The document provides specifications for the design, manufacture and testing of liquid/vapor separators. It outlines the scope, applicable codes and standards, design requirements, inspection and testing procedures, documentation requirements and warranty. Key design aspects include efficient separation of phases, surge capacity, retention time, materials of construction, inlet and outlet placement and sizing.
The document provides specifications for the design, manufacture and testing of liquid/vapor separators. It outlines the scope, applicable codes and standards, design requirements, inspection and testing procedures, documentation requirements and warranty. Key design aspects include efficient separation of phases, surge capacity, retention time, materials of construction, inlet and outlet placement and sizing.
The document provides specifications for the design, manufacture and testing of liquid/vapor separators. It outlines the scope, applicable codes and standards, design requirements, inspection and testing procedures, documentation requirements and warranty. Key design aspects include efficient separation of phases, surge capacity, retention time, materials of construction, inlet and outlet placement and sizing.
The document provides specifications for the design, manufacture and testing of liquid/vapor separators. It outlines the scope, applicable codes and standards, design requirements, inspection and testing procedures, documentation requirements and warranty. Key design aspects include efficient separation of phases, surge capacity, retention time, materials of construction, inlet and outlet placement and sizing.
LIQUID/VAPOR SEPARATORS TABLE OF CONTENTS PAGE 1.0
2.0
3.0
SCOPE
1.1 1.2
3 3
General Definitions
CODES AND STANDARDS
2.1 2.2 2.3 2.4
3 3 5 5
General Specific Codes and Standards Applicable Company Standards Data Sheet
DESIGN 3.1 3.2 3.3 3.4 3.5 3.6
Characteristics Design Inlets and Outlets Internals Instruments and Controls High Temperatures
5 6 7 8 10 12
4.0
INSPECTION AND TESTING
12
5.0
DOCUMENTATION REQUIREMENTS
13
6.0
PREPARATION FOR SHIPMENT
14
7.0
WARRANTY
14
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VES-5300 Rev. 4, 11/02
1.0
SCOPE 1.1
General This Specification covers the minimum technical requirements for the design, manufacture, and testing of liquid/vapor separators. For a specific separator, this specification shall be used in conjunction with the project specifications and data sheets for that separator. Any exceptions to the requirements of this specification shall be submitted in writing for resolution by the Company.
1.2
Definitions Definitions of contractual terms (Supplier, Company, etc.) may be found in VES-1000, General Technical Conditions for Tender and Purchase of Equipment and Materials. Item Definition
The liquid/vapor separator provides efficient separation between
phases for natural gas, crude oil, liquid hydrocarbons, water and other constituents at the volume, pressure, and temperature specified on the vessel data sheet. The vertical and horizontal separators are of the following types: -
2.0
Two-phase Three-phase Knockout drums Surge tanks
CODES AND STANDARDS
2.1
General The supplier shall consider the most recent issue of the applicable standards and codes issued by the following associations and approval bodies as part of this specification. -
2.2
American Iron and Steel Institute (AISI)
American National Standards Institute (ANSI) American Petroleum Institute (API) American Society for Testing and Materials (ASTM) American Society of Mechanical engineers (ASME)
Specific Codes and Standards
A list of Specific Industry Association standards and codes is provided below: American National Standards Institute (ANSI) B16.5
Pipe Flanges and Flanged Fittings
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American Petroleum Institute (API)
RP 250 Recommended Practice for the Design and Installation of Pressure-Relieving Systems in Refineries - Parts I and II. American Society for Testing and Materials (ASTM) A105
Specification for Forgings, Carbon Steel, for Piping Components
A106
Specification for Seamless Carbon Steel Pipe for High-Temperature Service
A181
Specification for Forgings, Carbon Steel, for General Purpose Piping
A193
Specification for Alloy-Steel and Stainless Steel Bolting Materials for Hightemperature Service
A194
Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service
A234
Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures
A283
Specification for Low and Intermediate Tensile Strength Carbon Steel Plates, Shapes, and Bars
A515
Specification for Pressure Vessel Plates, Carbon Steel, for Intermediate and Higher-Temperature Service
A516
Specification for Pressure Vessel Plates, Carbon Steel, for Moderate and Lower-Temperature Service
American Society of Mechanical Engineers (ASME)
Section II, Part A
Ferrous Materials
Section II, Part B
Nonferrous Materials
Section III, Part C
Welding Rods, Electrodes, and Filler Metals
Section V
Nondestructive Examination
Section VIII,
Division I
Section IX
Welding and Brazing Qualifications
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Pressure Vessels
VES-5300 Rev. 4, 11/02
2.3
Applicable Company Standards
A list of the applicable Company specifications is as follows. VES
2.4
1000
General Technical Condition for Tender and Purchase of Equipment and
Materials
5120
Unfired Pressure Vessels
5146
Thermal Insulation and Fireproofing
7000
Instrumentation Requirements
7110
Installation of Instruments on Packaged Equipment
Data Sheet The Vessel Specification Data Sheet applies to this specification.
3.0
DESIGN 3.1
Characteristics Liquid/Vapor separators shall be designed to provide the following characteristics. 3.1.1
Liquid/vapor separators shall be capable of continuous service at the
operating conditions specified on the data sheets.
3.1.2
Gas and liquid handling capacity shall be at least the volumes stated on the data sheets at the respective temperatures and pressures.
3.1.3
Separators shall have a service life of 20 years, as a minimum.
3.1.4
Separators shall be sized and rated to meet the maximum and minimum pressure and temperature requirements at the specified flowrates.
3.1.5
Separators shall operate efficiently over the full range of operating conditions with a maximum pressure drop of 3 pounds per square inch (psi).
3.1.6
The most efficient separator configuration (either vertical or horizontal) shall
be provided to allow the separation of all phases of the inlet stream so that 95 percent of the entrained liquids in the gas stream are removed in the primary section of the separator.
3.1.7
Unless otherwise specified, a surge capacity of 40 percent shall be added to
the steady-state flow conditions.
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3.2
3.1.8
The maximum liquid carryover of the mist eliminators shall not exceed 0.1 gallons per million standard cubic feet (MMSCF) of liquid particles 10 microns or larger.
3.1.9
Separators shall be designed and fabricated to facilitate maintenance, repairs,
and alterations of the separator internals.
3.1.10
Manways, handholes, and inspection openings shall be accessible from the
ground, ladders, or platforms and shall permit the maintenance and removal of all internal components.
3.1.11
The separator shall be suitable for environmental conditions specified in VES1000, General Technical Conditions for Tender and Purchase of Equipment and Materials.
Design 3.2.1
3.2.2
General 3.2.1.1
Liquid/vapor separators shall meet the requirements of VES-5120,
Unfired Pressure vessels.
3.2.1.2
Separators shall be designed and constructed in accordance with
ASME Section VIII, Division 1, Pressure Vessels.
3.2.1.3
The pressure vessel shall be designed and oriented to facilitate
interconnection among the separator and other equipment and piping associated with the vessel. The design shall incorporate any features necessary for interconnection.
3.2.1.4
Separators shall be designed and fabricated for safe operation in
the specified internal and external environments.
3.2.1.5
Vertical separators 24 inches in diameter and smaller shall be
fabricated from pipe. Diameter dimensions shall be the pipe outside diameter.
Materials Materials of construction for vessels shall conform to ASME Section VIII, Division 1, and the requirements of VES-5120, Unfired Pressure Vessels.
3.2.3
Size and Capacity
3.2.3.1
Separators shall be sized in accordance with the specified
operating conditions and stream data stated on the data sheets.
3.2.3.2
Sizing of horizontal separators shall not include the volume of the
dished heads.
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3.2.4
3.2.5
Liquid level 3.2.4.1
The maximum liquid level in horizontal separators shall provide a
minimum vapor space height of 15 inches. The liquid level shall not be below the vessel centerline.
3.2.4.2
The maximum liquid level in vertical separators shall be at least 12
inches below the lowest point of the vessel inlet nozzle opening.
Retention Time 3.2.5.1
Liquid retention time is defined by the following equation :
T =
V/L
Where: V is the volume in cubic feet (CF) occupied by the liquid at
the normal liquid level, and L is the liquid flowrate in actual cubic feet per minute (ACFM) as defined by the data sheet.
3.3
3.2.5.2
Retention time shall be as specified on the vessel data sheet.
3.2.5.3
Separators shall have a sufficient liquid retention time so that
equilibrium between the phases can be reached.
3.2.5.4
Separators shall have a built-in retention time sufficient to allow for
complete separation of phases and emulsion separation.
3.2.5.5
The minimum built-in retention time shall be 1 minute, except for
If foaming conditions exist, the retention time shall be increased
by a factor of 3.5.
Inlets and Outlets
3.3.1
General 3.3.1.1
On vertical separators with high-level safety shutdowns, the
horizontal centerline of the inlet nozzle shall be located either 12 inches above the shutdown switch or 6 inches plus a distance equal to 1/2 of the inlet nozzle diameter above the shutdown switch, whichever is greater.
3.3.1.2
Inlet and outlet nozzles on horizontal separators shall be located as
close as practical to the vessel tangent lines.
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3.3.1.3 3.3.2
3.3.3
Liquid outlets shall have antivortex baffles.
Oil and Water Outlets
3.3.2.1
Liquid outlet nozzles shall be sized in accordance with the
maximum anticipated liquid volumes. The nozzles shall be at least as large as the connecting piping.
3.3.2.2
Two-phase separators shall have a single outlet for discharging
both oil and water.
Gas Outlet The gas outlet nozzle shall be sized to accommodate the gas handling capacity of the separator.
3.3.4
3.4
Blowdown and Drain Outlets
3.3.4.1
Separators shall have, as a minimum, a 1 inch blowdown outlet
with a pressure rating equal to the separator design working pressure. The blowdown outlet shall have a 1-inch globe valve.
3.3.4.2
The blowdown shall not be connected to the vessel relief system.
3.3.4.3
Vertical separators shall have a drain nozzle. The nozzle shall be a
minimum of 1 inch and shall be located on the bottom of the lower vessel head or at the cone bottom.
3.3.4.4
Horizontal separators that handle appreciable sand production shall
have a minimum of three drain nozzles of the size specified on the vessel outline drawing. The nozzles shall be evenly spaced along the length of the vessel bottom.
3.3.4.5
Low-pressure vertical separators that handle appreciable sand
production shall be provided with 60-degree cone bottoms. The cone bottoms shall be equipped with sumps and water jetting connections.
Internals 3.4.1
General 3.4.1.1
Separator internals shall be removable through the manway.
3.4.1.2
Separator internals shall be designed to achieve the required flow
velocity reduction to enable separation between phases and prevent reentrainment from occurring.
3.4.1.3
A sufficient quantity of separator internal subdivisions shall be
installed to create optimum individual flow passes to minimize excessive turbulence within the separator.
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3.4.2
3.4.3
3.4.4
3.4.1.4
Splash plates or straightening vanes shall be provided in horizontal
separators.
3.4.1.5
Interceptor plates shall be provided in horizontal separators to
shorten the distance of small drops of liquid fall.
3.4.1.6
Quieting chambers shall be provided for the internal floats of level
controllers.
Inlet Diverter 3.4.2.1
An inlet diverter shall be provided on all vertical separators.
3.4.2.2
The diverter shall be located away from the shell a distance equal to one-half of the inlet nozzle diameter.
3.4.2.3
The diverter for separators fabricated from pipe shall be a 90degree welded ell.
Weir Boxes 3.4.3.1
Three-phase separators shall be provided with weirs and weir
boxes for discharging oil.
3.4.3.2
Weir boxes shall be sized to accommodate both a liquid level
controller and a low-level shutdown control.
3.4.3.3
Three-phase or two-phase separators shall not rely on weirs for
water-level control.
Mist Eliminators 3.4.4.1
The fabricator shall provide and install mist eliminators on
separators if required by the project specifications.
3.4.4.2
Unless otherwise specified on the separator data sheet or outline
drawing, mist eliminators shall be of the parallel plate (vane type) or wire mesh type.
3.4.4.3
If wire-mesh mist eliminators are specified, the mist eliminators
shall be installed by the fabricator complete with top and bottom expanded metal grids.
3.4.4.4
Mesh, support grids, and attaching wire shall be in AISI 316
stainless steel.
3.4.4.5
The mesh density shall be at least 11 pounds per cubic foot. The mesh thickness shall be at least 6 inches.
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3.5
3.4.4.6
The cross-sectional area of the mesh pad shall be determined by
the optimum vapor velocity recommended by the mesh pad manufacturer. If the cross-sectional area of the mesh pad on vertical separators is less than the cross-sectional area of the vessel, provision shall be made to ensure that the vapor cannot bypass the mesh pad.
3.4.4.7
Vane type mist extractors shall have a liquid collection pan. The pan shall be provided with a liquid seal allowing liquids to drain into the liquid section of the separator.
3.4.4.8
Mist eliminators in vertical vessels shall be located above the
centerline on the inlet nozzle at a distance equal to the separator diameter but no less than 3 feet above the centerline of the inlet nozzle.
3.4.4.9
he top of the mist eliminator on vertical separators shall be at least
15 inches below the top tangent line.
3.4.4.10
The bottom of the mist eliminator in horizontal vessels shall be at
least 12 inches above the high-level shutdown sensor.
3.4.4.11
In horizontal separators, a light-gauge steel plate shall be set on the
top surface of the mist eliminator pad. The steel plate shall have 1/2-inch diameter holes spaced 2 inches apart. The plate shall impose a water pressure drop of 2 to 4 inches across the pad in order to distribute the flow evenly.
Instrument and Controls
3.5.1
General 3.5.1.1
Instruments and controls shall comply with the requirements of
VES-7000, Instrumentation Requirements.
3.5.1.2
Nozzles, couplings, and other connections for installing
instruments and controls shall meet the requirements of VES-5120, Unfired Pressure Vessels.
3.5.1.3
Level control/shutdown devices shall be installed with welded
flange vessel nozzle connections.
3.5.1.4
Separators shall have provisions for installing at least the following
For separators with a design working pressure (DWP) greater than
400 psi, the shutdown sensors shall be set as follows: -
High-pressure sensor - at 90 percent of the PSV set pressure or
110 percent of the maximum operating pressure, whichever is lower.
Low-pressure sensor - minimum of 10 percent below the lowest
pressure in the operating pressure range.
For separators with a DWP of 400 psi or less, the shutdown
sensors shall be set as follows: -
High-pressure sensor - at 90 percent of the PSV set pressure or
110 percent of the maximum operating pressure, whichever is lower.
Low-pressure sensor - minimum of 5 PSI below the lowest
pressure in the operating pressure range.
The sensors shall be equipped to permit testing with an external
pressure source.
Pressure Relief Valves
3.5.3.1
Relief valves shall comply with VES-7000, Instrumentation
Requirements and API RP 520, Recommended Practice for the Design and Installation of Pressure Relieving Systems in Refineries - Parts I and II, and shall meet any government authority regulations for the specified location. Relief valves shall be set to operate at no more than the maximum stated design pressure.
3.5.3.2
Unless otherwise specified, two relief valves shall be provided.
3.5.3.3
The relief valves shall be set to open at the DWP of the vessel.
3.5.3.4
The relief valves shall be designed for 100 percent flow.
3.5.3.5
If relief valves are provided by the vessel manufacturer, the relief
valves shall be installed with block valves and testing inserts to allow testing of the relief valve while the vessel is in service. The block valve shall be located upstream of the relief valve and shall have a locking device to lock the valve in the open position.
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3.5.3.6 3.5.4
3.5.5
3.6
Unless specifically approved by the Company, rupture discs for
primary pressure relief shall not be provided.
Liquid Level Controls
3.5.4.1
Throttling type liquid level controls shall be mounted on the vessel.
3.5.4.2
A quieting chamber shall be provided for each internal float.
3.5.4.3
One level controller shall be provided for each liquid phase.
3.5.4.4
One level controller shall be provided for the water phase on free water knockouts. The level controller shall be of the throttling type and shall be connected to the primary dump valve.
3.5.4.5
Snap-acting controllers shall be provided for water service only.
External Control Columns
3.5.5.1
High-level and low-level shutdown sensors and level gauges shall
be installed on external control columns in accordance with VES7110, Installation of Instruments on Packaged Equipment, and if required by the project specifications.
3.5.5.2
Heating elements may be required of external control columns
containing liquids likely to freeze or congeal at low temperatures.
3.5.5.3
Gauge glasses shall be of the steel armored-type (reflex or
transparent) and shall be equipped with safety check valves. Tubular glasses shall not be installed on pressure vessels. Gauge glasses shall span the entire range of the liquid level including both low-level and high-level alarm points.
High Temperatures Any exposed surfaces subject to elevated temperatures in excess of 150 degrees Fahrenheit (oF) [66 degrees Centrigrade (oC)] shall be insulated with thermal insulation in accordance with VES-5146, Thermal Insulation and Fireproofing.
4.0
QUALITY ASSURANCE PROVISIONS
Quality assurance provisions shall be in accordance with VES-5120, Unfired Pressure Vessels, VES-1000, General Technical Condition for Tender and Purchase of Equipment and Materials and VES-1100, Requirements for Third Party Inspection Services.
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5.0
DOCUMENTATION REQUIREMENTS Documentation shall be provided in accordance with VES-1000 and VES-5120 with the following additional requirements. 5.1
The vessel fabricator shall provide detailed drawings of the separator internals.
5.2
Detail drawings of mist eliminators shall be submitted to the Company as part of the approval drawing set.
5.3
Statement of retention time for guaranteed liquid capacities shall be provided.
5.4
Vendor shall assemble the following information necessary for MIGAS certification into a separate document package. 5.4.1
Manufacturers Data Report
5.4.2
Assembly and Detail Drawings
5.4.3
Calculation Sheets signed by engineer
5.4.4
Welding procedure Specifications, Qualification Welder/Operator Qualification Test Records
5.4.5
Inspection Specifications
5.4.6 5.4.7
List of Material Mill Certificates (Showing location, heat number)
Mill Test Certificates
5.4.8
Manufacturers Inspection Results signed by inspector
5.4.9
Records
Actual Dimensional Records
NDT
Hydrostatic/Pneumatic Test Pressure Recording vs Time Chart
Post Weld Heat Treatment record charts (when applicable)
Hardness Test Records (when applicable)
and
Nameplate Rubbing
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6.0
PREPARATION FOR SHIPPING
Preparation for shipping and storage shall be in accordance with VES-1000, and VES-5120, with the following additional requirements.
6.0
6.1
After fabrication, ladders, platforms, and other removable pieces (including nuts and bolts) shall be completely fitted to the vessel in the shop to ensure the proper fitting, then disassembled and shipped separately.
6.2
Each removable piece of equipment that will be shipped separately from the vessel shall be identified with a metal tag. The tag shall be securely wired to the equipment. The identification tag shall include the vessel tag number to which each piece corresponds.
6.3
All instrumentation shall be shipped separately from the vessel.
6.4
Company shall be notified in writing of any of the following abnormal handling
procedures. -
Limitation on angle of lift
Restrictions for laying a vertical vessel down due to internals
Internal supports to be removed.
WARRANTY Warranty provisions shall comply with the requirements of VES-1000 as a minimum.
