Engineered Solutions toSeparation Problems

Slug Catchers

Separation Products from Taylor Forge

Taylor Forge EngineeredSystems has been aleading manufacturer ofliquid separation equip-ment for the pipelineindustry for over fortyyears. We design andmanufacture all types ofvessels, components,sub-assemblies andcomplete systems for liquid separation andstorage. Our extensiveexperience in componentmanufacturing andknowledge of field con-struction has helped usdesign products that minimize costs and installation time.

Each liquid separationsystem has its ownunique characteristicsand must be examinedon a case-by-case basis.This bulletin concen-trates on the separationand storage of large volume liquids from natural gas. We do, however, furnish all sizesof systems.

Horizontal Separator Vessel

� Can give small particle separation (10 microns)where there is more liquidand lower gas flow.

� Useful as three phaseseparator.

� Becomes expensive andheavy when large sizesare required.

� Good separation up to 5 - 700 bbls. slug size.

Vertical Separator Vessel

� Useful where small particle separation (10 microns) isrequired and gas flow islarge in relation to liquidslug size.

� Equipment is expensiveand heavy when large sizesare required.

� Good separation -- useful up to 5 - 700 bbls.slug size.

Pipe Fitting Type Slug Catcher

� Very economical where small liquid slugs are to be caught.

� Particle separation is poor and relatively unpredictable.

� Catches slugs up to 150 - 200 bbls.

This type of separation equipmenttypically has an impingement plateto knock out bulk liquids and a verti-cal column to form a gravity typeseparator, but it usually has insuffi-cient area to effectively removesmall particles. Normally, it is justused to catch the slugs of liquid andhold them. For economic reasons,these slug catchers are usuallydesigned as pipe and fittings, ratherthan as pressure vessels.

The pipe fitting type slug catcherprovides good slug separation andslug storage volume at a reasonablecost. Small particle separation ispoor, but it improves at low flowrates. A slug catcher of this type canbe used to protect a centrifugal typeseparator and the combination willgive separation and slug storagecapacity.

Harp Type Separator/Slug Catcher

� Economical way to catch large slugs(thousands of barrels).

� Gives predictable particle separation in the 50 micron and up sizes.

� Predictable separation up to tens of thousands of barrels slug size.

� Ships in pieces for field assembly with line pipe.

� When slug size is largeenough to justify the logistics of field assembly, and B31.8 type construction is allowed, the harp type separator/slug catcher will be considerably cheaper than vessels.

The Taylor Forge Engineered Systems harp type sepa-rator/slug catcher is a versatile device for catching slugsand separating liquid and solid particles from pipelinegas. It is built from high strength material and in its largersizes can offer cost and delivery savings over vesseltype slug catchers.

The units can be furnished completely engineered in-cluding the pig trap, separator/slug catcher, foundationand instrumentation The separator/slug catcher can beburied below groundor placedon piers above ground asconditions require. Controls can be integrated into theexisting systems. The system can be split in two halvesfor redundant operation and/or sequential construction.

Effective level controls are normally installed, including avent line from a level column near the liquid manifold tothe gas out manifold. With proper interconnections andthe addition of interface controls, the sludge manifoldcan be used to effectively separate water from hydro-carbon liquids. If liquid particles smaller than 50microns are to be removed from the gas stream, sepa-rator elements can be added to the dry gas manifold ordownstream of the slug catcher.

Depending on various conditions or the particular appli-cation, the basic design configuration may be easilymodified. The use of multiple slopes and/or elbowsallow the slug catcher to be filled to a higher level withoutdanger of re-entrainment and carryover of liquid. Theuse of reducers and/or a two-level arrangement allowsthe separation and storage tubes to bedifferent sizes foreconomy and more efficient operation. The two-levelarrangementalsoshortens theinstallation and allows thebulkof the liquid to be diverted from the gas stream priorto the separation of the smaller particles.

The separator/slug catcher consists of several modules— distribution header, separation chambers, dry gasrisers, storage harps, and liquids and sludge manifolds.

The distribution manifold takes the incoming gas/liquid stream, slows it down, and splits it into severalsmaller streams to allow uniform flow into the separationchambers.

In the separation chambers, the majority of the gasliquid separation is accomplished. The required length,size and number of these chambers is a combinedfunction of gas flow, gas chemistry and other knownconditions.

The primary functionof thedrygasrisers is todeliver drygas back into the system. As some secondary separa-tion occurs here, their sizing is important.

The storage harps hold the liquids at line pressure andthe number and length of these harps is determined bythe storage requirements, i.e., slug size — 2 phase andresidence time — 3 phase. Secondary separation alsooccurs here.

The liquid and sludge manifolds provide separation ofthe water, oil and debris. The oil and water are thenremoved from the storageend for further processing (oil)or reinjection (water). Thedebris is cleaned outon an asneeded basis. When the liquid build-up in the lines isheavy and lines are long, many barrels’ of liquid cancollect. When pigging lines, this liquid arrives at theslugging rate and must be stored at pressure or flashedand disposed. Inoffshore applications and cold climates,thousands of barrels of storage may be required.

Taylor Forge Pipe TypeSeparator/Slug Catcher Offers a Number of Benefits and Advantages!

� Predictable Efficiency -- Using worst-case design, our system is ableto perform separation when a vessel separator cannot.

� "Carryover" -- is prevented because our system is designed for worst caseand unexpected slugs are handled along with the uninterrupted gas flow.

� Ease of Installation -- Our TF separat-or/slug catcher system is shipped toyou in prefitted modules. The fieldcontractor only makes circumferentialbutt welds to fit the system together.

� Full Onstream Operation -- Our slugcatchers are on-line while pigging ordumping and can be automated to anydegree you wish.

� Short Lead Time -- We reduce the time required from purchase order to operation. Our delivery is normally less than one-third the time to get a large vessel-type separator.

� Planned Phase Addition -- Our de-signs allow your company to add more capacity as gas supply increases, with minimum lead time, minimal expenseand no shut-down.

� Cost Effective -- We offer cost sav-ings up to 50% over conventional large OD vessel and pipe collection programs. Particular savings are realized when ANSI B31.8 design is used.

� Large Volume Storage -- The largevolume storage is accomplished by themost economical way known -- in-linepipe or storage pipes.

� Sludge Manifolds -- The sludge mani-fold can be cleaned with on-line maintenance while unit is in operation.

� Single Source Responsibility -- Wecan supply all structural, process andmechanical engineering for your separation installation.

Stora

Dry Gas Risers

Separation Chambers

Two Phase In

STANDARD ARRANGEMENT

BETTER FLOW - FRONT ENDFILL HIGHER

age Harps

Liquid &Sludge

Manifold

Dry Gas Out

Distribution Manifold

SHORTER - SEPARATE SEPARATORFILL HIGHER

LIQUID DIVERTED SOONERSHORTER - SEPARATE SEPARATORFILL HIGHER

SHOP FIT REQUIRED

SHOP FIT REQUIRED

Subsea Slug CatcherDesigned to solve the problems associatedwith underwater production, the Subsea SlugCatcher is a compact and modular unit, suit-able for installation on the sea floor. TheSubsea Slug Catcher, built into its own struc-ture, can be dropped into place with a single lift.

Our patented Pig Bypassing Device directsliquid slugs and gas through the slug catcherwhile allowing the pig to bypass the slug catcher.This mechanism eliminates the need for diversto launch and receive pigs around the slugcatcher.

Typical Installation ofPig Bypassing Device at Slug Catcher

Detail of distribution header

We Can Offer Complete Process and Mechanical Responsibility Based on Total Project Management� VALUE ANALYSIS

What type of separator slug catcher is right for your application?

Long term plan for fieldDesign codesEquipment type and

arrangementType of materialType of construction

� PROCESS DESIGN

Gas Conditions2 or 3 phase

Constituent analysis

Slug ForecastingLine profileTemperaturePerformance

Separation EfficiencyMicron sizeMinimize carryover

Material Balance DiagramPiping and Instrument

DiagramVent SystemLiquid Removal

� MECHANICAL DESIGN

Design CodeANSI B31.8ANSI B31.3ASME CodeBS5500

Piping Flexibility AnalysisIncluding all thermaland

mechanical stresses

Anchoring systemPigging systemAbove and below grade

� MANUFACTURING/FABRICATION

MaterialsHigh yield -- Y-52

to Y-70Carbon steelLow temp. with charpy'sHIC resistant

In-House TestingCharpy V-notchTensilesHardness --

Brinell, RockwellWeld bend

RollingFive rollsHot or coldMax. 7-1/2" thick

WeldingASME IXAPI 1104

Closed Die FormedExtrusion

Controlled wallthickness and radius

Dimensional flexibility

Heat TreatingNormalizeQuench and temperStress relieve

Non-Destructive TestingAll in-house testingRadiographyUltrasonicMagnetic particleDye penetrant

FabricationLargest pieces

shippable to minimize field fabrication

Pre-Fit and Match-MarkSpecial Coatings

Above groundBelow ground

Site PeculiaritiesWater tableWeatherSeaside or mountains

� CONSTRUCTIONMANAGEMENT

Land SurveySoil SamplingField Weld ProceduresQualify & Train Field

WeldersNDT ServicesConstruction SequencingOn-Site Surveillance

� START-UP AND TRAINING SERVICES

Start-Up System including Valve Sequencing

Establish Operating CyclesVerify PerformanceOperations/Maintenance

Training

� MATERIALS MANAGEMENT

Project coordination and uniformity

Worldwide sourcing capabilities

Domestic sourcing as required

Material delivery timingLinepipeInstrumentsElectrical

� CIVIL DESIGN

Optimize Site LocationOptimize Site Utilization

Single levelMulti-level

Facility Expansion or Grass Roots Facility

Company Name Phone No.AddressPerson to ContactPosition Date

Pressure Design OperatingTemperature Design Operating

Gas S.G.Composition

Flow Rate Design Initial

Liquids S.G.Composition

Flow Rate Design InitialWater Flow Rate Design InitialEstimated Liquid Slugging Rate Design InitialDesired Hold Up (bbls.or time) Design InitialSpecial Conditions and Site Limitations:Instrumentation and controls:

Project timing:

QUESTIONNAIRE

Extruded Outlets (Air Grid Hub and Arm)

Slug Catcher (Offshore Facility Utilizing Headers)

12,000 psi Y-70/Y-80 Scraper Trap Skid High Yield and NuclearReducers and Elbows

208 N. Iron StreetPaola, Kansas 66071Telephone: (913) 294-5331Telex; 62192610FAX: (913) 294-5337

High Yield and Nuclear Tees and Caps

Trap with Patented Closure (Skid Mounted for Export)

Pressure Vessels (Steam Drum)

Traditionally Dependable