Vapor Recovery Unit (VRU) Principles

Vapor recovery units are designed to Vapor tight tanks have specialized
recover hydrocarbon vapors which for equipment, e.g. thief hatches, vent valves,
years were allowed to escape from etc. which maintain a positive pressure in
storage tanks. These vapors were thought the tank and keep evaporation to a
to be insignificant in terms of company minimum.
revenue and unimportant as a source of
pollution. As a result of common
production practices, these_vapors were
lost to the atmosphere. However, with the
installation of vapor recovery units, both
your company and your community
benefit. The value to your company lies
primarily in increased revenue, and to your
community in cleaner air to breathe.

Oil Storage
The first efforts at oil storage, which
included open pits and barrels, were
unsuccessful because of excessive
evaporation of the oil. Steel tanks were
better, but they still allowed significant
evaporation. Covering the tank helped, but
evaporation continued to be a major
problem until vapor tight tanks were used.
Vapor Pressure
As previously stated, part of the crude oil
vaporizes and fills the space between the
top of the oil and the tank top. As
temperature changes, pressure of the
vapor also changes. The warmer the crude
oil, the more it vaporizes, and the greater
the pressure. As the vapor cools, it

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condenses and pressure inside the tank
decreases. Even though pressure changes
are generally small, they can increase to a
point which makes venting necessary.
Within a tank battery (two or more tanks
together) if vapor pressure is high in one
tank, vapor moves to another tank with
less pressure through an equalizing line.
This occurs until pressure in all tanks is
equal and reaches a set point. At this
pressure the vapor recovery system
begins to operate by drawing vapor from
the stock tanks through a gas vent line to
the vapor recovery unit.
Vapor pressure inside the tank affects
operation of a vapor recovery unit the
most. Various pieces of equipment work
together to maintain a set pressure.
Maintaining this heated pressure helps to
ensure the vapor recovery system will
operate properly and efficiently. Also, it
reduces the probability that tank damage
will occur due to implosion or collapse
caused from pulling a vacuum on the tank.
Vapor Recovery Unit
Vapor recovery units (VRU’s) are designed
to recover vapors which ordinarily would
be lost to the atmosphere. Vapor recovery
units are installed when they are required
by federal regulation or when it is
determined that the quantity and vapors of
the lost vapors warrant the expense of a
VRU. These units are designed to comply
with Environmental Protection Agency
(ERA) standards regarding emission of
pollutants to the atmosphere.
Vapor recovery units have four basic
purposes :
- recover valuable hydrocarbons
- prevent air pollution
- reduce fire hazards
- prevent emission of poisonous gases,
e.g. hydrogen sulfide (H2S)
PROCESS FLOW AND COMPONENTS
A typical vapor recovery unit is shown
here. It consists of the following
components: suction scrubber, liquid
transfer pump, compressor, lubricator,
gas by-pass system, and control panel
(not shown).
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Suction Scrubber
Vapors enter the VRU through the suction
scrubber. It is here that any liquids, which
may have condensed in the gas vent line,
will settle out and collect in the bottom. If
liquids are allowed to enter the
compressor damage could result from the
liquids diluting compressor lubricant,
causing unnecessary wear to compressor
components.
Liquid Transfer Pump
When liquid level reaches a set point in the
scrubber, a liquid level controller starts the
liquid transfer pump. This pump transfers
liquid through the outlet line on the side of
the scrubber back to stock tanks. While
liquids return to the stock tanks,
hydrocarbon vapors at the top of the
scrubber are discharged to the
compressor. The vapors are compressed
so they can be injected into the gas
gathering system.
Compressor
The main component of the VRU is the
compressor. It may either be a single-
stage unit or a multi-stage unit depending
on the pressure requirements. There are
two types of compressors commonly
used:
Rotary Compressors :
Rotary compressors are generally used for
single-stage compression up to discharge
pressures of 50 psig. If higher discharge
pressures are needed, dual-stage rotary
compressors can compress gas up to
discharge pressures of 125 psig.
Reciprocating Compressors :
Reciprocating compressors are generally
used for single-stage compression up to
discharge pressures of 75 psig. When
discharge pressures in excess of 125 psig
are needed, multi-stage reciprocating
compressors are used.
When dual-stage compressors are used, a
second scrubber is installed to remove any
liquids from the vapor which may have
condensed as a result of first-stage
compression. This liquid removal is done
to prevent liquid slugs from entering the
second stage of compression which could
damage the compressor.
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Compressor and Vapor order:
Cooling. - maintain proper coolant level

In a VRU there may be more than one - keep hoses and seals in good condition
cooling system: one to cool the
compressor and one to cool the
- add antifreeze in cold weather
compressed vapors.
On reciprocating compressors, heat from
- use corrosion inhibitor
the compressor cylinder is dispersed to
cooling fins on the compressor housing
where heat is spread out over a larger - keep free of rust and dirt
surface area cooling the compressor and
preventing damage to the compressor. - keep free of any salt or scale forming
The larger the surface area, the more heat minerals.
will transfer over time. Fins must be kept
clean in order to effectively transfer heat
and keep the compressor from over
heating.
On rotary compressors, heat from the
compressor is transferred by water to a
cooling system which resembles an
automobile radiator. Hot water enters a
cooling coil in the radiator where heat is
passed through the coil wall to attached
cooling fins. Fins on the coil increase
_the;surface area as they do on the
compressor. In order to increase the flow
of air over the fins, a fan can be utilized.

When cooling compressed vapors, the hot Gas By-Pass System

vapors from the compressor pass through
an aerial cooler. This type of cooling
system is made up of a series of tubes with
fins which allow heat to transfer from the
hot vapors to the atmosphere, thus
cooling the vapors.
This system is in place to reduce electrical
energy usage and compressor
maintenance. The gas by-pass system is
designed to reduce frequent starting and
stopping of the compressor, which is
caused by changing vapor pressure inside
the stock tanks.

Cooling systems which utilize water

instead of air as a heat transfer medium
have special problems. Here are some
steps which must be taken to keep a
water-cooled system in proper working
The gas by-pass system is made up of a
bypass valve and piping that recirculates
compressed vapor back through the
scrubber and compressor. This is done to

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maintain vapor pressure at a level which
keeps the compressor running until
pressure inside the stock tanks can
increase.
Pressure inside stock tanks is usually
measured in inches of water. The
compressor starts when vapor pressure
increases to a predetermined set point,
usually two inches of water.

When vapor pressure drops to about one

inch of water, the compressor stops. In the
gas bypass system the by-pass valve,
operated by a control pilot, partially opens
and some of the compressed vapor
resirculates while the rest is discharged to
the gas gathering system.

If vapor pressure drops well below one

inch, the by-pass valve fully opens and all
compressed gas is recirculated; however,
a continued decrease beyond a pre-
determined set point will cause an
automatic timing device to shut down the
unit.