. Pressure Vessel Design Consultancy – 20 Services for HP/HT Separator

1. HP/HT separator vessel design per ASME Section VIII Div.1

2. Phase separation design for optimal oil, gas, and water phases

3. Thermal analysis for high-temperature operations

4. Pressure vessel fatigue and stress analysis

5. Corrosion protection strategies (internal and external)

6. Design of internals for separation efficiency (baffles, demisters)

7. Seismic analysis for HP/HT systems in high-risk zones

8. Design of safety relief systems (PRVs and emergency vents)

9. Nozzle and flange design for HP/HT connections

10. Corrosion monitoring system design

11. Chemical injection system design (for corrosion inhibition)

12. Design of safety shutdown systems (ESD systems)

13. Hydrostatic and pneumatic testing for HP/HT vessels

14. Vibration monitoring system design

15. Design for operator accessibility (inspection ports, platforms)

16. Welding procedure specification (WPS) design

17. Energy recovery and vent gas systems design

18. Fatigue analysis for HP/HT conditions

19. NDT (Non-Destructive Testing) consultation for material integrity

20. HAZOP and SIL safety studies for HP/HT process systems

 

🔷 1. HP/HT Separator System Design & Engineering Scope

📌 Piping Design

1. High-pressure feed inlet piping (from the wellhead or production stream)

2. Separation outlet piping (for oil, gas, and water phases)

3. Gas venting lines (for flare or vent gas disposal)

4. Water disposal piping (for separated produced water)

5. Oil transfer piping (for crude or product oil)

6. Purge and drain lines (for separator cleaning and maintenance)

7. Chemical injection lines (for corrosion and scale prevention)

8. Test and sampling piping (for liquid and gas samples)

9. Pressure relief piping (for overpressure scenarios)

10. Bypass and isolation lines (for maintenance and system switching)

📌 Civil & Foundation Engineering

1. Heavy-duty foundation design for HP/HT separator (supporting high pressure and temperature)

2. Skid-mounted or modular foundation for flexible design and transport

3. Structural foundation for piping supports and structural members

4. Platform design for personnel access to separator and instrumentation

5. Reinforced concrete foundations for separator stability under dynamic loads

6. Corrosion protection for piping supports, structural components, and foundations

7. Access walkways and staircases for safe access to the separator and instrumentation

8. Drainage and bunding design for fluid containment and environmental protection

9. Fire protection and suppression systems (to manage potential risks)

10. Seismic design (if applicable, for regions prone to earthquakes)

📌 Pumps (Related to HP/HT Separator)

1. Produced water pump (for disposal or treatment of produced water)

2. Oil transfer pump (for sending separated crude oil or product)

3. Gas compressor (for gas phase compression if required)

4. Test gas pump (for pressurizing systems or testing)

5. Chemical injection pump (for controlled chemical dosing)

6. Slop or waste liquid pump (for handling waste hydrocarbons)

7. Slurry pump (if separation results in slurries)

8. Recirculation pump (for recirculating fluids within the separator system)

📌 P&ID (Piping & Instrumentation Diagram)

1. Separator feed control (for managing feed pressure and flow)

2. Phase separation control loops (for accurate oil, gas, and water phase division)

3. Level control systems for managing the interface between phases

4. Pressure control loops (for maintaining pressure within safe limits)

5. Flow meters for oil, gas, and water streams

6. Temperature control systems for temperature regulation within separator

7. Sampling points for process analysis (oil, gas, water)

8. Safety valves (PRV) for pressure relief in case of overpressure

9. Blowdown and purge lines for periodic system cleaning and maintenance

10. Isolation valves for switching systems or isolating equipment

📌 Related Heat Exchangers

1. Produced gas cooler (for cooling separated gas prior to venting)

2. Oil cooler (for maintaining oil temperature post-separation)

3. Produced water cooler (for temperature control before disposal or treatment)

4. Shell and tube heat exchangers for heat recovery or temperature management

5. Condenser heat exchangers for gas cooling or condensation

6. Heat exchangers for energy recovery (if vent gas is reused or heat is transferred)

7. Air coolers (for cooling systems when water is unavailable)

📌 Instrumentation

1. Flow meters for accurate measurement of oil, gas, and water streams

2. Pressure transmitters for monitoring vessel and pipeline pressures

3. Level transmitters for managing phase separation and vessel control

4. Temperature transmitters for controlling high-temperature fluids

5. Density meters for measuring separation efficiency between phases

6. pH meters (for water phase quality monitoring)

7. Gas analyzers for gas phase composition measurement

8. Vibration sensors for monitoring pump and separator health

9. Corrosion probes for real-time monitoring of material degradation

10. Differential pressure gauges for monitoring phase separation effectiveness

📌 Related Day & Temporary Storage Tanks

1. Oil storage tank (for storing separated crude oil)

2. Produced water storage tank (for storing produced water before treatment or disposal)

3. Slop tank (for storing waste or slop fluids during separator operation)

4. Chemical injection tank (for chemicals required in the separation process)

5. Gas surge tank (for storing vent gas or stabilized gas streams)

6. Test gas storage tank (if test gas is generated and requires storage)

7. Overflow tank (for handling any excess fluids during operation)

8. Slurry storage tank (for waste byproducts or sludges)

9. Backup fuel tank (for fuel storage for backup power generation)

10. Sampling tank (for representative samples of oil, gas, and water phases)

📌 Process Design

1. Separator design for high-pressure and high-temperature conditions

2. Phase separation optimization (efficiency in oil, water, and gas phase separation)

3. Flow distribution and balancing between oil, gas, and water streams

4. Heat management (temperature control for efficient separation)

5. Separation time calculations for ensuring adequate retention time

6. Energy recovery strategies for vent gases or heat

7. Chemical dosing systems for corrosion or scale inhibition

8. Pressure drop management across the separator and associated piping

9. Startup and shutdown procedures for smooth commissioning and decommissioning

10. Safety analysis and design (HAZOP, SIL studies for HP/HT operations)

📌 Mechanical Design

1. Pressure vessel design (for ASME Section VIII compliance under HP/HT conditions)

2. Separator internals design (baffles, mist eliminators, etc.)

3. Thermal expansion analysis for high-temperature systems

4. Structural supports (skirt or saddle design)

5. Corrosion-resistant material selection (appropriate for HP/HT environments)

6. Nozzle and flange design for high-pressure connections

7. Vibration analysis for separator and associated equipment

8. Design of emergency vent systems (relief valves and blowdown systems)

9. Internal coating design for corrosion protection

10. Fatigue and stress analysis for separator materials under HP/HT conditions

🔷 2. Surge Tank Applications – 20 Relevant Examples

1. Feed surge tank (for stabilization of feed to the separator)

2. Oil surge tank (for storing separated oil product)

3. Gas surge tank (for storing gas phase or vent gas)

4. Produced water surge tank (for temporary storage of produced water)

5. Slurry surge tank (for waste byproducts)

6. Chemical dosing surge tank (for temporary chemical injection storage)

7. Test gas surge tank (for storing generated test gases)

8. Overflow surge tank (for overflow during shutdown or surge conditions)

9. Slop surge tank (for collecting unwanted liquids)

10. Recirculation surge tank (for controlling recirculating flow)

11. Condensate surge tank (for light hydrocarbons and condensates)

12. Vibration damping surge tank (for controlling flow surges)

13. Emergency backup surge tank (for storing fluids during emergencies)

14. Discharge surge tank (for storing final phase-separated fluid)

15. Bypass surge tank (for flow control when bypassing the separator)

16. Knock-out drum surge tank (for gas/liquid phase separation)

17. Water treatment surge tank (for storing water pre-treatment)

18. Pre-separation surge tank (for temporary storage prior to separation)

19. Contingency surge tank (for unexpected fluid accumulation)

20. De-oiling surge tank (for storing produced water post-de-oiling process)