VES - 5300

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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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

the following conditions:
-

Three-phase separators handling nonfoaming crude - 3 minutes

Free-water knockouts - 10 minutes

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

safety devices, instruments, and controls.
-

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High-pressure shutdown sensor

Low-pressure shutdown sensor
High-level shutdown sensor
Low-level shutdown sensor
Pressure relief valve
Liquid level controls

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Rev. 4, 11/02

3.5.2

High-Pressure and Low-Pressure Shutdown Sensors

3.5.2.1

3.5.2.2

3.5.2.3
3.5.3

Pressure controls
Level gauges
Pressure gauges
Thermometer

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.

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VES-5300
Rev. 4, 11/02