SPE

Society of Petrolelm EngineeI'S of AIME

SPE 7175
APRACTICAL APPROACH TO CRUDE OIL STOCK TANK VAPOR RECOVERY
by John A. Griswold, Member SPE-AIME, Power Service, Inc., and Ted C.
Ambler, A &N Sales, Inc.

Copyright 1978, American Institute of Mining, Metallurgical, and Petroleum Engineers, Inc.
This paper was presented at the 1978 Rocky Mountain Regional Meeting of the Society of Petroleum Engineers of AIME held in Cody, Wyoming, May 17-19,1978. The material is sUbject to correction by the
author. Permission to copy is restricted to an abstract Qf not more than 300 words. Write 6200 N. Central Expwy., Dallas, Texas 75206.

ABSTRACT secondary and tertiary projects. Vapor Recovery Units

(VRUs) have also become more important to all inter-
Vapor Recovery, along with low pressure gas, is mittent low pressure gas or wet vapor production
finally becoming a'practica1 and profitable under- whether at the well head, battery, gas plant, or
taking. Its increased priority rating among pro- refinery. The reasons being that the problems of
ducers' initial, secondary and tertiary considerations automatically and safely handling a fractional suction
has been due to the steadily increasing value of gas pressure along with a fluctuating availability are
and liquids as well as environmental pressures. Power similar.
Service, Inc (PSI) and A & N Sales (VAREC) have
collaborated to successfully produce Vapor Recovery A & N Sales, who represents VAREC (the name is a
Units that reliably cover the important requirements. shortened form of Vapor Recovery) equipment, has
They have found through considerable study and exper- developed, through both companies considerable years
ience, from the producers' viewpoint, there are (6) of experience, a patented (Pat.#3,8l7,265-USA) con-
important requirements. First, a good estimate of the trol process that has been very successful even in
volume available and it's value economically justifi- the severe conditions of North Dakota sour gas. PSI
able. Second, a suitable discharge source located has combined the Allis-Chalmers Rotary (Ro-F10) Gas
close enough to fit the economics. Third, well sealed fitted Compressor, which they represent, with the A &N
and relief protected storage vessels to prevent their system to provide simple and practical but complete
collapse or burst, without the introduction of air and packaged units that have performed successfully in the
i~'s resulting corrosion and explosion hazards. adverse conditions and gas of the Rocky Mountains.
Fourth, a large diameter light weight vapor collection In this co-authored paper, they describe, from a
system with pressure sensing line, both having maximum producer's viewpoint, what factors must be considered
gradient, overhead mounting (no dips or underground), in order to size and properly fit an application for
good insulation and preferably, heat taping or tracing. good results.
Fifth, since suction pressures are 0 PSIG or fractional
negative or positive, a complete and very sensitive PROJECT SELECTION
pneumatic control system. Sixth, the least complicated
low pressure single. stage compressor unit possible. Naturally an economic amount of gas or vapors
The authors have attempted to show a practical and must be available, but these are of no value if there
reliable approach to these requirements that will is no practical place to deliver them. Thus a gas or
result in a successful, low maintenance, profitable crude oil pipeline, fuel pipeline, gas plant, or
and complete system, subject to minimal operating refinery must be, sufficiently close to fit the econo-
problems. mics of your project. This discharge source should
be able to accept gas at single stage pressures of not
INTRODUCTION over 70 PSIG and preferably 60 PSIG and under. How-
ever, two stage and even three stage is not out of
Until recent years or months, vapor recovery had the picture on projects with volumes or economics to
very low priority rating in producers' considerations, justify the additional original and upkeep costs and
as the value of the loss to the atmosphere was not complication. Generally in these cases only a reci-
great enough to compete with the other problems and procating machine can be considered with its increased
equipment required for a production facility. This is number of moving parts and pieces, added to the need
not quite as true in other oil field areas as it is in for intercoo1ing, with additional scrubbing, fluid
the Rocky Mountains. Now with environmental pressures handling, accessories, size and etc. Some refinery and
and the more important practical and profitable gas plant vapor recovery is possible at higher suction
reasons, caused by increased value of gas and liquids, pressures. With these, single stage compression is
this has changed to one of major priority on initial, still possible, but at discharge pressures up to 150
PSIG and more, since the overall compression ratio may
References and illustrations at end of paper.
 2 A PRACTICAL APPROACH TO CRUDE OIL STOCK TANK VAPOR RECOVERY
started when more than .2" W.C. vapor pressure is
again available. See Figure 3 for a hook-up illus-
tration.
BLANKETING CONTROL
The above would seem to be enough control but
there is another very real consideration found from
actual operation, and that is facility for tank gas
blanketing in a hurry. When the crude oil is dumped
from a tank manually or by LACT unit, this can cause
a large drain on the vapor system going rapidly to a
negative vapor pressure. With a combination vacuum
and pressure relief on the tanks or gathering system,
air would be sucked in before tank collapse, but the
air is almost as undesirable. So a second, smaller,
very sensitive pneumatic regulator is tied in with the
same above sensing line connected to its large dia-
phram, but set to start opening at .2" W.C. negative.
It also closes at this point on vapor pressure rise.
This regulator (called the "dry gas" regulator as
opposed to the "wet gas" regulator above)3is pre-
ferably connected to a separate 20 PSIG source of dry
or make-up gas which it feeds quickly back into the
tank before air can come in. It too is full open at
.6" W.C. negative. The VRU discharge can also be used
as a gas source, but it is usually hot and wet, so it
is less desirable. See Figure 3, 4 & 5 for typical
hook-ups.
COMPRESSOR SYSTEM
Most vapor recovery projects can not justify
more than single stage compression because of the
greater initial cost, additional complication, and
continuing operational and maintenance costs. Thus
it is well worth pursuing the discharge pressure
options to as low as is practical to maintain single
stage compression (less than 70 PSIG). This will
usually allow utilization of either Rotary or
Reciprocating Compression for a broader choice of
equipment.
We've found the liquid cooled rotary compressor
well suited for VRUs because of its simplicity, no
valves or surge bottles, only 15 parts to its make
up, reduced noise and vibration, automatic unloaded
starting, constant volume during wear, and normal
(2) year service, even in sour gas, before
requiring only blades, bearings, seals and gaskets. 2
We prefer to size for twice the capacity
indicated on the graph in Figure 1 when vapor
production is intermittent, for this requires higher
capacity rates at times than are indicated by the
24 hour total production, in order to get it all.
When continuous dump treaters are used vapor produc-
tion should be steady, so sizing could be reduced,
but it is always wise to have some oversize. Since
most compressors can be direct connected or belt
driven, we select belt drive so that the capacity can
be easily changed up or down with the life of the
field.
Jacket cooling on discharge pressures around
200°F can be handled successfully with static or
thermo syphon cooling to further eliminate cost and
equipment. This is usually accomplished with
50/50% glycol (or light oil), excess piping surface,
a surge tank and a high temperature shut down.
Lubrication is normally by a forced feed
lubricator with level control and shut-down. 15
SPE 7175
gallon tank, hose, and stand.
DRIVERS
Explosion proof electric motors are the simplest
driver system, but with no electricity, engines
work fine and have the advantage of easy speed
control. Engines usually limit the control and panel
to strictly pneumatic (gas operated), involving
considerable more space, cost, complication and
maintenance. The micro switch - solenoid valve
combination is then l2v DC, run from a battery and
alternator. This all works well since very little
power is required. In some situations, a little
A-C power is often available for even more electrical
control. Everything is either pneumatic or
explosion proof except for the motor controller,
which can be weather proof and mounted out of the
hazardous area.
INLET SYSTEM
A good low pressure scrubber (non-code if 15 PSIG
or less - relief valve protected) with S.S. mist
extractor, relief valve, gage glass, high liquid
level shut down, manual drain and some sort of
automatic drain,is required. Since this accumulated
liquid, which amounts to approximately 1 to 2
gal/lOOO CF (GPM) dependent on suction temperature
and pressure variance, is usually a hydrocarbon
.mixture of valve, it should be collected. We
usually equip the scrubber with an additional level
control that automatically starts and stops a
transfer pump on the VRU. They are then pumped
back to the crude oil stock tanks for gravity
improvement, or into the VRU discharge downstream
from the discharge check valve to be pushed on to
sales. See Figures 3, 4 and 5 for examples.
When an engine is utilized, or if preferred,
a blow case is added instead of the pump, complete
with another level control (electric or pneumatic).
The liquids are then automatically transferred
(or blown down) through the force of the VRU
discharge gas, or q separate dry gas source, to
whatever location is preferred and of a suitable
pressure lower than the blow down source.
A 100% area perforated cone screen is also a
good investment downstream of the scrubber at the
compressor inlet flange. It can be permanently
removed after the first month of operation or retained
with regular cleaning and inspection.
With the wet gas regulator, automatic by-pass,
suction relief valve, and dry gas regulator for
multiple suction protection, we do not believe a
high-low suction pressure shut down is required. A
combination inches W.C. vacuum to inches W.C.
pressure gage, close to the compressor inlet flange,
is helpful. A red fluid manometer is connected to
the sensing line to accurately show the more impor-
tant tank vapor pressure and allow for regulator
adjustment. If a high-low suction pressure shut
down were to be included it should be connected
with the manometer to the sensing line or to the
gathering line ahead of the VRU inlet butterfly
valve. It must also be combination inches W.C.
vacuum and pressure.
The VRU inlet line, as shown in Figures 3, 4
and 5 usually consists of a flanged spool with dry
SPE 7175 JOHN A. GRISWOLD AND TED C. AMBLER 3

still not be too great to be practical for rotary or on the tanks.

reciprocating compressors.
The graph in Figure 1 has been found to be an
accurate estimating tool l All you need know is
treater dumping pressure and API gravity to select an
estimated tank battery GOR. This same graph works well
for gas plant or refinery vapors.
The VRU needs to be placed as close as practical
to the tanks, so gradient can be maintained to enter
the suction scrubber from above. This prevents
possible freeze traps from occuring in dips or under-
ground piping. See Figure 3 for a typical good con-
nection.

A more accurate measurement of vapor volumes can An option that is advisable is a pressure relief
be made with an orifice well test meter on the tank in the gathering line just ahead of the VRU, set a ll:!
battery vent or flare line. This can be rented or ounce positive and connected to the flare line. This
purchased, and a few weeks or months' run will provide insures that for any reason the VRU is down, the
a good record both at high day-time and low night-time vapors will go to flare. A flame arrestor and auto-
temperatures. The meter must be of the very low rna tic igniter can be included. This is very impbrtant
pressure range, able to handle tenths of an inch water for sour gas.
column (W.C.) pressure with large enough orifice plates
to create the minimum back pressure. When vapors are SENSING LINE
produced intermittently and eratically, it is easy to
miss the excess which pops out the thief hatch or Crude oil stock tank physical strength is so low
other relieving device, because the vent or flare line that accurate, reliable control is required to operate
back pressure shot up too high. The tank sealing, within tenths of an inch W.C. Thus the sensed pressure
covered below, also applies to the accuracy of this should come from a separate line, preferably 2" dia-
measurement. meter. This line is static with no flow and can also
be light weight. It should attach to the gathering
. Laboratory tests on crude oil samples whether manifold as close to the center of the tanks as
measured from original pressure through decline, or possible to provide an average pressure. Maximum
gas recombining, are also helpful guides. Our exper- gradient, insulation, and heat as suggested above for
ience has found the actual field measurement, properly the gathering line also applies to this line. Our
accomplished, to be the most accurate with Figure 1 preference is that the controls be mounted on the VRU
the best estimating tool. A good gas analysis is for better adjustment, attention, and maintenance.
required for specific gravity, K- or N-value calcula- Thus this line should follow all the way back with the
tion, and corrosion awareness, to guide equipment gathering line and can share its insulation and heat.
sizing and selection. The BTU and liquids content Controls can, however, be mounted up on the tank
along with suction temperature is also helpful. batteries, but the added expense of the longer line to
the VRU usually more than pays for itself in better
TANK EQUIPMENT performance of the controls. An automatic float type
trap and dump should be included at the end of this
Good tank sealing is a must, as most batteries line to handle condensed liquids. Figures 2 and 3
have several ways to leak valuable profit and to take show a good sensing line hook-up.
on air. Gaskets on thief hatches can deteriorate
rapidly and their maintenance is generally low priori~ CONTROLS
Thus a non relieving, tight, but easily removable cover
is recommended. Relieving through one reliable com- As mentioned several times above, the suction
bination vacuum and pressure relief valve (with pressure working range is so limited, the controls
optional fl~me arrestor, if preferred), mounted on must be, very sensitive and repeatable. Large diaphram
~~~h tank (API 2000), set at 2 to 4 ounce positive and pneumatic regulators fit this requirement well. The
.5 ounce negative, appe;r:ttsbest. One should also be wet gas or vapors coming off the tanks are regulated
installed on the gathering line. Unfortunately most down to .2" W.C. positive. Sensing comes through the
systems we S'e'tl are losing vapors to atmosphere and,.special 2" line to the back side of the diaphram.
taking on air. Thus the tank top pressure is held in a range below
2 ounces (relief valve setting on tank gathering line)
GATHERING and generally 1 ounce (below relief to flare) down to
.2" W.C. positive. Through this ra.nge vapors are con-
Gathering requires mlnlmum pressure drop in tinually being recovered. The regulator valve closes
tenths of an inch W.C., so large diameter pipe is at .2" W.C. and also starts to open at this pressure.
needed. Use the maximum affordable. Fiber glass or It is full open at .6" W.C. When the tank vapors have
plastic is ideal, as the pressures do not justify code been removed down to .2" W.C. the regulator trips a
construction. If these are not acceptable, then cer- micro switch and solenoid valve combination that
tainly thin wall metal for light weight in overhead pneuma.tically opens a by-pass valve (on Rotary Com-
mounting and handling. Excessive gradient helps pressors) or unloads the compressor (on Reciprocating
insure that any liquids formed will gravity drain to Compressors) awaiting production of more vapor. We've
the VRU suction scrubber, for very little pressure or found this much better than start-stop, as often it
differential is available to push them. Insulation in can occur more than (5) times an hour. This is a rule
cold climate is necessary to prevent freeze offs. of thumb for switching to continuous load-unload or
Heat taping or tracing can also be very helpful. by-pass service, since the start-stop wear and tear on
Ideally, the gathering manifold should run in the equipment as well as electric power supply becomes
center of the tanks to allow each tank equal access excessive at this point. On engine drive VRUs this
with no tank first or last on the line; for hardly type service is a must. On electric motor drive units
any pressure is available to overcome friction loss the control can be overridden by an adjustable timer
differentials. This requires additional mounting so that if unloading or by-passing runs for say 30 or
supports. Figure 2 shows a compromise hook-up mounted 60 minutes the unit is shut down, but automatically
 4 A PRACTICAL APPROACH TO CRUDE OIL STOCK TANK VAPOR RECOVERY SPE 7175
gas regulator discharge port, butterfly valve, wet VRU but in the hazardous area.
gas regulator, check valve, scrubber, combination
suction pressure gage, cone screen and compressor The (5) shut-downs are: High suction scrubber
inlet. liquid, low lubricator level, high-low compressor
coolant temperature, high-low discharge pressure,
DISCHARGE SYSTEM and high-low discharge temperature. Some options
are high-low suction pressure, vibration-compressor,
Figures 3, 4 and 5 show typical discharge compon- and vibration-motor.
ents. On the compressor discharge flange is a port for
high-low discharge pressure shut down and gaging. The Engine units require a considerable amount more.
next spool contains a port for a high-low discharge They are normally pneumatic, gas-operated with a
temperature shut-down and gaging, automatic pneumatic fuel shut-off and vent valve the stopping mechan-
by-pass valve system tied back into the scrubber, ism. The (5) main shut-downs listed above are
discharge relief valve and optional manual discharge included along with low engine oil level, high-
blow down valve by-passing around the relief valve. The low engine oil pressure and high-low engine coolant
rotary compressor mentioned above always starts temperature. Options can include vibration for
unloaded and does not act as a check valve so a blow the engine, compressor and cooler (if one is
down in unnecessary, unless it is used for initial included), high-low engine oil temperature and
line purging. The valve can also be tied back to the coolant pump pressure differential. These panels
suction scrubber to conserve the vapor if utilized are usually mounted on the VRU or on a building
more frequently and another valve, outside the VRU in wall or floor with piping to the sensing points.
the sales line, used for purging. A check valve They are also tied into the filter, regulation
~sually ends this line. and venting systems that 'supply blow case (blow
down) gas, fuel gas, engine starter gas, and level
COOLING control gas. All vents are collected to pipe out
side or back to the suction scrubber, whichever
The discharge would be continued to an after- is most convenient or preferred.
cooler if one was required. We feel this can be
eliminated most of the time to save cost and complica- MEASUREMENT
tion, as the hot wet gas is usually going into another
compressor suction scrubber. If the piping is such Most VRUs have no orifice meters on their
that any liquids which form, due to cooling, could discharge to allow a good evaluation of their
be handled in the next compression suction scrubber or performance. They are only noticed, when down,
other similar receiving system, it is unnecessary to by the rich liquid loss and gas volume decline
after-cool and scrub on the VRU. This may not be true at downstream plants. To complete a project of
on long buried and wrapped discharge lines because this nature and evaluate it properly, requires
hydrates could form, wrapping deteriorate or dehydrat- some form of gas and/or liquid measurement.
ors Dunction improperly. In these cases, after-cooling
with scrubbing and all accessories as on the suction CORROSION
scrubber should be added.
Sour gas is the main corrosion problem encoun-
When after-cooling is required it is normally tered. Since VRUs are low pressure and generally
advisable to add jacket cooling for the compressor not considered a code restricted unit, just the
(and engine if used). This does not add that much elimination of copper and copper alloys on the
cost or facility and produces better results. A equipment covers this well. The control regulators
circulation pump with thermostatic control generally are obtainable in all aluminum with viton or teflon
becomes part of the compressor jacket cooling system. diaphrams, or cast steel with the same trim.
When only circulated compressor jacket cooling is Cast iron or aluminum on other valves and piping
required a separate radiator system with pump and will usually supply adequate rating, life and
thermostatic control is supplied at a much lower protection.
cost. On all electric VRUs, fans and pumps are
usually direct driven by individual electric motors If the unit is preferred built to code require-
and tied into the main controls. On engine drive ments, there are many new provisions for welding,
units they are belt driven. Shutters are manual but stress relieving, x-ray and NACE specifications to
can be automatic, optionally. include with the old standards, wherever dangerous
gases are involved. All of these can be met at
CONTROL PANELS additional cost.

Electric units generally hav.e (5) shut downs, all
explosion proof. These are either mounted at the sens-
ing point or grouped on a small panel. This panel can
be supplied loose for separate mounting or mounted at
a central location on the unit, with sensing piping
and capillary run to it. The electrical signals are
wired with explosion proof fittings to a weather
proof combination starter-fused disconnect with
control transformer and HOA. It is mounted outside
the hazardous area. Indicating lights or tattletales
are usually incorporated in the cover of this outside
panel. As mentioned before, an adjustable timer can
be included to limit the amount of time on vapor by-
passing. All of this can be combined in an explosion
proof enclosure for mounting at one spot on or off the
Compressors need be special fitted and adapted
for this service, but for most this is only an
additional cost as it is readily available or
standard, as it is on the liquid cooled rotary.
Teflon or Micarta rotary blades, rings, valve
p1ates~ packing and gaskets are used with stainless
steel, double mechanical seals, special lubrication
and venting to accomplish this adaption.
Although the sour gas and its atmosphere does
reduce the material life of the equipment, enclos-
ures, and buildings, if fitted properly, a good
economic cost compromise can be reached. Personnel
safety can normally be well covered by the addition
of gas detectors, automatic building venting when
 SPE 7175 JOHN A. GRISWOLD AND TED C. AMBLER 5

doors open, fire d'etection and the above special REFERENCES

fitting.
TYPICAL INSTALLATIONS
Even though vapor recovery is still new to the
Rocky Mountains, there are installations, of several
manufacturers, on which the operators may be
willing to comment. Contacting them will add to the
practical considerations the authors have tried to
present in this paper. Some of these are listed below
and have been in existence long enough for good
conclusions:
Colorado:
Amoco Production Co. - Peoria, Spindle,
Third Creek
Montana:
Texaco - Sidney
1. Weldon, R. E. Jr.
The Atlantic Richfield Co., Dallas, Texas
"Could You Recover Stoc~ Tank Vapors at a
Profit"
The Petroleum Engineer, May 1961
2. Hansen, J. P., Sr. Application Engineer,
Rotary Compressors
Allis-Chalmers Corp., Milwaukee Wisconsin
"Rotary Compressors as Ideal Vapor Recovery
Machines" 72-Pet-l8
The American Society of Mechanical Engineers
Petroleum Mechanical Engineering & Pressure
Vessels & Piping Conference
New Orleans, LA - Sept. 17-21, 1972
3. VAREC, Inc.
"Pollution & Gas Control Equipment."
Technical Bulletin CP-6003 6-72

North Dakota
Amerada-Hess - Tioga
Northland Oil & Refinery Co.- Dickinson
Texaco - Blue Buttes, Charlson, Keene
True Oil Co. - Red Wing Creek

Utah:
Gary Operating Co. - Roosevelt
Shell Oil Co. - Roosevelt, Duchesne

Wyoming:
Amoco Production Co. - Elk Basin, Ryckman
Creek
Chevron Oil Co. - Painted Reservoir
Marathon Oil Co. - Byron, Garland
True Oil Co. - Donkey Creek

CONCLUSION

If the following requirements are properly

considered and included in the project design, a
successful operation should result.

1. Utilize good vapor volume estimates

and gas analysis to arrive at a total
value, with all possible costs included.
2. Select the least expensive, lowest
pressure discharge source or sales outlet.
3. Fit the tanks for minimal vapor loss or
air intake.
4. Include a large diameter, insulated,
gathering and sensing system with extra
gradient to drain.
5. MOST IMPORTANT: Choose complete, sensitive
and reliable controls.
6. Search out the simplest and least expensive
compression system and accessories.

NOMENCLATURE

"Dry Gas" - processed gas or at least another gas

source
PSI - Power Service, Inc. & Pounds Per Square Inch -
Gage Pressure measurement
Ro-Flo - Allis Chalmers Rotary Compressor - Trade Name
VAREC - Vapor Recovery Inc. or VAREC, Inc. and
A&N sales, their local repres61tative
VRU - Vapor Recovery Unit
W.C. - Inches, Water Column Pressure Measurement
"Wet Gas" - Tank Vapors
//0

~
~
~4
Q
~~ Jt+----+--r---+----.--

~
~
~ 2!u-c-------+--~__+_.--_+_--___+_

~
~
/l""'"r----L.2Q----:::-sl...:-o--40+-----l-O--G...,..L-O---7i-!..v--a-=-'o
o Si
PReSS. 0;:= 14-55E.(. DUM !=:J//VS TO 7AN~/S - PS I G
Fig. 1 - Estimated volume of tank vapors.
Fig. 2 .. Schematic - Ta nk vapors' .
pl pwg.
 Fig. 3 - Schematic - flow diagram, VRU.

Fig. 4 - Typical electric powered VRU. Fig. 5 - Typical engine powered VRU.