Multi-stage vessel and separator/coalescer filter element

A tubular separator/coalescer filter element for simultaneously filtering solids, separating liquids, pre-coalescing liquids, and coalescing liquids from a gas stream in a multi-stage vessel having a first stage and a second stage, the first stage being separated from the second stage by a partition having at least one opening, the separator/coalescer filter element comprising:

• a filter wall having a plurality of overlapped layers of non-woven fabric strips;
• a hollow core;
• a seal holder permanently disposed on the filter wall;
• and
• a seal removably carried by the seal holder, the seal forming a fluid-tight seal between the seal holder and the opening, such that the gas stream flows through the filter wall into the hollow core in the first stage and the gas stream flows out of the hollow core and back through the filter wall in the second stage.

An apparatus for simultaneously filtering solids from a gas stream, separating liquids from the gas stream, pre-coalescing liquids from the gas stream, and coalescing liquids from the gas stream, the apparatus comprising:

• a closed vessel having a generally vertically extending length and an initially open interior;
• a partition disposed within the vessel interior, the partition dividing the vessel interior into a first stage and a second stage;
• at least one opening in the partition;
• an inlet port in fluid communication with the first stage;
• an outlet port in fluid communication with the second stage;
• at least one tubular separator/coalescer filter element having a filter wall and a hollow core, each tubular separator/coalescer filter element being disposed within the vessel to sealingly extend from within the first stage through one of the openings into the second stage;
• a tubular filter guide coupled to the partition and aligned with each opening, each tubular filter guide extending into the second stage, each tubular filter guide facilitating disposal of one of the tubular separator/coalescer filter elements through one of the openings;
• an annular seal holder sealingly disposed around each tubular separator/coalescer filter element, the annular seal holder being selectively located along the extent of the tubular separator/coalescer filter element;
• and
• an annular seal disposed between each annular seal holder and each tubular guide member to prevent the gas stream from flowing from the first stage into the second stage without flowing through the tubular separator/coalescer filter element;
• the input port, the vessel interior, the tubular separator/coalescer filter element, and the output port together defining a flow passage within the apparatus, whereby the gas stream flows into the first stage through the input port and through the filter wall, thereby separating solids out of the gas stream, separating liquids from the gas stream, and pre-coalescing liquids in the gas stream, whereby the gas stream then flows along the hollow core past the partition and back through the filter wall into the second stage, thereby coalescing liquids out of the gas stream, and whereby the gas stream then flows out of the second stage through the outlet port.

An apparatus for converting an existing single-stage vessel having an inlet port, and an outlet port, and a closure member into a multi-stage vessel having a first stage and a second stage, the apparatus comprising:

• a partition having at least one opening, the partition being adapted to be inserted through the closure member and sealingly disposed within the existing single-stage vessel between the inlet port and the outlet port, the partition thereby converting the existing single-stage vessel into the multi-stage vessel in which the inlet port opens into the first stage and the outlet port opens into the second stage;
• a tubular filter guide aligned with each opening, each tubular filter guide extending into the first stage;
• a removable louvered impingement baffle configured to be inserted through the tubular filter guide, each louvered impingement baffle extending from the partition into the second stage;
• a tubular separator/coalescer filter element having a filter wall, a hollow core, a seal holder bonded to the filter wall, and a seal carried by the seal holder, the separator/coalescer filter element being configured for insertion through the filter guide and into the louvered impingement baffle, such that a positive seal is created between the seal and the filter guide.

A method of filtering solids, separating liquids, and pre-coalescing liquids, and simultaneously coalescing liquids from a gas stream, the method comprising the steps of:

• providing a multi-stage vessel having a first stage and a second stage, the first stage being separated from the second stage by a partition having at least one opening;
• installing at least one replaceable separator/coalescer filter element within the multi-stage vessel, the separator/coalescer filter element being sealed within the opening in the partition by means of a permanent seal holder and a replaceable seal, the replaceable seal being adapted to form a seal with the opening;
• filtering solids, separating liquids, and pre-coalescing liquids from the gas stream in the first stage;
• and
• simultaneously coalescing liquids from the gas stream in the second stage.

A method of maintaining a multi-stage vessel and separator/coalescer filter elements, the multistage vessel having a first stage and a second stage, the first stage being separated from the second stage by a partition having at least one opening through which the separator/coalescer filter elements are sealingly disposed, the method comprising the steps of:

• opening the multi-stage vessel;
• removing a filter support member;
• removing at least one separator/coalescer filter element from the multi-stage vessel;
• replacing the separator/coalescer filter element with a replacement separator/coalescer filter element;
• creating a fluid-tight seal between the replacement separator/coalescer filter element and the opening;
• replacing the filter support member;
• and
• closing the multi-stage vessel.

A method of simultaneously filtering solids, separating liquids, pre-coalescing liquids, and coalescing liquids from a gas stream, the method comprising the steps of:

• providing a closed vessel having an initially open interior, a partition located within the closed interior, the partition dividing the vessel into a first stage and a second stage, there being at least one opening in the partition;
• providing an inlet port in the first stage and an outlet port in the second stage;
• installing at least one replaceable tubular separator/coalescer filter element within the vessel, such that the tubular separator/coalescer filter element sealingly extends from within the first stage through one of the openings into the second stage, each tubular separator/coalescer filter element having a filter wall and a hollow core;
• providing an annular seal guide sealingly disposed around each tubular separator/coalescer filter element, the annular seal guide being selectively located along the extent of the tubular separator/coalescer filter element;
• providing a tubular guide member coupled to the partition and aligned with each opening, each tubular guide member extending into the first stage, each tubular guide member facilitating disposal of one of the tubular separator/coalescer filter elements through one of the openings, each tubular guide member being disposed in the first stage such that the gas stream from the inlet port impinges thereupon, thereby extracting free liquids from the gas stream;
• providing an annular seal disposed between each annular seal guide and each tubular guide member to prevent the gas stream from flowing from the first stage into the second stage without flowing through the tubular separator/coalescer filter element;
• directing the gas stream into the first stage through the input port;
• impinging the gas stream upon the tubular guide members thereby extracting free liquids from the gas stream;
• directing the gas stream through the filter element sidewalls into the hollow core, thereby filtering solids out of the gas stream, separating liquids from the gas stream, and pre-coalescing liquids in the gas stream;
• directing the gas stream along the hollow core of the filter element past the partition;
• directing the gas stream back through the filter element sidewalls into the vessel second stage, thereby coalescing liquids out of the gas stream;
• and
• directing the gas stream out of the vessel second stage through the outlet port.