20 Pressure Vessel Design Consultancy Services

 for Vapor Recovery Towers

1. ASME-compliant mechanical design & calculations

2. Process simulation and sizing (HYSYS/ProMax)

3. VOC emission reduction evaluation

4. Retention time & separation efficiency analysis

5. 3D design & modeling for fabrication

6. Internal mist eliminator specification

7. Flare and VRU interface engineering

8. Skid-mount system design for modular deployment

9. Coating and corrosion protection design (NACE)

10. Seismic and wind loading calculations

11. Inspection Test Plan (ITP) development

12. Field erection and lifting study

13. Instrumentation & control loop integration

14. Interface with SCADA/DCS systems

15. P&ID generation and tag numbering

16. HAZOP and operability review

17. Commissioning and FAT/SAT support

18. Emission testing and reporting documentation

19. Upgrade/retrofit design for old systems

20. Owner's engineer services for EPC or FEED

 

 

 1. Vapor Recovery Tower (VRT) – Overview

A Vapor Recovery Tower (VRT) is a vertical pressure vessel installed upstream of vapor recovery units to reduce flash emissions by separating gas vapors from oil or condensate before storage tanks. VRTs operate slightly above atmospheric pressure, reducing VOC emissions, improving oil recovery, and enhancing environmental compliance.

🧱 2. Key Engineering and Equipment Elements

🔹 a. Piping

• Inlet line from separator or heater-treater

• Vapor outlet to VRU or flare

• Liquid outlet to storage tanks

• Drain line

• Relief line to flare or vent

• Bypass loop for operational flexibility

🔹 b. Civil Foundation

• Concrete pad with anchor bolts

• Support skid for modular designs

• Earthing for static charge dissipation

• Drain collection sump (optional)

• Maintenance access ladders/platforms

🔹 c. Pumps

(Not mounted on the VRT, but used downstream)

• Oil/condensate transfer pumps

• Drain sump pumps

• VRU booster pumps

• Tank unloading pumps

🔹 d. P&ID Elements

• Feed line from separator

• Vapor outlet to VRU/compressor

• Liquid out to tankage

• Emergency relief to flare

• Level control system

• Isolation and check valves

• Optional mist eliminator or demister pad

🔹 e. Instrumentation

• Level transmitter (LT)

• Pressure transmitter (PT)

• Temperature element (TE)

• High- and low-level switches

• Emergency vent PSV

• Interface to VRU panel or SCADA

🔹 f. Related Equipment

• Vapor Recovery Unit (VRU)

• Storage tanks (day tanks, condensate tanks)

• Flare system or vapor combustor

• Gas-liquid separator (upstream)

• Knockout drum (optional)

⚙️ 3. Process Design Considerations

• Operates at 1–10 psig to minimize flash loss

• Reduces hydrocarbon vapor emissions before tank entry

• Designed based on API 12R1 / ASME VIII

• Handles 3-phase fluid surge

• Retention time and settling velocity criteria

• Vapor handling capacity in SCFM or MSCFD

• VOC reduction >95% (if paired with VRU)

⚙️ 4. Mechanical Design Considerations

• Vertical pressure vessel per ASME Sec VIII Div. 1

• Pressure rating: 5–50 psig

• Corrosion allowance: typically 3 mm

• Internal mist extractor or mesh pad

• Quick drain and manway access

• Internal coating for H₂S or corrosive service

• Suitable for sour or sweet crude

🧾 5. 20 Vapor Recovery Tower Equipment Naming Styles

1. VRT-FlashSafe 1000 – Standard tower

2. EcoVap-TX – Environmental compliance design

3. ZeroLoss-VRT – Optimized vapor capture

4. TankSaver V2000 – High-capacity system

5. FlashControl VRT Elite – Precision vapor management

6. OilClean-VRT Compact – Skid-based model

7. AirGuard VRT-750 – Integrated mist eliminator

8. PurePhase-VRT HD – Heavy-duty build

9. CrudeTrap-VR – Designed for upstream crude

10. SafeFlash V-Tower – With high-level protection

11. GreenFlow VRT – Environmental variant

12. VapoShield Tower – For VOC compliance

13. MiniFlash VRT-400 – Small facility model

14. CondensGuard-VRT – With corrosion protection

15. UltraVap V500 – High-pressure service

16. VRT-ComboSafe – With integrated flare bypass

17. SmartFlash VRT – SCADA-ready

18. EmissZero VRT – Zero VOC loss design

19. BulkPhase Recovery-VRT – For large oil volumes

20. FlashGuard EcoLine – Cost-effective unit

🌍 6. 20 Applications of Vapor Recovery Towers

1. Crude oil production sites

2. Condensate production facilities

3. Tank battery systems

4. Gas wellhead separation facilities

5. Offshore wellhead platforms

6. Oil stabilization units

7. Oil tank truck loading facilities

8. Vapor Recovery Unit (VRU) front-end

9. Lease Automatic Custody Transfer (LACT) units

10. Refinery tank farms

11. Hydrocarbon condensate terminals

12. Enhanced oil recovery (EOR) operations

13. Midstream pipeline LACT units

14. Fuel blending terminals

15. Environmental compliance retrofits

16. Sour oil vapor control

17. Oil sands and shale oil facilities

18. Mobile crude storage solutions

19. Flare gas reduction projects

20. Tank VOC emission control upgrades