Pressure Vessel Design Consultancy – 20 Services for Test Separator

1. ASME Section VIII compliant design for test separator vessels

2. Phase separation system optimization for accurate testing

3. Dynamic load and stress analysis for separator and associated piping

4. Design of separator internals (trays, baffles, demisters)

5. Material selection for corrosion resistance (e.g., stainless steel, carbon steel)

6. Pressure and temperature profile design for separation processes

7. Design of isolation valves and control systems

8. Vibration analysis for pump and separator equipment

9. Corrosion monitoring and mitigation strategies

10. Energy recovery system design for vent gases or heat exchange

11. Safety valve and vent system design for overpressure scenarios

12. Flow balancing and optimization for oil, gas, and water phases

13. Testing and validation of separation efficiency

14. Design of blowdown and purging systems

15. Design for easy maintenance and cleaning access (inspection ports, manways)

16. Hydrostatic and pneumatic testing support for pressure vessels

17. Design of emergency shutdown (ESD) systems

18. Shop and field welding quality assurance

19. NDT (Non-Destructive Testing) services

Test Separator System Design & Engineering Scope

📌 Piping Design

1. Feed inlet piping (from the wellhead or upstream system)

2. Test gas line (for flow rate measurement)

3. Oil outlet piping (for measured product or crude oil)

4. Water outlet piping (for produced water)

5. Gas and liquid phase vent lines (for flash gases)

6. Bypass piping for test system switchovers

7. Sampling piping (for oil, gas, and water analysis)

8. Pressure relief and vent piping (for overpressure protection)

9. Drain lines for purging and system cleaning

10. Instrument tapping lines for pressure, flow, and level control

📌 Civil & Foundation Engineering

1. Foundation design for test separator (dynamic and static loads)

2. Skid-mounted foundation or standalone base for modular systems

3. Piping support foundations

4. Structural support design for piping racks and platforms

5. Platform design for easy access to separator and instrumentation

6. Access road and walkways for ease of operation

7. Drainage and bunding for spill containment

8. Corrosion protection for piping and supports

9. Cable trenching and electrical foundation work

10. Soil investigation and foundation design for stability

📌 Pumps (Related to Test Separator)

1. Produced water pump for separation and disposal

2. Oil transfer pump for sending separated oil to storage

3. Test gas pump for pressurization (if required)

4. Sample pumps for transferring liquids for testing

5. Drainage pump for accumulated liquid/slop

6. Chemical injection pump for corrosion inhibition

📌 P&ID (Piping & Instrumentation Diagram)

1. Gas, oil, and water phase control loops

2. Level control loops for separators and interface between phases

3. Pressure control for vessel and pipeline protection

4. Flow measurement instrumentation (for oil, gas, water)

5. Pressure relief valves (PRV) for overpressure protection

6. Gas vent and liquid purge piping

7. Sampling and instrument tapping points

8. Bypass and isolation valves for system maintenance

9. Vent and flare system integration

10. Shutdown and emergency control logic

📌 Related Heat Exchangers

1. Oil cooler (for maintaining oil temperature)

2. Gas cooler (for cooling test gas prior to measurement)

3. Water cooling exchanger (for produced water treatment)

4. Condensate coolers (for separation of hydrocarbons)

5. Gas-to-liquid heat exchangers (for energy recovery)

6. Water-to-water exchangers (for cooling or reusing produced water)

📌 Instrumentation

1. Flow meters for measuring oil, gas, and water phases

2. Temperature transmitters for monitoring test conditions

3. Level transmitters (for separator liquid levels)

4. Pressure transmitters for both separator and outlet systems

5. Differential pressure gauges for phase separation efficiency

6. Density meters for measuring oil/water separation quality

7. pH meters for water quality monitoring

8. Gas analysis instrumentation for composition measurement (if required)

9. Vibration sensors for pump monitoring

10. Corrosion probes for pipeline protection

📌 Related Day & Temporary Storage Tanks

1. Oil storage tank (for tested crude or product)

2. Produced water tank for storing separated water

3. Slop tank for waste product collection

4. Temporary chemical injection tank

5. Test gas storage tank (if applicable)

6. Flare knock-out drum for separating liquid from vent gases

7. Emergency storage tank for overflow scenarios

8. Sample collection tank for testing

📌 Process Design

1. Separator design (including phase separation calculations)

2. Temperature and pressure profiles for stable operation

3. Liquid-gas phase equilibrium for accurate test measurements

4. Flow balancing between test streams

5. Retention time calculations for proper separation

6. Energy recovery design for vent gases or heat exchange

7. System startup and shutdown procedures

8. Separation efficiency and optimization (for accurate test data)

📌 Mechanical Design

1. Separator vessel design per ASME Sec. VIII

2. Nozzle and flange design

3. Thermal expansion and stress analysis for the separator shell

4. Structural supports (including saddles or skirts)

5. Corrosion-resistant material selection (stainless steel, alloys)

6. Drum internals design (baffles, mist eliminators, separators)

7. Design for ease of inspection and maintenance (manways, inspection ports)

8. Vibration analysis for pump and separator internals

9. Welding procedures for pressure vessel construction

🔷 2. Surge Tank Applications – 20 Relevant Examples

1. Feedstock surge tank for test separator flow balancing

2. Oil surge tank for storing separated crude

3. Water surge tank for produced water handling

4. Gas surge tank for gas phase stabilization

5. Test product surge tank for sampled output

6. Test gas accumulator for vent gas storage

7. Slurry surge tank for slop or chemical waste

8. Separation slurry surge tank

9. Condensate surge tank

10. Overflow surge tank for system overflow conditions

11. Bypass surge tank for maintenance bypasses

12. Sample collection surge tank

13. Cooling water surge tank

14. Slop and waste surge tank

15. Backup storage tank for emergency scenarios

16. Pressure relief surge tank (for venting gases)

17. Temporary surge tank for system cleaning and startup

18. Hydrocarbon vent surge tank

19. Emergency overflow surge tank

20. Flare surge tank for gas handling during high-pressure conditions