Vibration Resistant Coalescer: Unwavering Performance in High-Vibration Environments
Product Introduction
The Vibration Resistant Coalescer is a ruggedized filtration solution designed to deliver reliable gas-liquid separation and liquid-liquid coalescence in environments plagued by mechanical vibrations, shocks, or pulsating flows. Engineered for industries such as oilfield operations, aerospace fuel systems, and industrial hydraulic machinery, this coalescer combines a patented vibration-dampening frame, reinforced media, and shock-absorbing seals to maintain 99.9% efficiency even under extreme vibrational stress (e.g., pipeline pulsations, compressor vibrations, or offshore platform movements). Its ability to operate seamlessly in dynamic environments ensures continuous contaminant removal, protecting downstream equipment and optimizing process efficiency.
Key Features & Advantages
1. Superior Vibration Resistance
Shock-Absorbing Frame: A flexible yet durable frame design isolates internal components from external vibrations, preventing misalignment or damage.
Seismic Certification: Tested to withstand IEC 60068-2-6 vibration standards (up to 50 Hz, 2 mm amplitude) and shocks up to 50G.
2. Unmatched Filtration Efficiency
Beta Ratio (β) > 10,000: Removes 99.9% of droplets ≥0.1 μm, including water, oil, and emulsions, even during intense vibrations.
Self-Cleaning Media: Hydrophobic/hydrophilic coatings and electrostatic fibers prevent clogging, ensuring consistent performance.
3. Rugged Durability
Materials: 316L stainless steel, duplex stainless steel, or aluminum alloy (for weight-sensitive applications) resist corrosion and fatigue.
Explosion-Proof Seals: Double O-ring gaskets and welded joints eliminate leakage risks in hazardous environments.
4. Wide Application Flexibility
Fluid Compatibility: Safely handles natural gas, aviation fuel, hydraulic oil, sour gas, and emulsions.
Customizable Configurations: Single/multi-stage setups, specialized media coatings, and modular designs for tailored performance.
5. Energy Efficiency
Low Pressure Drop: Optimized flow paths maintain pressure drops below 0.07 bar, reducing pumping costs.
Lightweight Design: Aluminum variants cut weight by 40% for aerospace or mobile applications.
Working Principle
The Vibration Resistant Coalescer combines advanced fluid dynamics with shock-mitigation technology to ensure stable operation:
1. Droplet Capture
Fluid (gas or liquid) enters the coalescer and flows through a bed of nanostructured fibers. Vibrations are absorbed by the frame, allowing droplets (0.1–3 μm) to collide and merge into larger aggregates (50–500 μm).
2. Separation
3. Clean Fluid Discharge
Purified gas/liquid exits through the upper outlet, while collected liquid is drained via an automated valve or manual port.
Application Scenarios
1. Oilfield Gas-Liquid Separation
Challenge: Vibrations from pumps, compressors, and pipeline movements disrupt conventional separators, causing liquid carryover.
Solution: Maintains 99.9% water removal efficiency (<0.1 ppm) in shale gas dehydration and crude oil stabilization.
2. Aviation Fuel Systems
Challenge: Engine vibrations and turbulence degrade filter performance, risking fuel contamination.
Solution: Delivers <1 ppm free water and <0.3 μm particulate removal, compliant with DEF STAN 91-91 and Airbus/Airbus standards.
3. Hydraulic Machinery
Challenge: Pulsating flows and shocks in hydraulic systems cause emulsion formation and wear.
Solution: Breaks emulsions, removes water to <10 ppm, and extends pump life by 30% or more.
Technical Data
Parameter | Specification |
|---|
Model | VRC-200 (Single-Stage), VRC-400 (Multi-Stage) |
Fluid Type | Natural gas, aviation fuel, hydraulic oil, sour gas |
Operating Pressure | 1–100 bar (14.5–1450 psi) |
Temperature Range | -60°C to +200°C (-76°F to +392°F) |
Flow Rate | 50–50,000 Nm³/h (gas); 10–2000 GPM (liquid) |
Beta Ratio (β) | β≥10,000 @ 0.1 μm; β≥20,000 @ 0.5 μm |
Removal Efficiency | 99.9% for 0.1–3 μm droplets; 99.99% for >3 μm |
Pressure Drop | <0.05 bar @ rated flow |
Lifespan | 24–36 months (depending on contamination levels) |
Certifications | API 618, ISO 16889, ASTM D1655, ATEX Zone 1, MIL-STD-810G |
Maintenance Guidelines
1. Routine Inspection
2. Cartridge Replacement
3. Cleaning Procedures
Gas Service: Flush with dry nitrogen or compressed air to remove residual moisture.
Liquid Service: Soak in a mild detergent solution (e.g., isopropyl alcohol for aviation fuel), then rinse with deionized water.
4. Troubleshooting
High ΔP: Clean or replace clogged pre-filters, or inspect for upstream equipment failure.
Leakage: Tighten flange bolts to torque specs or replace degraded seals.
8 Frequently Asked Questions (FAQs)
1. How does vibration resistance affect filtration efficiency?
Vibration can dislodge media fibers or misalign components, reducing efficiency. Our design isolates internal parts, ensuring consistent performance even during extreme vibrations.
2. Can this coalescer handle both gas and liquid streams?
Yes. It excels in gas-liquid separation (e.g., natural gas dehydration) and liquid-liquid coalescence (e.g., oil-water emulsion treatment).
3. Is it suitable for offshore drilling platforms?
Absolutely. ATEX-certified models resist explosive atmospheres, while corrosion-resistant alloys withstand saltwater exposure.
4. What is the maximum vibration frequency it can tolerate?
Up to 50 Hz continuous vibration and transient shocks up to 50G (tested per IEC 60068-2-6).
5. Does it require special installation considerations?
Mount the unit securely using anti-vibration mounts, and align inlet/outlet ports to minimize stress on seals.
6. How often should maintenance be performed in high-vibration environments?
Monthly visual inspections and quarterly ΔP checks are recommended to preempt failures.
7. Can it be used for cryogenic LNG applications?
Specialized cryogenic models operate down to -162°C, ensuring efficient separation in liquefied natural gas systems.
8. What is the ROI of upgrading to a Vibration Resistant Coalescer?
Reduces downtime by 70%, lowers maintenance costs by 50%, and extends filter life—payback in 6–12 months.
Conclusion
The Vibration Resistant Coalescer is the ultimate safeguard for industries where motion meets precision. Whether stabilizing gas pipelines, purifying jet fuel, or protecting hydraulic systems, its unmatched durability and efficiency ensure peak performance. By investing in this technology, operators eliminate risks, reduce costs, and maximize productivity in the world’s harshest environments.
Need a custom solution? Contact our engineers today to design a coalescer tailored to your exact needs.
