Patent Publication Number: US-2017355006-A1

Title: Flange Assembly for Heater Treaters and Other Vessels

Description:
CROSS REFERENCES TO RELATED APPLICATION 
     Priority of U.S. Provisional Patent Application Ser. No. 62/349,919, filed Jun. 14, 2016, incorporated herein by reference, is hereby claimed. 
    
    
     STATEMENTS AS TO THE RIGHTS TO THE INVENTION MADE UNDER FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 
     None 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention pertains to a connection assembly for use in connection with vessels. More particularly, the present invention pertains to a flange assembly for use on oil and gas processing equipment. More particularly still, the present invention pertains to a flange assembly for use with fire tubes of heat-treating separator vessels. 
     2. Brief Description of the Prior Art 
     Generally, processing equipment in the oil and gas industry has remained substantially unchanged for many years with very little variation in design or innovation. One such piece of equipment that has remained essentially unchanged over time is the emulsion/oil treating vessel or heated separator, which is also commonly referred to as a “heater treater”. 
     Conventional heater treaters generally comprise a vessel defining an inner chamber. A fire tube—typically in the shape of a “U” or other similar configuration—at least partially extends into said inner chamber. A fire or other heat source provides heat energy to said fire tube, typically within the inner portion of said tube. Heater treaters can be found on both onshore (land) and marine locations, and are commonly used in very low pressure or artificial lift applications. 
     Fluids produced from subterranean wellbore (typically oil, other liquid hydrocarbons, water, natural gas and/or combinations thereof) are introduced into said inner chamber. Heat from the fire tube is transferred from said fire tube to such fluids contained within the inner chamber of the heater treater vessel. Application of heat to said fluids helps to improve separation of such components. 
     Originally, conventional heater treaters comprised relatively small vessels designed for relatively low pressure service, typically with a Maximum Allowable Working Pressure (“MAWP”) of 25 psi or less. Over time, the size (fluid capacity) and MAWP of such vessels have increased significantly; in some instances, conventional heater treaters can exceed 8 feet in diameter with a MAWP in excess of 250 psi. Nonetheless, despite such dramatic increases in size and operating parameters, the basic design of heater treaters has not changed. As a result, such conventional heater treaters are frequently being used in applications for which they were never designed. 
     Fire tube flange assemblies of conventional heater treater vessels often sustain significant damage and have high potential for failure. Such conventional fire tube assemblies, which are used to mount a fire tube within the internal chamber of a heater treater vessel, generally comprise mating bolted flanges having a neoprene rubber gasket disposed said flanges. As operating conditions become more extreme MAWPs increase, such flange assemblies (including, without limitation, such rubber gaskets) are frequently at risk of failing. 
     When said rubber gaskets degrade—particularly over time—said conventional flange assemblies can lose fluid pressure seal integrity, resulting in fluid leakage from said flange assemblies. Such fluid leakage can negatively impact the environment surrounding a heater treater, resulting in significant remediation expense and production downtime. Moreover, because leaking fluids can be flammable (such as oil, natural gas or other hydrocarbons) and/or toxic, such fluids can cause bodily injury or death to personnel. 
     Further, fire tube flange assemblies generally are not universal or interchangeable. As a result, it is frequently difficult and/or expensive to change out fire tubes between heater treater vessels because attachment flanges often do not match from one heater treater to another. Heater treater manufacturers generally each make their own flange pattern or design; fire tubes from one manufacturer generally cannot replace the fire tubes of another manufacturer. 
     Thus, there is a need for a fire tube flange assembly for use on heater treater vessels. The fire tube flange assembly should provide greater pressure sealing integrity, while permitting efficient removal and installation of heater treater fire tubes. 
     SUMMARY OF THE INVENTION 
     The present invention comprises a substantially oval-shaped raised face blind flange member. Said raised face blind flange member has a plurality of holes for receiving a fire tube of a conventional heater treater or other heated separator vessel. A plurality of bores is disposed around said oval-shaped, raised face blind flange member in spaced relationship. 
     A mating substantially oval-shaped, raised face slip-on flange member, also sometimes referred to as a vessel flange member, is provided on said heater treater or other heated separator vessel. A plurality of bores is disposed around said oval-shaped, raised face blind flange member in spaced relationship. In a preferred embodiment, dimensions of said raised face slip-on flange member are substantially consistent with the dimensions of said raised face blind flange member, allowing said opposing flange members to be secured together against each other in mating face-to-face relationship. 
     At least one alignment pin extends outwardly from said raised face slip-on flange member in a substantially perpendicular orientation or direction. At least one alignment aperture is provided on said raised face blind flange member; said at least one alignment aperture is beneficially aligned with said at least one alignment pin and adapted to receive said at least one alignment pin. 
     In a preferred embodiment, said bores disposed around said raised face slip-on flange member are aligned with bores disposed around said raised face blind flange member. Fasteners can be received within each set of aligned bores in order to apply compressive forces to said opposing flange members and secure said flange members together. By way of illustration, but not limitation, said fasteners can each comprise threaded bolts and threaded nuts. 
     In a preferred embodiment, each of said oval-shaped, raised face blind flange member and said oval-shaped, raised face slip-on flange member complies with ANSI B16.5 Class 75, 150, 300, 600, and/or 900 series specifications, including bolt pattern and type requirements. Further, a non-asbestos sealing gasket is disposed between said opposing flange members. 
     The present invention eliminates current risks and limitations associated with conventional flange designs. Among other benefits, the flange assembly of the present invention provides improved safety, and allows for quick and efficient replacement and/or repair. Further, because said flange assembly provides greater fluid pressure sealing capacity, said flange assembly of the present invention permits safe operation of heater treaters and/or other heated separator vessels at higher MAWPs. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS/FIGURES 
       The present invention comprises a substantially oval-shaped, raised face blind flange member. Said raised face blind flange member has a plurality of holes for receiving a fire tube of a conventional heater treater or other heated separator vessel. A plurality of bores is disposed around said oval-shaped, raised face blind flange member in spaced relationship. 
       The foregoing summary, as well as any detailed description of the preferred embodiments, is better understood when read in conjunction with the drawings and figures contained herein. For the purpose of illustrating the invention, the drawings and figures show certain preferred embodiments. It is understood, however, that the invention is not limited to the specific methods and devices disclosed in such drawings or figures. 
         FIG. 1  depicts a side perspective view of an outer surface of a raised face blind flange member of the present invention. 
         FIG. 2  depicts a side perspective view of an inner surface of a raised face blind flange member of the present invention. 
         FIG. 3  depicts a sectional view of a raised face blind flange member of the present invention along line  3 - 3  of  FIG. 2 . 
         FIG. 3A  depicts a detailed view of the area highlighted area  3 A depicted in  FIG. 2 . 
         FIG. 4  depicts a side perspective view of an inner side of a raised face blind flange member of the present invention equipped with a conventional fire tube. 
         FIG. 5  depicts a side view of a raised face blind flange member of the present invention equipped with a conventional fire tube. 
         FIG. 6  depicts a perspective view of an inner side of a raised face slip-on flange member of the present invention. 
         FIG. 7  depicts a perspective view of an outer side of a raised face slip-on flange member of the present invention. 
         FIG. 7A  depicts a detailed view of the area highlighted area  7 A depicted in  FIG. 7 . 
         FIG. 8  depicts a sectional view of a raised face slip-on flange member of the present invention along line  8 - 8  of  FIG. 7 . 
         FIG. 9  depicts a side perspective view of a gasket member of the present invention. 
         FIG. 10  depicts a side partially exploded view of a conventional heater treater vessel equipped with a flange member of the present invention. 
         FIG. 11  depicts a side view of a conventional heater treater vessel equipped with a flange member of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     Referring to the drawings,  FIG. 1  depicts a perspective view of a raised face blind flange member  10  of the present invention including, without limitation, outer surface  20  thereof. In a preferred embodiment, raised face blind flange member  10  of the present invention comprises a substantially planar member having a substantially flat outer surface  20  and oval outer shape defining circumferential edge  13 . 
     Still referring to  FIG. 1 , said raised face blind flange member  10  has a plurality of holes  40  and  41  for receiving a fire tube of a conventional heater treater or other heated separator vessel, as described more fully herein. Further, a plurality of bores  50  is disposed around said oval-shaped, raised face blind flange member in spaced relationship, and provide apertures for receiving fasteners. 
       FIG. 2  depicts a side perspective view of an inner surface  30  of said raised face blind flange member  10  of the present invention (generally representing the opposite side of said raised face blind flange member  10  that is depicted in  FIG. 1 ). Raised face blind flange member  10  has substantially oval outer shape defining circumferential edge  13 . Holes  40  and  41  extend through said raised face blind flange member  10  for receiving a fire tube of a conventional heater treater or other heated separator vessel (not shown in  FIG. 2 ). A plurality of bores  50  is disposed around said oval-shaped, raised face blind flange member in spaced relationship. 
     A raised section  60 —that is, an area having a greater thickness than the remainder of said flange member  10 —forms a substantially-oval shaped loop and is disposed along inner surface  30  of flange member  10 . Said raised section  60  is generally positioned in a space formed between bores  50 , on one side, and holes  40  and  41  on the other. Put another way, said holes  40  and  41  are disposed inside of a closed loop formed by raised section  60 . 
       FIG. 3  depicts a sectional view of a raised face blind flange member  10  of the present invention along line  3 - 3  of  FIG. 2 . Raised face blind flange member  10  has inner surface  30 , outer surface  20 , and outer circumferential edge  13 ; in a preferred embodiment, said inner surface  30  and outer surface  20  are substantially flat. Although not visible in  FIG. 3 , it is to be observed that holes  40  and  41  extend through said flange member from inner surface  30  to outer surface  20 . A plurality of bores  50  is disposed around said oval-shaped, raised face blind flange member  10  in spaced relationship. Raised section or area  60  protrudes or extends from inner surface  30  of flange member  10 . 
       FIG. 3A  depicts a detailed view of the area highlighted area “ 3 A” depicted in  FIG. 2 . Raised face blind flange member  10  has substantially flat inner surface  30  and outer circumferential edge  13 . A plurality of bores  50  is disposed around said oval-shaped, raised face blind flange member  10  in spaced relationship. Raised section  60  protrudes or extends from inner surface  30  of flange member  10 , and defines a plurality of substantially parallel and alternating grooves  61  and ridges  62 . As depicted in  FIG. 3A , said ridges  62  have substantially flat upper surfaces; however, it is to be observed that said upper surfaces of said ridges can have other shapes including, without limitation, pointed edges or rounded edges. 
       FIG. 4  depicts a side perspective view of raised face blind flange member  10  of the present invention equipped with a conventional fire tube  210 , while  FIG. 5  depicts a side view of said raised face blind flange member  10  of the present invention equipped with said conventional fire tube  210 . Referring to  FIGS. 4 and 5 , raised face blind flange member  10  has substantially flat inner surface  30  and oval shape defining outer circumferential edge  13 . Fire tube  210 , the general design and configuration of which is well known to those having skill in the art, is disposed through holes  40  and  41  that extend through said raised face blind flange member  10 . A plurality of bores  50  is disposed around said oval-shaped, raised face blind flange member in spaced relationship. Raised section  60  forms a substantially-oval shaped loop and is disposed along inner surface  30  of flange member  10 , and is generally positioned between bores  50 , on one side, and holes  40  and  41  on the other. Put another way, raised section or area  60  forms a loop that substantially extends around conventional fire tube  210 . 
       FIG. 6  depicts a side perspective view of a raised face slip-on flange member  110  of the present invention including, without limitation, inner surface  130  thereof. In a preferred embodiment, raised face slip-on flange member  110  of the present invention comprises a substantially planar member having a substantially oval outer shape defining circumferential edge  113 . Said raised face slip-on flange member  110  has a central opening  140 ; slip-on lip member  141  is disposed around the outer edge of said central opening. In a preferred embodiment, said slip-on lip member  141  is oriented substantially perpendicular to substantially planar flange member  110 . Further, a plurality of bores  150  is disposed around said oval-shaped, raised face slip-on flange member  110  in spaced relationship, and provide apertures for receiving fasteners. 
       FIG. 7  depicts a side perspective view of an outer surface  120  of said raised face slip-on flange member  110  of the present invention (generally representing the opposite side of said raised face slip-on flange member  110  that is depicted in  FIG. 6 ). Raised face slip-on flange member  110  has central opening  140  and a substantially oval outer shape defining circumferential edge  113 ; slip-on lip member  141  is disposed around said central opening  140  and is oriented substantially perpendicular to substantially planar flange member  110 . A plurality of bores  150  is disposed around said oval-shaped, raised face slip-on flange member  110  in spaced relationship. Raised section  160 —that is, a portion having a greater thickness than the remainder of slip-on flange member  110 —forms a substantially-oval shaped loop and is disposed along outer surface  120  of flange member  110 , and is generally positioned in a space formed between bores  150 , on one side, and central opening  140  on the other. 
       FIG. 7A  depicts a detailed view of the area highlighted area “ 7 A” depicted in  FIG. 7 . Raised face slip-on flange member  110  has substantially flat outer surface  120  and outer circumferential edge  113 . A plurality of bores  150  is disposed around said oval-shaped, raised face blind flange member  110  in spaced relationship. Raised section  160  protrudes or extends from said outer surface  120  of flange member  110 , and defines a plurality of substantially parallel and alternating grooves  161  and ridges  162 . As depicted in  FIG. 7A , said ridges  162  have substantially flat upper surfaces; however, it is to be observed that said upper surfaces of said ridges  162  can have other shapes including, without limitation, pointed edges or rounded edges without departing from the scope of the present invention. 
       FIG. 8  depicts a side sectional view of a raised face slip-on flange member  110  of the present invention along line  8 - 8  of  FIG. 7 . Raised face slip-on flange member  110  has outer surface  120 , inner surface  130 , and outer circumferential edge  113 ; in a preferred embodiment, said inner surface  130  and outer surface  120  are substantially flat and generally oriented parallel relative to each other. Raised face slip-on flange member  110  has central opening  140  and slip-on lip member  141 ; said slip-on lip member  141  is disposed around said central opening  140  and is oriented substantially perpendicular to outer surface  120  and inner surface  130 . A plurality of bores  150  is disposed around said oval-shaped, raised face slip-on flange member  110  in spaced relationship. Raised section or area  160  protrudes or extends from outer surface  120  of flange member  110 . 
       FIG. 9  depicts a side perspective view of a gasket member  180  of the present invention. Gasket member  180  generally has substantially flat and oval-shaped body section  181  defining a loop having a central opening  182 . A plurality of bores  183  is disposed around said gasket member  180  in spaced relationship. It is to be observed that said gasket member  180  is designed to be received between opposing inner surface  30  of blind flange member  10  and outer surface  120  of slip-on flange member  110 . In this position, apertures  183  can be aligned between (also aligned) apertures  50  and  150  of said blind flange member  10  and slip-on flange member  110 , respectively. Gasket member  180  can comprise any number of different materials including, without limitation, flat ring sheet types and/or metallic composites such as spiral wound and double jacketed types well known to those having skill in the art. 
       FIG. 10  depicts a side partially exploded view of a conventional heater treater vessel  200  equipped with the raised face flange members of the present invention. As depicted in  FIG. 10 , heater treater vessel  200  defines inner chamber  201 , and has external drain ports  202 . Fire tube port neck  203  extends outward from said heater treater vessel  200  and substantially surrounds an opening for receiving a fire tube, such as fire tube  210 . In this configuration, outer surface  120  and raised section or area  160  of said raised face slip-on flange member  110  face outward relative to heater treater vessel  200 . 
     Still referring to  FIG. 10 , slip-on flange member  110  is disposed on said heater treater vessel  200 . Specifically, as depicted in  FIG. 10 , slip-on lip member  141  is sized so that it can fit over/around fire tube port neck  203 ; said slip-on lip member  141  is then welded or otherwise permanently attached to said fire tube port neck  203 , with an impervious fluid pressure seal. 
     Fire tube  210  is received within bores  40  and  41  (not visible in  FIG. 10 ) of blind flange member  10 , and said blind flange member  10  is aligned with slip-on flange member  110 . In a preferred embodiment, dimensions of said raised face blind flange member  10  are substantially consistent with the dimensions of said raised face slip-on flange member  110 , allowing said opposing flange members to be secured together against each other in mating face-to-face relationship, with gasket member  180  disposed there between. Said gasket member  180  is beneficially compressed, thereby energizing said gasket member and creating a fluid pressure seal. 
     Still referring to  FIG. 10 , at least one alignment pin  190  extends outwardly from said raised face slip-on flange member  110  in a substantially perpendicular orientation or direction. In a preferred embodiment, said at least one alignment pin  190  is substantially cylindrical in shape; however, it is to be observed that other protruding extensions having other shapes can be used without departing from the scope of the present invention. At least one mating alignment aperture is provided on said raised face blind flange member  10 ; said at least one alignment aperture is beneficially vertically and horizontally aligned with said at least one alignment pin  190 , and is adapted to receive said at least one alignment pin  190  when said blind flange member  10  and slip-on flange member  110  are moved together in joined relationship. 
     During installation of a fire tube (such as fire tube  210 ) into a heater treater vessel (such as heater treater vessel  200 ), the weight and configuration of said fire tube  210  can make it difficult to properly align said fire tube relative to said heater treater vessel opening. For example, said fire tube  210  can have a tendency to “skew”, such that it does not enter heater treater vessel  200  in a truly horizontal alignment which, in turn, can cause blind flange member  10  to tilt from a vertical orientation. Such tiling of blind flange member  10  can cause difficulty when attempting to align blind flange member  10  with slip-on flange member  110  in a substantially flush or face-to-face orientation. 
     In order to aid such alignment, said at least one alignment pin  190  can be aligned with and slidably received in opposing aperture(s) in blind flange member  10  (such as aperture  191  depicted in  FIG. 3A ) before fire tube  210  is fully inserted into heater treater vessel  200 . When at least partially inserted within an opposing aperture  191 , said at least one alignment pin  190  prevents said blind flange member  10  from tilting from vertical and keeps said blind flange member  10  oriented substantially parallel with slip-on flange member  110 , particularly as said flange members  10  and  110  are moved together. As fire tube  210  penetrates deeper into heater treater vessel  200 , blind flange member  10  and slip-on flange member  110  remain substantially parallel to each other until they ultimately meet in face-to-face opposing relationship. 
     In a preferred embodiment, bores  150  disposed around said raised face slip-on flange  110  member are aligned with bores  183  of gasket member  180  and bores  50  disposed around said raised face blind flange member  10 . Fasteners can be received within each set of aligned bores in order to apply compressive forces to said opposing flange members and secure said opposing flange members  10  and  110  together. By way of illustration, but not limitation, said fasteners can each comprise threaded bolts and threaded nuts; however, other fasteners can be used without departing from the scope of the present invention. 
     In a preferred embodiment, each of said oval-shaped, raised face blind flange member  10  and said oval-shaped, raised face slip-on flange member  110  complies with ANSI B16.5 Class 75, 150, 300, 600, and/or 900 series specifications, including bolt pattern and type requirements. Further, gasket member  180  comprises a non-asbestos sealing gasket, and is disposed between said opposing flange members  10  and  110 . 
     Referring to  FIGS. 3 and 8 , raised section or area  160  protrudes or extends from outer surface  120  of flange member  110 , while opposing raised section  60  protrudes or extends from inner surface  30  of flange member  10 . It is to be observed that said raised face sections or areas  160  and  60  are raised above or extend beyond the other opposing surfaces of said flange members. As such, said raised sections or areas  160  and  60  concentrate more pressure on a smaller area of gasket member  180 , with ridges  62  and  162 , respectively, optionally penetrating and/or deforming said compressed gasket member  180 , thereby increasing the pressure containment capability of mated flange members  10  and  110 . 
     The present invention eliminates current risks and limitations associated with conventional flange designs. Among other benefits, the flange assembly of the present invention provides improved safety, and allows for quick and efficient replacement and/or repair. Further, because said flange assembly provides greater fluid pressure sealing capacity, said flange assembly of the present invention permits safe operation of heater treaters and/or other heated separator vessels at higher MAWPs. 
     The above-described invention has a number of particular features that should preferably be employed in combination, although each is useful separately without departure from the scope of the invention. While the preferred embodiment of the present invention is shown and described herein, it will be understood that the invention may be embodied otherwise than herein specifically illustrated or described, and that certain changes in form and arrangement of parts and the specific manner of practicing the invention may be made within the underlying idea or principles of the invention.