Inspection and evaluation of damage mechanisms in two-phase vertical separator

Abstract

Pressure vessels are critical components in various industries that store or transport fluids under pressure. Ensuring their mechanical integrity prevents catastrophic failures and maintains safe and reliable operations, regular inspections are necessary to identify potential defects and damages that can compromise the vessel's integrity. However, practical guidelines for pressure vessel inspection are often not readily available in educational institutions and require specialized certification courses or on-field experience. This article aims to provide a comprehensive and practical approach to inspecting a two-phase vertical separator commonly used in oil and gas based on industry standards and codes, specifically targeting mechanical engineers, engineering students, and professionals entering the inspection field. It demonstrates the application of a standardized methodology for inspecting a pressure vessel and analyzing its damage mechanisms. The inspection standards applied in this study include API-510, API-571, API-572, API-579, and API-580. The inspection process encompasses both external and internal evaluations. External inspections focus on identifying conditions that may affect the mechanical integrity of the vessel, such as support structures, corrosion, or external damage. Internal inspections utilize visual and non-destructive testing (NDT) techniques to detect damage or discontinuities within the vessel. It includes inspection planning, component selection, thickness measurements, and NDT techniques. The external inspection findings include thickness measurements of the shell, nozzle, and coupling areas. The identified material loss percentages are compared to design limits, enabling the determination of remaining structural integrity and the need for repairs or further evaluations.