Pressure Vessels

Introduction

Objective
 Familiarise you with different types of process vessels
 Identify what the vessels are used for
 Consider any complications to linings
 Selection of linings for pressure vessels
o Review appropriate testing for the service
 Sherwin-Williams’ linings for vessels

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Upstream Oil and Gas

 Process vessels are to remove unwanted components and to make

suitable (non-corrosive) for transport and storage
 Upstream generally means exploration and production: Often offshore
 New construction – vessel fabricators or on site
 M & R – at site

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Linings for Pressure Vessels

 Many different types of pressure vessels exist

 Lining demands for each type differ
o Source of Crude
o Temperature
o Acidity
o Gas Composition
o Pressures
 Fast-cure in maintenance situations is often a requirement
o Vessels can be crucial to process

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 Oil Treatment
“Separation of oil and other hydrocarbons from
water and associated gas”
Test separators

 Testing of well fluids and flow rates

 May also be used as spare separation capacity
 Containing fluids from well work-over programs

Characteristic Potential Issue

Oil, Gas and Water 3 Phase immersion
Temperature Potential Cold Wall
Acidic Conditions Chemical Resistance
Sand Abrasion
High Pressures Decompression
Small bore nozzles Application and protection

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 Primary production Separators

 Separation of multiple phase systems once well established

Characteristic Potential Issue

Oil, Gas and Water 3 Phase immersion
Temperature Potential Cold Wall
Acidic Conditions Chemical Resistance
Sand and Jet Wash Systems Abrasion
High Pressures Decompression
Small bore nozzles Application and protection

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Secondary & Tertiary production separators

 Additional separation of already cut oil (Longer

residence time)

Characteristic Potential Issue

Oil and Water 2 Phase immersion
Temperature Potential Cold Wall (but lower
water content)
No abrasion
High Pressures Decompression
Small bore nozzles Application and protection

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Electrostatic precipitators (coalescers)

 Removal of final amounts of water from oil

Characteristic Potential Issue

Oil Simple immersion exposure
No abrasion
Installation of baffles Damage to lining

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Open / closed drains vessel

 Collection of run off hydrocarbon / water (open)

 Collection of additional process fluids (closed) – ie under pressure

Characteristic Potential Issue

Oil and Water 2 Phase immersion
Located in cool areas Potential cold wall
Potential Chemical exposure
No abrasion
Small bore nozzles Application

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 Gas Treatment
“Removal of liquid hydrocarbon from process gas”
“Removal of corrosive substances from gas prior to transport (gas sweetening)”
Fuel gas scrubber

 Removal of liquid from fuel gas

 Maintaining constant pressure in fuel gas system
 Vertical vessel shown but may be horizontal for
offshore systems

Characteristic Potential Issue

Liquid and Gas 2 Phase immersion
High Pressure
No abrasion
Small bore nozzles Application

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Flare gas scrubber (knock out drums)

 Removal of liquid from flare gas

 Prevents boil over of flare stack due to gas condensate or damage due to
water
 Vertical vessel shown but may be horizontal for offshore systems

Characteristic Potential Issue

Gas/water or gas / gas condensate 2 Phase immersion
High Pressure Depends on field
No abrasion
Small bore nozzles Application

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 Water Treatment
“Removal of final traces of oil
from process water”
Hydrocyclones (VortoilTM)

 Water treatment
 Final stages of oil removal

Characteristic Potential Issue

Water and some oil 2 Phase immersion
Maybe at high temperature Potential cold wall
No abrasion
Small bore nozzles Application

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WEMCO (Flotcell similar)

 Removal of oil from process water

Characteristic Potential Issue

Water 2 Phase immersion
Maybe at high temperature Potential cold wall
No abrasion
Access for linings Application

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 Injection System
“Use of seawater to boost
pressure in well reservoir”
Seawater injection filter (coarse strainer)

 Water treatment
 Removal of solids which may plug well / lines

Characteristic Potential Issue

Water + Solids 2 Phase immersion
Maybe at high temperature Potential cold wall
Solids Abrasion
Access for linings Application
Strainer may cause mechanical Damage to any linings
damage

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Dense medium filter

 Water treatment
 Removal of solids which may plug well / lines

Characteristic Potential Issue

Water + Solids 2 Phase immersion
Maybe at high temperature Potential cold wall
Solids Abrasion
Access for linings Application
Strainer may cause mechanical Damage to any linings
damage

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De-aerator vessels

 Water treatment
 Removal of oxygen from water prior to re-injection in the
well so as to allow different materials of construction.

Characteristic Potential Issue

Water Simpler requirements
Temperature depends on the field Potential cold wall
No abrasion
Access for linings Application

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Sources of Corrosion in Vessels
Pitting Corrosion

 Pitting is common in storage tank floor areas

o Electrochemical (Cathodic) corrosion
o Anaerobic (MIC)
 If not stopped may result in holes and loss of integrity
 Linings can be used to repair and prevent further corrosion

https://www.nace.org/resources/general-resources/corrosion-basics/group-1/pitting-corrosion

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How pitting is initiated

 The surface layer becomes the cathode when it is damaged and cracked
 A small area of metal is then exposed and becomes the anode.
o Cracks in protective coating o Mechanical Impact Damage
o Scratches, scuffs & small chips o Abrasion
o Non-uniform stress o Thermal expansion and decompression
o Defective metal substrate
o Turbulent fluid flow o Baffles and Fluctuating Pressure
o Non-uniform protective coating o Too thick or too thin
o Chemical attack on protective coating o Variable Chemistries present:
o Sour Gas
o Amines
o Water

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Lining Selection for Pressure Vessels
Requirements for Linings Recommendations

 There is currently NO single standard for testing pressure vessels

o One is under development (ISO 18796-2)

 We need to consider the likely service of the vessel

 There needs to be confirmatory testing to support recommendations

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Lining Selection

 The following information is required

o Chemical Composition
o Operating temperature (real not design – hence need for vessel datasheet)
o Operating pressure (again operating not design)
o Decompression rate (otherwise recommendations based on 100psi per min)
o If the vessel is insulated
o Steel Condition (if a maintenance project)

 It is important to specify on operating conditions

 Upset conditions (or cleaning) should be considered – but it is important
to appreciate that you do not need to specify a lining based on worst
case
o Potential for prohibitive cost and application

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Testing of linings for pressure vessels

 Chemical Immersion testing

 Standard Atlas Cell (as required by
customer or conditions)
 Pressurised Atlas Cell & Autoclave
 Steam Out?
 Typical exposures by vessel

Tests need to be representative of the

conditions otherwise the lining may
a. Not perform
b. Be over Engineered

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Other tests to consider

 Adhesion (before and after exposure)

 Cathodic Disbonding
o Care should be taken interpreting test data
o High temperature suggests better performance – but Oxygen levels are lower
at high temperatures (so the test can be less aggressive)
o Ambient and 65°C are often more representative of performance
 Flexibility
 Hardness
 Taber Abrasion (some vessels have sands)

CD test at 160°C
ASTM G8 at 23°C

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Application

Plural Single Leg

All Sherwin linings can be applied plural Next Generation linings designed for single leg

Practical for shop application Practical for shop and Field application

Great for “short” pot-life materials Care required for short pot-life materials

Reduces waste (mix what you need)

Complex specialty equipment Readily available equipment

Often Fast return to service Next generation linings have performance, cure
and application built in

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Plural Equipment Single Leg Equipment

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Sherwin-Williams linings
Typical Lining Requirements

Key Characteristics
Single Coat Options (removes intercoat adhesion and reduces application time)
Extended recoat interval to allow touch up during vital inspection
Suitable for the service conditions
Flexibility to allow for vessel expansion and contraction (thermal expansion and pressure fluctuations)
Proven Track Record
Superior Application / Inspection:
• Airless Spray
• Edge Retention

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Typical Test requirements

Test Method Requirement

Chemical Immersion In appropriate chemical exposure

Cathodic Disbondment 65°C as per CSA Z245.20-06

Flexibility Typically 2-3% Required

Taber Abrasion Required where abrasion an issue
Autoclave In appropriate chemical exposure
Steam Out As per conditions
Atlas Cell If thermal gradient a concern
Pressurised Atlas Cell If thermal gradient a concern

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Summary of test data for a typical lining

Test Method Result

Cathodic Disbondment ASTM G8 - 0mm

Cathodic Disbondment Elevated Temp CD (≤180°C) (BS EN ISO 20340:2009)
~ 10mm
Autoclave Shell 6 months exposure at 130°C / 30 Bar in
produced water (adhesion > 25MPa)
Autoclave Temperature: 149°C Pressure: 2000psi
Gas: 5 % H2S, 5% CO2, and 90 % CH4
Hydrocarbon: Toluene: Kerosene @ 1:1 by volume
Aqueous: 1% NaCl in Distilled Water
No degradation
Steam Out Meets requirements of Shell DEP

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Summary of Key Test Data – Next Generation

Test Method Result

Cathodic Disbondment Average 3mm as per ASTM G8

Flexibility 2.3%
Autoclave Temperature: 135°C Pressure: 500psi
Gas: 5 % H2S, 5% CO2, and 90 % CH4
Hydrocarbon: Toluene: Kerosene @ 1:1 by volume
Aqueous: 1% NaCl in Distilled Water
No degradation and post-test adhesion > 15MPa
Taber Abrasion: ASTM D4060
51mg/1000 cycles

Atlas Cell 28 days Pressurised Atlas Cell in DI water 65°C

Isothermal Immersion (>12 months) No failure: Sour Crude Oil at 275°F (149°C)

Isothermal Immersion (>12 months) No failure: Sour Crude Oil/5% NaCl in water at 99°C

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Its not just the paint!
How Sherwin-Williams Ensure Performance

 Office Based Technical Experts

o Review the operating data and customise recommendation

 Field Application
o Ensure application carried out correctly
o Train the applicators

 Opti-Check – visual pin-hole detection

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Ease of Inspection

 Opti-Check (OAP) technology visually identifies holidays (striped areas)

o New Construction
o Remains active to identify damage in planned inspections
 Light colours may be required for aviation fuels and water storage

Fluorescent blue pigment

in topcoat in this example

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Summary

 Vessels come in many shapes, sizes AND service conditions

 Lining selection is more complex due to variations in
o Chemical exposure
o Temperature
o Gas composition and Pressures
 It is not possible to specify generically (not all linings behave the same)
 Sherwin have a process for specifying linings (based on studying the
conditions AND reviewing history and test data)
 Sherwin Technology and Field Service help improve QC of the
performance linings needed in Pressure Vessels

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