacity, the control system would seamlessly divert flow to the second unit, ensuring continuous sand removal. The entire package was skid-mounted and enclosed with insulation and electric trace heating, enabling reliable operation in cold climates where process fluids and equipment could otherwise be compromised. Kapwell’s engineering team optimized the cyclone design to achieve very high separation efficiency within a compact footprint.
Key
Features
Automated Dual-Unit Operation
The package includes two cyclone separators in an automatic duty/standby arrangement. A smart control system monitors performance and can instantly switchover to the standby unit if the primary unit needs service or cleaning, resulting in seamless operation with essentially zero downtime
High-Efficiency Sand Removal
Using proprietary cyclone technology, the system removes up to 99% of entrained solids (sand) from the production stream[6]. By capturing the vast majority of sand particles, the desander protects downstream pipelines, valves, and vessels from abrasion and fouling, significantly extending their service life.
Cold-Weather Design
To ensure year-round operability, the skid is thermally insulated and equipped with electric heat tracing[5]. This design keeps the equipment above minimum operating temperatures in freezing conditions, maintaining performance in harsh climates. It demonstrates Kapwell’s commitment to innovation by adapting the system for extreme environmental conditions.
Challenges & Innovation
This project faced the challenge of providing uninterrupted sand separation in an environment with heavy solids and cold weather. Any downtime for sand removal could cause process upsets, so the innovation was the fully automated dual-cyclone system. Kapwell’s design ensures that when one cyclone needs cleaning, the second one takes over instantly, eliminating the traditional downtime associated with desanding operations. Another challenge was achieving such a high separation efficiency (99% solids removal). Kapwell met this by leveraging advanced computational fluid dynamics (CFD) modeling to refine the cyclone geometry for optimal particle capture. Additionally, operating in sub-zero temperatures required an innovative approach to skid design – the inclusion of insulation and heat tracing not only prevents freezing but also exemplifies Kapwell’s ability to tailor solutions to client-specific challenges
Client Benefit
Protected Equipment & Reduced Wear
By extracting ~99% of sand from the fluid, the system protects downstream equipment from erosion and clogging, leading to less frequent repairs and longer equipment life. The client experiences improved reliability and lower maintenance costs.
Continuous Operation
The automated switchover feature provides continuous, uninterrupted operation. The client benefits from minimal process downtime, as sand removal no longer necessitates shutdowns. This ensures stable production and optimizes operational uptime.
Year-Round Reliability
With the cold-weather enhancements, the package operates reliably even in winter conditions. The client can maintain production rates and separation efficiency regardless of ambient temperature, avoiding weather-related slowdowns.
Confidentiality & Trust
The solution was delivered under a strict NDA, and Kapwell adhered to all confidentiality requirements. This gives the client confidence that their proprietary process details are protected while still getting a cutting-edge solution.
Timeline
Delivered on schedule. (Exact timeline withheld due to confidentiality.) Kapwell executed the project within the agreed project schedule, coordinating closely with the client’s team. Meeting the timeline was crucial to allow timely installation during a planned maintenance window.