Total Company Process Eng Design Manuall
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PROCESS ENGINEERING DESIGN MANUAL
U m l
TOTAL
1111
I
TOTAL -
Revisiot~: 0
Page Nu. :
FOREWORD TO REVISION 0
TEPIDPIEXPtSUR
Date:
2/85 I
The purpose of this manual is t o present in a practical way the process design methods to be used by TEP personnel lor quick calculations as well as detailed ones. They have been careluliy selected by the most experienced engineers of the Process and Operations Department
ITEPlDDPtDiPlEXPlSUR). The physical presentation i s different from that of the other TEP/DDP/DIP manuals i n order to get an easily transportable docurncnt as well as one whlch 1s convenient for photocopies.
I
I
Most methods are illustrated by seleeted examples.
Chapter 15 gives a selection of basic data which
is
sufficient for most calculations.
Chapters 16 and 17 consist of blank calculation sheets and Process data sheets that can easily
I
be photocopied.
I
Blank pa& :are scattered along the chapters for personal notes.
In addition, blank pages are placed a t the end of the manual.
They arc to be used !or comments
regarding the content as well as the typing and prcsentation and should be sent back to TEP/DDP/DIP/EXP/SUR in Paris to be incorporeted in the next rcvislon. Use them plea= : they
will be part of our feedback. The following persons have cooperated to the revlsion 0 of t h t manual : MM. J.L. BAGGIO,
P. BERLIN,
Ph.BOURGEOIS,
J.C.
FORESTIER,
B.K.
MARSHALL,
A.
MINKKINEN,
J.P. LUCIANI, M. LE METAIS, R. ODELLO, B. PERISSE, U. WEBER, Mmc K. COTTIN,
fl. LEGRAND
I
TOTAL ..
urnvision '
Page No. :
I N D E X Date :
TEPIDPEXPISUR
I. DESIGN CONDITIONS 2. VESSELS (vapwr-liquid separators)
.. HorizontaI Vertical
3. COLUMNS
.. Tray Packed 4. HEAT EXCHANGERS
+ tube .. Shell Air cmlers
. Plate exchangers
. Furnaces
5 PUMPS
.. Centrifugal Reciprocating 6. DRIVERS
. Gas turbines
.
, Steam turblnes
Electric drivers
7. COMPRESSORS 8. EXPANDERS
9. FLARE SYSTEMS 10.
PIPES VALVES + FITTINGS
. Line sizing
.
Piplng classes
.. AControl P through valves and fittings valves - sizing and sdection
11. PIPELINES
,
Pressure and temperature drops
12. PACKAGE UNITS
., Dehydration Refrigeration 13. UTILITIES
..
Watw Nitrogen
. Gas sweetening .
Air , Drainage
10.COMPUTER PROGRAMS 15. DATA 16. PROCESS CALCULATION SHEETS
L7. PROCESS DATA SHEETS 2 u
-
r u BML
r - r t u c t h h r l u b I I u t l r l t l N l r UtSltiN
MANUAL
TEPIDPIEXPISUR
R ~ Y ~ S ;~ O I I
Date
1. D E S I G N
CONDITIONS
: 2/85
Pave No :
TOTAL
Revls~on: 0
Page No
Date : 2fg5
1.1
DEIGN CONDITIONS
TEPIDPl€XPISUR
I. APPLICABILITY The f~llowingdesign criteria are applicable far both feasibility studies and pre-project studie:.
2. PRESSURES The design pressure of a vessel shall be taken as of the following ;
-
Operating pressure bar13 0 - 10 10 50
MOP t 10 %
50
MOP + 5 barg
)
.
-
Desinn pressure bark MOP + 1 bar
I00
LO0
MOP z Maximum Process Operating
Pressure
MOP+5%
Vesscls subject to
vacuum during operation shall be designed for
the maxlmurn external
operating pressure plus a margin of 0.15 bar. 11 the internal pressure Is 0.35 bara or less the vessel will be designed lor full vacuum.
.
Deslgn pressure for pump discharges shall be calculated by taking 120 % ofithe nvrmal pump AP)when operating at design conditions.
3-0 DESIGN TEMPERATURES
.
Design vessel temperatures shall be as lollows :
I5 *C
Maximum design temperature =
max. operating Ternp
Minimum design temperature =
min. operating Temp - 5 "C
t
or minimum ambient temperature.
.
Consideratian for t l ~rninlrnurn dcsign temperature must take
d s @ f s s a u r m 4f Lhe v t s s ~ lthat m a y (Set sectlon on flaring). 4.0 MATERIAL OF
.
GCWE
durLng e m - e r w 9r&t
lnro a a u n t W do~n.&~alhS.
CONSTRUCTION
Details of the required material of c o n s t r ~ t i o nfor various tcrnperatures are given in Table I.
.
Details on corrosion allowances and wall thirkness a r t given i n the vessel design section.
5
TOTAL TEPlDPlE>
t R e E a ENGINEERIND DPIGN MANUAL
:UR
Data
2,
1
Revision :
VESSELS
7
: 2f85
Pws No ;
TOTAL.
VAPOUR
- LIQUID SEPARATORS
TEPIDPIEXPISUR
neuisioh :0
Page NO. :
Date: 2f85
2.1
1. APPLICABILITY Virtually sll procers zchernes use phase scpararlan. The deslgn and sizing of a separator with
acceptable accuracy b required for both the feasibility and pre-projet phases.
Consideration is given in this section l o the spccifkatian of vertical and harlzontal separators for vapow-liquid and vapour-llquid-liquid separation. Details are also given concerning vessel internals,
Separation of solida from gas or Bquids is not cavcred in this design guide. Gencraliy a vendor will be cmsultcd for details af a proprlctory designed vessel. 2. SEPARATOR APPLICATIONS AND COPWOERATEONS
2.1.
2 PHASE SEPARATORS (uwaly
.
unless stated)
Compres~lra d Fwl G u KO drums
Efficient sepretbn of liquid from vapour rtqulred. Always consider a mlae elimina-. Provide sufficbmtirurge t1me)ll to 2 minutes) between ttte HLL and t r l p p i q the compressor.
. -
-
R d l d Syrm KO drum See =tian
9 4 F1are Sys%erns
Udt ~ma#oaumP R q h d u p t ~ a mof acid gas ahsorbtrs, glycol conmetors and dcrslcant bed
dehydratws. Can ba incarporated into base of towcr for weight and spa= saviw.
Always
.
USE
dcrnuter pads.
Produetian W r a t o r s (Vertical or horizontal) Liquid separation from eas not as critical as compr-lor
KO drum unless a
ewnpreswr is located immediately downstream of separator. Always stpr_t*
2.2.
--dm
C
O
~
and prvcas slu&swhen des-
3 P W E -TORS
.
3
production separators are g ~ ~ l hlo ry i ~ @ l .If good liquid-vapour dc
entraimntnt is rqulrad dmisters arc usualjy stated. Oil scparatfon kom the water.must be sufficient sa as not to overload water treatment units Chemkd additives (demulsiflers, anti-Enam, pour point dcprasants) may be added to aid m a t i o n .
9
~
W
I
PDTAL,
Revis~on: 0
-
Page NO.
.
YAPOUR LIQUID SEPARATORS
TEPIOPIEXPISUR
Date:
2/85
2.2
3. HORIZONTAL OR VERTICAL DESIGN
.
Vapwr velacity! in a horizontal drum can exceed the llquld scttIlng velocity provided
LID ) 1. Far vertical drums the velocity cannot. H
.
y
.
Horizontal drums arc more effective and geometrically more practical for a heavy liquid phase removal than vertical drums. A rising liquid level
in a
vertical drum dces not alter the vapaur f k w area.
Cmsqucntly vertical drums are preferred for compresmr and fuel gas KO drums. y
, Vtrtlcal drums utilise a smalkr plot and
arc easier to instrument with alarms and
shutdown controls. For (floating installatiom) they are preferred as less "sloshing" occurs.
.
Each design case must be evaluated separately but in general the Iollowlng can be u9ed as
-
a guideline : Qwtlcaldrums
Cm~~pre~sar KO drum
Degassing boots
Fuel gas KO drums
Absorber fctd K O drums
FCwtlfq instellatlmm '?
-
.
Horizontal drums
P r d u c t h n sqwatars HP 3-pharc separation
Reihrr drums
Flare KO drums
Try to avold v e s ~ l swith wall thickness grea#r than 100 m m as th-
require special
fabrication and can prwe expensive. I
6- CALCULATION THEORY AND EQUATIONS (for use in calcuIation sheets)
(Valid only for pure gravity settlers with no intcrnals to enhance q a r a t i o n )
4.1.
LIQUID-YAPOUR SETTLING VELOCITY s
=K
[yp
pv- liquid or yap- density kglrn3 V$ - settling velocity m/s K
(2) K ' =
0.003616(g) k
D
r
correlating parameter mls
- particle diameter -microns
- drag cocfficicnt P - vapour viscosity - centipoise C
la vs
=
o.oo3616(ff[
rv
P - PJ J
%
10 A
TOTAL
VAPOUR
- LIQUID SEPARATORS
TEPIOPIEXPISUR
Revisiori :O
Date :
2/g5
Page No. :
2.3
For medium and low pressure with gases af viscosity less than 0.01 cp Figure 1 can be used t o estimate Vs.
-
For higher pressures (> 50 bar) or viscosities i n excess of 0.01 cp it i s necessary t o calculate Vs. The drag coefficient C 1s calculated using Figure 2 (curve 2) where
CRe 2
(8)
=
t
f . ~ O ~ ~ , ~ o ~ " - ~ ~ ~ ~ ' ~ ( ~ - ~ v )
PL
Equation 3 1s then used to calculate Vs.
- 2
LIQUID-LIQUID SETTLING VELOCITY (based on Stokes law of terminal settling) The fallowing equation can be used for calculating the settling velocity of water in o i l or the upwards "settling" of o i l i n water. The important fact is to use the viscosity
of the continuous phase 1.e : for oll s e t t l i q upwards through water use the water v~scoslty,for water settling i n oil use the oil viscosity.
Ut = L
Ut =
8.D 18
a
(p--fL)
p c
I
(3)
densIty heavy fluid density light fluid
kglrn3
= D=
viscosity (continuous)
kg1m.s
particle diameter
m
rnls2
kglm3
125 microns and using more useful units gives :
( P;I?-)
Ut = O . ~ ~ O S
U t in mm/min
)& in centipoise
.
I
70
= l =
f h
*PC
Setting the particle size
4 s
E
terminal velocity gravitation accet
3
The above equatlon 1s valid lor REYNOLDS number of 0.1
- (1.3
If calculated settling velocity is > 250 rnmlmin use 250 rnax
VESSEL VOLUMES
.
Partial volumes of a l~orlzontalcylinder can be calculated using the partial valurnt charts i n Figure 3 or estimated using the following equations : (for vessels with a diameter
< 1.2
rn ignore head volumes)
TOTAL
Revision : 0 VAPOUR
- LIQUID SEPARATORS
TEPtDPlEXPlSlJR
Oste :
(see p a ~ c2.13 for sketch)
Page No. :
2/85
9-(;-h)PK"Z
A~=D'A~CCDS
HORIZONTAL CYLINDER
2 DISHED HEADS
7
Vc = A1.L
m3
Arccos
2.4 rn2
i n radians
-
Vdh = 0.21543 h2 (1.5 D h) m3
2 ELLIPTICAL HEADS
Veh = 0.52194 hZ (1.5. D
2 HEMISPHERICAL HEADS
Vhh
=
-
- h)
1.047 h2 (1.5 D h)
VOLUME UP TO BAFFLE (see page 2.23) 0.52194 hf for depth h Ielltptical heads)
(1.50-h)
my (most common)
rn3 (gives extra vol)
+ AL.B
2
.
These formula are accurate enough for general design and are easily programmed
.
on to 4 calculator for time saving. More accurate formula are available, ace ref list, but are often too complicated t o be useful for multip1e calculations.
.
For greater accuracy the l e n g t l ~L should bc the tan-tan length and not the
flowpath length between nozzles. This is especially true w i t h large vessels and a tight design. 4.4.
CALCULATION PROCEDURE VERTICAL VESSEL (vapour-liquid separation)
A guide for filling In the attached calculation sheet.
.
.
Decide i f Figure 1 can be applied i.c P
< 10 bata,
Y < 0.01
cp
lpplicable use the 500 micron curve to evaluate settling velocity (this assume? a inist eliminator will be installed) or 150 micron w i t h no mist cllrrilnator. I t is
recommended to install a mist clirninator for most applications. If not calculate Vs using equ 3.
.
Derate the calculated settling velocity by 85 % design margin to give a maximum allowable vapour velocity.
.
Calculate drum internal diameter and round t o nearest 50 mmb (further adjustment of I D : OD can be made to l u i t standard head dirncnsions).
.
Check if wall thickness i s less than I00 mm (See para b.8).
t2
-
-
TOTAL
Rev~sron: 0
VAPOUR
- LIQUID SEPARATORS
TEPIDPIEXPISUR
.
Page Mo. :
D ~ t c : 2/85
2J
calculate v e s x l height based on following criteria :
h l :max (15 % of C or 400 rnrn)
h2 r 100 rnm i f mesh selected
n hl
150 mrn for compressor KO
--
/ /;
I///
h2 7-
a
-
.
h3 : max (SO % of 0 or 600 mm)
h3 .L
I f no mesh use h l + h2 + h3
F&
= 60 % d
or 800 mm
hl
h~ : 900 mrn + dl2
ma mu -
hS
- - -nLL
h6
h7
h5 : calculate based on 1-2 minutes residence time at
maximum liquid inflow (rnin 200 rnm)
u
7
~
-
.
WL
-
h6 ! base on follow~nghold up times r (min 350)
-
he i
= inlet nozzle
-
TL
L
-
-
rcflux drums
4 min
product drums
5 min 3 rnin
heater feed
8 rnin
HP sep.
Y min
to LP sep.
with pump
no pump
h7 : 1-2 rnin residence tlme (rnin~rnurn150 mm)
h8 : 150 mrn tor bottom connected LC
300 mm for side connecred LC Note :
Far compressor suction drums that are normally dry set HLL at b 5 O mm
above tan line and u x bottom connected LC. This will reduce vessel height if required. No specific
I
a
HLL-ILL hold up
t~rnerequired.
TOTAL
Revision: 0
YAPOUR
- LlQUlD SEPARATORS
TEP~DP~EXP~SUR
4.5.
Page No. :
mate:
2/85
2.6
CALCULATlON PROCEOURE HORIZONTAL VESSEL (2 phase) A guide on how to fill in the attached calculatEon sheet.
1. Calculate settllng velocity Vs far partic4Ksize 5 0 0 ~(use Fie 1 or equ. 3.) 2. Ckrate this by F
Vm =
= 0.85
and calculate required vapour
P x Y s x (LID) mls
vclwit~Vmm/s
use LID of 3 t o 4 max (3 first est)
3- Evaluate required vapout cross sectional area, Av 4. Assume drum is 70 % full i.c h/D = .I and evaluate drum 0 to give required Av (to nearest 50
mm). For "dry" vwwls use h/D = .3>
5. For required(Jiqold surge volume) calculate vol at HLL, 1X insufficient adjust D or L (note 11 L/D changes signliicantly recheck Av using new Vm). 6. Set position of LLL in drum and confirm required surge vol between HLL-LLL, If volume & Insufficient increase 9, L or h. Include volumes in heads. 7 , When setting LLL height take into account any LSLL, LSL alarms and vortex breakers which may set mlnimum value usable. Usually 300-350 mm.
8,
~ t i o n a l i s eall heights and dimensions to nearest 10 mm.
-
NOTLA :
.
For high volumetric flows of gas with small liquld volurnes consider using split
flow arrangement. Design ia as above but with half vapour volurnc
Haw.
Normal design is with top entry, exit nozzles, However if spacc is limiting
(primarily offslrorc) head mounted nozzles can be used to increase flowpath.
.
L
i3
daignated as the flow path length i.e distance between inlet and outlet
nozzle. L' is the tangent-tangent length. For 1st estitnates L' = I + 1.5 9i + 1.5 82 02 c outlet nozzle diameter Q i = inlet nozzle diameter
-
"Normal" liquid levels are taken
as midway between the high-and low levels.
r4
-
TOTAL
VAPOUR
- LlQUlD SEPARATORS
TEPIDPlEXPISUR
4.6.
Page No. :
Datm: 2fb5
CALCULATION PROCEDURE HORIZONTAL
.
~evision:O
2.7
VESSEL 3 PHASE (See Figure 4)
Sufficient residence time to allow separation of the ail-water mixt!trc as well as the o i l surge and vapour
f l o w areas
must be provided.
1. Proceed with steps 1 t o 0 as for a two phase separation. Use L / D = 3 (1st estimate) and evaluate L.
2. Provision now has to be made ta accommodate both oil and water surge volumes.
Use Tan-Tan Jength 1'and not rrozz-nozz distance L. 3. Calculate L'LL required to give approx 4 rnins oil surge capacity (minimum). Inspection will reveal whether sufficient height exists below LLL to include the interface levels. I f not, adjust the vessel Qor L to give sufficient room.
Note:
If the water cut is very small, consideration may be given t o using a water boot instead of a baffle arrangement ace step 10.
Having dstkrnined HLL and LLL now set both position and height 01 b f f l c . Calculate terminal settling velocity of watcr droplet (equ 5 sect b.2) and settling t i m t at both HLL and LLL; Volumetric flqw of llquld h i n both cases the oll plus
the water. Calculate fall distance of a droplet across length o f the drum. Baffle height and positlon can now be set noting :
-
the baffle should be a t least 75 rnm below the
the baffle should be a t
LLL least 213 down the length of thc drum Irotn the inlet
In some cases the water droplets w i l l settle t o the f l m r in a short distance.
The baffle should s t i l l be s e t at a minimum a1 213 along the vessel.
. 6.
-
k l the HIL a t baffte height 7 5 mm. The LIL according vortex breaker + LSLL use a minimum of 300-390 mm.
t o height determined by
Check If an oil droplet will r i s e through the water layer (from drurn floor) to LIC
before reaching water outlet. Use area at
LlL
with normal oil + water flowratcs.
(Thls criteria is very rarely governing but must he checked).
7. Calculate water surge time b e t w t t n HI1 and LIL, snd residence time between NIL and outlet. Remember t o use only one head volume, and length 01 drum upto baffle. Minimum acceptable times are '4-5 rnins. I f calculated times are very long consider using a watcr boot arrangement.
8 . Rationalise all dimensions and "tidytt levels to standard values if possible i.e : 150 mm, 200,250, 300 etc. This allows use of standard displacers.
9. Rtcalcutate a l l residence times based on "tidicd" levels (if required). Note :
i n calculating the final residence times make sure that the vcsscl tantan length is used and n
g
the nozzle to nozzle distance L.
/5
i
Revision : 0
TOTAL
Page No. :
VAPOUR - LIQUID SEPARATORS
TEPIOPIEXPfSUR
Oate : 2/85
2.8
L.
10. Boot calcuIatian (See Fig. 5)
.
If the water volumetric flow is
50
$mail as to not warrant a separate belflcd
settling campartement as detailed above a water boot should be used instead. 70 design p r w e c d as follows :
1. Prmeed as previaua upto step 3. 2. Calculate settling distance of water droplet when vesstl Is operating at LLL.
Water droplet should reach floor
gf
drum before 011 w t l e t . Remember that
the all e r l t nozzle w i l l be raised above the floor as a standpipe. Adjust drum
fl or
C to achieve &ttling.
3. Check that ~ t t i i n gis aim possible when operating at HLL, droplet to fall below d r a w d f nozzle level.
4 Size water drawoff boot fl
(try to use standard pipe diameters). Celculate
rising vcloclty of the oil in water, set downward velocity of water in boot at
90 % of this and evaluate bwt q. Boot length b y inspection (use standard displacers). Note -
Boot fl must be less than 35 % of vessel 0 When heavy walled vessels are used a remote boot may be more
economical t o prevent large cuts in the main vessel.
4.7.
NOZZLE SIZING (see section 10.0 also) Inlet nozzle
Size bawd on normal volumetric Ilow + 10 % (liquid + vapour flow)
-
L i m i t inlet vclocity t o 7 13 rnls Round nozzle diameter up or down to nearest standard sire
.
Can outlet
.
Liquid outlet
+
Size an normal flow
,
Normal flaw
Velocity limit 15-30 m/s
.
Velocity limit
10 %
1-3 m/s HC 2-4 m/s water
Manholes : 450 mm or 600 4.8-
,
Min. diameter = 2" (avoid plugging)
VESSEL WALL THICKNESS
Calculate vessel wall thickness usin8 the ASME VIl1 div. I formula. The wall thlckness should be calculated immediatly after t
<
100 mm.
D is knowtr t o confirm if
I
1
Revision :O
(TOTAL[
VAPOUR
- LIQUID SEPARATORS
Date : a185
Di = diameter t
:
Page NO. :
2.9
I
mm
wall thickness
P = design pressure E = jolnt etficlency
rnm barg
ure 1 for seamless shells -85 otherwise S 3 rnax. allowable stress bar
C
z
use 1220 bar for CS plate 1000 bar for 55 plate
corrosion allowance mm
-
use 3 m m unless stated
oth,erwise by EXP/TRT
for 100 <
t C I00 mrn t < 150 mm t
>
130 mm
;
no fabrication problems
c
vendor advkc may be needed
: Major labrication problems
In order to meet standard vessel head sizes and wall thicknesses the followlns ranges shwld be observed :
- I250
n m in increments of SO m m i.e. 250, 300. 350... 1300 4000 m m in increments of 100 mm i.c. 1300, 1400, 1500
Vessel diameter : 250
Srandhrd wall thlckn=tser
:
1
...
-
- 30 mm in increments of 1 mrn
-
30 60 m m in increments of 2 rnm 60 140 rnrh in increments of 5 mm
-
i.e.
1,2, 3;4... i.e. 30, 32, 3(r, 36..,
i.e. 65, 70, 75, SO...
Vessel weights either MdsontaI or vertical can bc estimated udng Flg. 6. 'This tigurt is for the steel shell Including manholes, nozzles, Iittings etc but nut the removable internal5 or support skid. The heads can be estimated by using weight of 2 heads z e2 (m2) x wall thickness (mm) x 20 ks.
I I
I
1,
5. VESSEL INTERllALS
1.1.
MIST ELIMINATORS
,
Mist tlirninatars or
mesh pads are located under the vapwr outlet nozzles at all compressor sucrion drums and fuel gas KO drums. For production separators it is slways good practlce to install an exit mesh pad.
I
I
- ..--
TOTAL
Rru~ritrr~ : 0
YAPOUR
Page NQ.:
- LIQUIDSEPARATORS
tEPIDPIEXPlSUR
2/85
Date:
2.10
A
.
Mesh is usually made from 304 SS. YORK DATA as follows : Types of pad :
York ng
Thickness
Residual*
mm
-
entrain~nentPPM
General purpose
43 1
144
100
1.L- 1.2
High efficiency
021
192
100
.I5
- -61
115 80
1DO
Dirty service
326 931
110
.I7 1.6
-
150
-8
604
.
- 0.19 1.8
- -87
The engineer should speciiy type, diameter and thickness of pad required on
the vefisel data sheet.
.
For particle sizes of 5 microns or less use two pads spaced 300 mm apart eg : glycol contactor.
5.2.
I N L E l 'TERNALS Inlet internals can be specified l o aid feed distrlbulion and promotc uspour-liquid separation. Generally for prt-project stage dctalla are not required.
5.3.
LIQUID PHASE INTERNAL5
.
Vortex breakers should be dctalled for each oiIlcondensate nnd produced water outlet where the oulet flowdirection is vertical.
.
Vendors wlLI sometimes specify internal packs of tilted plates or baffles or other arrangements to promote phase separation.
-
Sand jetting facilities should be provided for on services where there is a rBk
of
silting or sediment build up in the vessel. Generally jetting facilities are not requlred On gas-condcnsatc systems. 6.0.
SHORTCUT METHOD FOR
HORIZONTAL DRUM SlZlNG (2 w 3 phases)
1
Y
-
2.1 1
EQUtPMENT N*
I] Calculate settling velocity V s 2) Calculate vessel diameter required lor drapltts separation :
s 3) Calculate vessel dlamcter reqdlred for sufficient liquid residence time :
"2
'
c 16 QIfres
4) Select D = max (Dl,02). Round ro upper value Qg =
gas flowrate a t P,T
m3/s
Ql
z
m?s
Vs
I
total liquid [lowrate settling velocity
D
z
m/s
vessel diameter m vessel design ratio (L/D= 3-41 security factor (0.85) -
LID = F
liquid residence tilne
ires :
5:
'7
mIL3 TOTAL IC17
SHORT CUT METHOD
T~P~OWWP~IXP~IUR
nv
1 I
CHU
I
..
PROCESS CnCCULATlON SHEET
OAT€
HORIZONTAL DRUM
1
1108 I I ~ L E
ITEM
Na IOUNO
1
REV
I
TOTA'
YAPOUR
Rovitio~l: 0
Page HI
Oat% : 2/85
2.12
- LIQUID SEPARATORS
TEPtDPIEXPISUR
7.0 REFERENCES AND USEFUL LITERATURE
7.1.
LUDWIG VOL I CHAPTER 4
7.2.
PERRY CHAPTER 6
7.3.
Program calculates partial volumes Pierre Koch
OC3 Dec. 3 1983
2u
.
CALCULATION SHEET FOR VERnCfiL TWO PHASE SEPARATOR
EQUIPMENT
1e3~
D
NO
B E W S S ; N ~&oor
Operatinp data : Pressure (operating)
bare
= ~.WI
Temperature (operating) Gas MW
'C
= 31,
Gas flow rate
kdh
Gas density
Liquid description : C l l ~ b LD;L
= 51.4
= ?PI0 k g h 3 = 3.1
(T,P)
Actual volume flow Qg
m3ts
-
6-97
r
kgh
Liquid flow rate
10290
Liquid density (T,PI kg/m3 Actual volume flow m3/min
2 10 = 0.t 3
Plrticle size
= !So
microns
c
.
Esdmate Vs usin8 Figure 1 and 500 micron curve : , If P < 50 bar and p < 0.01 u x Fig. l and 150 microns
Mesh pad
:
No
'
1. Yapour-liquid ~ t t l i n pvclocltv . :from Fig -1
. c :
VS =
&
m/~
vs =
rnls
* Delete as applicable 2. berating % = 85
=
1
Drum flow area
3. Actual volumetric.
as flow
~m
maximum velocity
0 . 57
=
Calculated drum 6 =
~ . q qm3/s
m/s
1.7
2s:
m2 mm
5. Required liquid hold-up tiines
h>:
HLA-HLL
h6:
HLL-LLL
h7:
LLL-LLA
5. Mesh pad:
1
@no
= = =
e
mi"
=
min
r
(.1cm3
~ . . / , 6 m3
thickness =
. TOTAL ma3
a
0 . L 6 d
min
30
. = =
mrn
lgoc 700
mm mm
mm
21 Sheet 1 of 2
PROCE~S CALCULATlOM S H E E T
:
IrrM:
TLFIOOP'O~P~IKP SVLl
VERTICAL YAPOUR-LIQUID SEPARATOR w,
I Y
QSrt
CHK
700
lbl1111€ I
SAM*?~L
,
.
c.".--
D I ,: i;.
101NO
RtY
1
hl :
I5 % of fl or lr00 mm (Use mar)
h2 :
mesh pad
h3 : 50 % of d or 600 mrn With mesh :h l + h l + h3 N o mesh : hJ + hZ + h3 1 60 % @ or 800 h4 a 400 mrn + d / 2 t d = inlet nozz fl
hJ
h5 a
From step 4 or 200 mrn
h6 :
From step I or 350 m m
h7 : ha :
From step 4 or 150 rnrn
-
rnm
e
5SO
mm
= =
700
mm
I
mm
150 mm for bottorn LC
I S
300 mrn for side LC
mrn
For ''dry" vessel
h6 + h7
+ h8
= $650 rnm
TOTAL VESSEL HT TANITAN L L
7. Wall thickness
.
DESIGN PRESSURE
*
CORt
P c 2.5 . C= 3
;ION ALLOWANCE
barg
Diameter
D =
?OO
mm
mm
Max st1 :s : 5 =,I220bar CS 1000 bar CS
Joint eiflciency f.85)
.
t
S = 1?r:3
E=
PxD
I
2xsxE-1.2P
+c
Z A . 1
C l.j
Vessel weight (Fig. 6) t =
5
mrn
L=
6
m
(s+I)
D = s.-I m
r
IPCO kg
Head weight =
80 kg
She11 weight
(t
x d x 20)
1340
TOTAL WEIGHT r
kg
22 TOTAL
-71
PROCESS CALCULATION SHEET
VERTICAL VAWUR-LIQUID SEPARATOR 1TEM.
TIP'DWOR.IXP.SUR Ir
cnn
NO
ma IE
l ~ O Q ~ I ~ tL I
.1:
L
.
IOU uo
!\I :.dv I
'*J.-
Sheet 2 of ..
Z
-
. atv
I
-.
2+1J CALCULATION SHEET FOR HORIZONTAL 2 PHASE SEPARATOR
I
. Head type elliptic all^ Indicate on sketch if demister mesh requlred Delete as applicable
EQUIPMENT N u ! v$oio
DESCRIPTION : I""'AS~ S f Prtplf! l o *
Omrating data :
= %a Operating temperature .C = I g Operating pressure bara
Gas density T, P
= h.,4 k d h = 14qSo kglm3 = 1f.u
~g actual vol flow
m'f5
Gas viscosiry
CP
Gas molecular
weight
Gas mass f l o w rate
L.
Vapour-lquid settling
0 ; ~ .
Liquid flowrate
kgfh
'
!?b6iu kgfln3 = 7CS
0 . !y?
~ l ~ u dendry id T,P ~1 actual vol flow
m3/rnin =
e.O\o?r
Particle size
microns
. =
Liquid nature :
z
-c
~nls
vm=
1.8
mls
a = 3.'sh
m2
v5=
*
velocity : frorn Fig. 11-
2
G.
1
C =
* Delete as applicable 2. Max. vapwrr velocity
Vm=YsxFxL
B
LID = 3 3. Actual vapour ~olurnetricflow
Q g = 6-2-77m3/5
Av
V rn
2'5 PROCESS CALCULATIONSHEET
1-
TOTAL
ITJT7
TE~~O~P,~IWEIPIZUR #I
CM*
CALCULATfOH FOR HORIZONTAL PHASE SEPARATOR
o d rt
z
,on
rlrLr
1
r oS3
' I f L ~
No
106 no
I
.-
.dl,
r
to
Sheet 1 01 3 : , r * " ' "' '
1
RIY
-
4.
Nozzle sizing I velocity limits (rnls)
8
Inlet : 7-13, Gas outlet : 15-30, liquid outlet 1 - 3
Nozzle ID =
B i : Inlet flow = 0.31' m3/s (+ 1 %) c.3b 82 : Gas c. 'let = 9.2 $ m3/s Liquid outlet = a.Ci. m3/s
8
Actual vcl =
I'
lo-5 tn/s
NozzIe ID = " Actual vcl = I T mls Nozzle ID t & " Actual vel = .'. 1 m/s
5. Drum sizing = 4 mln
For trial I t,,,
vol required = 4 x Q1 =
I Selected h/D Vapour area % fotal area {Fig. 31 Total area Liquid area
Av
17-12
At A1
m2
D
mrn
Calculated drum Selected drum
fi
-
I
I I If 1 31 I c.GrC I a.ft62 I I I 1 t I I I :ro I t c n ~ 3 I 1
m rn
LID O 41
I
L
mm
TanlTan length
L'
mm
HLL height Volume at HLL LLL height Volume at LLL Surge volume (HLL
Calculated
1
180r I 2.68 t I I I
m rn
m3
m3
I 3.3E I
I
d n
1 NOTES :
I I SELECTED DRUM : DIAMETER 0 ?o.v
1
1
1 I I 2
1
I I I
1 I I I 1lt00 I 1 l?.q% I I 350 I 1 1.36 1 I I..SC II
I
m3
tres
3
1 3 1 . C ~ j LO--3 I 1 !1'34 1 cs30
rnm
- LLL)
i0.c
.
1 a*4
mZ
Flowpath length
0
.I 1
" I
I
TRIAL
I
1 I I
I I
of.
I I I
I 1
I I I I
I
I I I I
I I
I 1 1 I
I
I I I I
I
I
I I
I I 1 I
I I 1 I
1 I I
I 1
I
I I I
I I I
I
m m x ; Z : , mrn tadtan
a1
f anltan length L' iL + l + x bi + I t 62 (ignore this correctidn if D C 1.2 m and use L for volume calcs. For trial I uae t and ignore heads). .
b)
If VOL HLL is less than required surge increase D, L or h/D or reduce ires (by
Inspection).
2 4
'
EZ3
TOTAL
1717
rEPIDDPrDIP.EXP~SuR
IY
I I
I
ID,^ m3
ctix
l
PROCESS CnlcuintloN SHEET
CALCULATION FOR HORIZONTAL 2 PHASE SEPARATOR
onrr
I
I 100 TI ~ L C
.
..n
,.
.
'rtM
-_
Sheet 2 of 3
'
Uo 100
wo
I
I
I
RLv
6. Wall thickness
, DESIGN PRESSURE , CORROSION ALLOWANCE
P=
22
barg
C= 3
Max stress
55 = 1000 bar 5 . l2:o
mrn
Joint efficiency
t.
ig
L
rC.53
D
Shell weight
m
Head weight =
rn
(t x D=X 20)
=
E=
0 .f l
= Il 0 0 0 kg
mm
TOTAL WEIGHT
CS = 1220 bar
JdaO k~
1 3 OOc
..
kg
-
PROCESS cnLCU1ATtON SHEET
ltP'DDP,DIPtt XC'SUU
CALCULATION FOR HORIZONTAL 2 PHASE SEPARATOR
, ~ ~ p . q , b!'
L,qp.pi
n o L'!:
to
5heet 3 of 3 1 f.:!
t
'
!.
,...
1
ntv 1
I-
-
TXEllfAN'tENCTH L' ;$00 FLOW PATH LENGTH L = +*am
I-
.Amend ske~ehif h o t requitad inrtwd of baffle . Indicate on sketch if mesh rqulrtd
. Heads :2 :1 elliptical EQUIPEMENT No : D 5 0 1 0 DESCRIPTION : 0F-y-
T L S 7 SLIAMT*&
Operating d a t a . Operating pressure ' Operating temperature
Ad
barn
:
'C
= so
CONDENSATE Flowrate Density T,P
PC
Mass flowrate
kglh
Density
kglm3 = 31. o
T,P
Qg Vol flow
=
PC
bi04
WATER CUT
m3/h = = 0.0I03
Y
1. Vapour-liquid s e t t l i n ~velocity
t
719.h
=6.7S
Viscosity
cp
Flowrate
kg/h
44fs
kg/m3 = S t % Vat flow TIP m31min = o. 16P Density T,P
PW Qw
rw
microns= I a:
Particle size
kdm3
Val flow T,P rn3/min x 0.3 I
Ql
CAS MW
-
= 3 1~ 3 3
kg/h
from Fig, llc-
= 17.54
cp
Viscosity
Vs = 0.17
r
1n/5
-
C
* Delete as applicable 2. Maximum vapour velocity LID = 3
Vm
= Vs x
0.85
rL I3
3. Liquid-lit: I settling
Ut = 0.110l[&lf?]
Oil in water
Utall =
rnrn/min
Pw Wa~erIn oil
&water
-
rnmlmin
\IT
mrnlmin
.--
Sheer 101 4
26
mZY
TOTAL
a
L P I W P : ~ r t Y P5ua
v
CMK
PROCESS CALCULATION SHEET
-
CALCULATION FOR HONZONTAL 3 PHASE SEPARATOR DATE
j rosrlr~t E n n r r r t i
ITEM
no
orc~~:,~
> So10
108 wo
~r
,,I
1
I
RIV
9-
2.19
I.
:qelocity
*Olz~a
,
....
I. Inlet [low : (+ I0 %)
2. Gas outlet :
3. HC outlet :
4.
outkt
Water
:
0.6 .
5. Vessel siring tres oil
trial 1
(HLL-LLL)= 4 mln
1. f 4
r
.-
1
"
OIL SECTION TRIAL
I
I I
Selected h/D
calculated (QglVm) Av as % AT (Fig. 3) Total area
Av
rn2
At
m2 mZ
A1
Liquid area
--
Calculated Q Selected P
I 0.7 1 0.38 I I 1 rr I Sr 1 r4.r I \.u+ \ 3 I n-3L I o . Z k I o-6bh I 1.383
mm , ,
D
1 I1 1ObO 6So 1
1
LlD 13
41 Flowpath length TanlTan Length
L'
HLL height Vblume' a t HLL LLL height ' Volume at LLL Surge volu~nc(HLL
1
mm mm
L h1
mm rn3
hZ
mm
I jLS0
,
I I goo
Calculated tres
.
I
I
m3
- LLL)
3
m3
I
rnin
I
I
I
11 \IIQ I I
1(
CO-Q
0
I I 1
1
1 3 . 2 I lFPo 1 io-0
1 1
I 1 I I
if00
1100
b.63
I 7.-
LOO
1 300 I II t
\.q
tlk
I
I
I
I
1 I
I I
I I
I
I
I
I
1 1 .I I I II
1 1 I
1
,-,.
I I
I I I I
I I
c=L+ H
I.,@
I
1
I 1
Notes or comments :
),
I I I 1 I
+
h)mm
- Ignore if
<
'-2
27 ~ROCESSCALCULATIOH SHEET ITEM:orftwvt
CA~.CULATIONFOR HORIZONTAL
3 PHASE SEPARATOR
If PIOOPIMI~~XP'TUR
UY
CHI:
OAT€
)tostnu
i*fiit;.r-
wo.. D iolo 100 NO
TI!'
Sheet 2 of 9 ' I.fifi**': 8 ' : a
I
Rtu
1
WATEK SECTION
B = 213 x L = 3 f 3
Trial I
mm (rounded)
T
Total liquld vol flowrate Qw
* QI
i
Baffle distance Liquid area at HLL
B A1 Vl
Horizontal vel at HLL
I
TRIAL
1
n
m2
Ut water (step 3) Verticdl fall from HLL = B X Ut/VI
rnrnlmin mrn
fSPd
HLL vertical fall
mm
I
A1 VZ
'
Selected baffle height h3 Selected HIL level hq [adjust h3 and B if necessary)
Chw.k oil r i w :
I 1 mmfrnin 1 I rnZ rnmtrnin
I??.$
1240
rnm
I I
,400
mm
[
3fo
1 I I
Horizontal vel at L L L Y2 Ut oil (step 3) Vertical rise within dist B m B x UtlV2 = max. outlet htlght
rnmlrnin 1 0 1 1 ~ rnmlmin I fk+
h5 selected LIL level
rnm
h6 selected outlet height
m rn
q l water vol at HIL (upto baffle)
m3
92 water vol at LIL (upto bmfflt)
m3
q3 water vol a t NIL (upto balfle)
m3
qU water vol at outlet (
q Eurge
1 I I I I 1
mm
1
1 2L7 I I qcT
I I 1
I I l.a\
1
I
I
I
l0.01
I 0.69 I 1-3c I 1 o I
I 1 0 . I 1 0.&5 t I I I . I
surt 'irne q surgelQw min r c s i ~ ce time q3-qQIQw rnin
..
I
I
I
I
1.s
-*a
I I I I I
I I
I
IA
Y~XC
I I 1 I I I 1 I I I I I I I I I I
I 1 I I
I 1 I I I I I I I I
I
I
I
I I I 1 I I I I I I I
I I I f
I I I I
I I I
1
I I
I I I
I
I I
I I I I I
1
I I
I I I
I
I
I
1
I
I t
I
I 1 I
I i I I
I 1
-
I I
I
I
?r
I i.17
9
calculated oil residence time (upto baffle) Yo1 (NLL NIL)/QI min
?r0
I I -0 1 1 ?.I&
I0.6L
m3
-
SO
I Za3
m3
= vol (ql - q2)
boo
I I I I I
1
I ST0 I I
1 0 0
1 I I I I
4
I
I
I n I I Clf
I I
I
I I I
I f 1 I
I95r
dl10
I
I I I
I
I tra I I a.82f 1 loC? I 1 I
I
I
CSI
I I7q.r
Q4l-t
mrn
1.Jtt
I
0
I
Liquid area at LLL Horizontal vel a t LLL UJ water (step 3) Vertical tall'from LLL = 0 x UtiV2
I
I
3
I I
IJClao
I b.S$L, I loff I 191.r 1
mmlmin
I I
2
II
OPS
I I3.Ago
mm
-
I
1
1
I
I I I
I
1
0Y
2 2?' TOTAL
m T LP'OOPlOIPltaPlIUR I
I I
CHK
I
PROCESS CALCULATION SHEET
CALCULATION FOR H O R ~ ~ O N T A L , 3 PHASE SEPARATOR oArc
1
I~
<
~ T I ~ KAI L F
r n ~
,
:1
Sheet
r ::
51
,:+t
.',
3 o f 4. 11
U O . r01o ~ ~ ,nm W-
I
aru
i
6. Wall thidntss
, DESLGN PRESSURE
P = bf.9 barg
.
C
CORROSION ALLOWANCE
= 3
Ma* stress
55 a lD00 bar
mm
5.
.
3
L=
D=
l
o
m
1.r m
Shell wclght
e
Head weight = (t x DX' 20)
lo Po0
kg
kcP
k&
TOTAL WEIGHT = 12 me)
I'll0
E = o.rJ
Joint cf llcicncy
t
CS = 1220 bar
kg
24
a
m
rc~~nnm~nmm c11n ~r~o
PROCESS CALCULATION SHEET :C~(ir.cr;.r
CALCULATION FOR HORIZONTAL 3 PHASE SEPARATOR
rva. 3
~ 0 1 3
5heet 4 of 4 Tf4T
~ C ~ P ~ ' , ~ . ~ < I L
-.
TOTAL
PROCESS ENGINEERING DESIGN MANUAL V A W U R AND
LlQUrD SEPhRATOAS
fhviliol! : U
Pmgc NO :
TOTAL
PROCESS ENGINEERING UESlLiN MAIUU-L VAPOUR
I,L~B..W~.
.
AND LIQUID SEPARATORS Date
TEPIOPJEXPISUR FIGURE 2 DRAG COEFFICIENT iCI
vs
RI or
c(
~ 4 2
: 2/85
2.23
3,
COLUMNS
Revision : 0
TOTAL
Page NO.
TRAY COLUMNS
TEPIDPRXPISUR
Oate :
2/83
3.1
1. p.pP~1chBfLlTY
It
is not expected that a hand calculatjon of a tray distillation or absorbtion column
be
performed by the engineer. For the purpose at a feasibility or pre-project rtudy any required r i g o r w s column sizing would be performed using SSI PROCESS simulator, or similar. Should, however, a quick tstlrnati~nof tower diameter and height b e required one of the most common methods of hand calculation for valve trays is the "GLITSCH
METHOD". An
example of the procedure for this method is given in Section 3. A detailed mechanical design of a tray column i s beyond the scope of this ~uide.For details
o) see packageunits. on ~ ~ l y ctowers, 2. DESCRIPTION AND NOTE5 2.1.
TRAYS
There arc basically three types of tray used Ln dl3tlllation columns ;sieve, bubble cap and valve trays. Each type has specific applications and flcxibilities dependant an the process criteria. Some of the major aspects a r t detailed as follows :
Bubble caps Operation
: V s p w r passes through "risers" i n t o the bubble cap then bubbles into
the surrounding liquid on the tray. Bubbling action effects liquidvapwr contact. The liquid exits the tray via outlet weir and
downcomer arrangement to the tray below. Capacity
i
Moderately high t l l i c i e w y (minimum 50 861 is maintained a t varying
rates due t o weir maintaining liquid head. Etficiency
: For many years was the most common type of tray-consequently many publlahed tray eifielencies are available from vendor
aources.
Note : most expensive type of tray.
Application
:
A l l major services excepts coking. pmlymer formation or other high fouling conditions. Ideal lor use i n low f l o w conditions where tray must remain flooded to maintain a v a p u r seal.
Tray spacing :
18" Is normal. Consider 24" to 36" for vacuum conditions.
2
q
-
TOTAL
~ a u i s i a:l ~ 0 f RAY
Pago No. :
COLUMNS
TEPIDPIEXPISUR
oate:
2/85
3.2
Sieve trays Wlth downcorners Operation
:
W l t h w t downcorners
Vapwr rises through 118" to 1"
Vapour rises through holes in
holes
and
and
bubbles
through
bubbles
through
liquid.
forces
liquid
through
Jarnc
liquid. Liquld flows across tray
Liquid
over weir via downcomer to
countercurrent
tray below.
holes t o tray below. Flow is
head
generally random and does not form continuous streams from
each hole.
Capacity
1
As high as or higher than bubble cap trays for design rates or down t o 60 % o i design. A t lower rates cfiiciency falls and performance
h poor. Generally unacceptable t o operate below 60 % capaclty. Efficiency
,
: As high as bubble caps at design capacity. Efficiency becomes
unacceptable below 60 % design capacity. Not5ultablc lor variable
load columns. Application
:
Syste~ns where
high capaclty near design rates are to be
maintained in continuous service. Handler wspendtd solld particles we11 flushing them down t o tray below. Can be problem to run with salting-wt sysxerns where trays run hot and dry, holes may plug.
Not recommended for oil Tray spacing :
t
gas rervice due t o paor flexibility.
15" average, 9" to 12" accep-
table.
Use 20"
to
30"
vacuum.
for
12" average, 9" to 18" acctptable. Use I S " t o 30" for vacuum.
Vaive trays/ballast cap
Generally the same aspects as [or sieve trays. Most valve trays are specialist proprietry design for specific operation problems and capacities. Specialist vendors
include GIitsch, Koch (flexitray), Nutter, Union Carbide. Best choice of tray for distillation application. Tray layouts N o t only may the type of bubble caplvalvefsieve hole be specified for a particular
design but also the tray hydrauljcs by liquid path. Common arrangements are shown i n Figure I.
0
---~~
TOTAL
Revision : 0
Page NO. :
TRAY COLUMNS
TEPIOPIEXP/~UR
Dale:
2/85
3.3
Tray eliiciencies General tray cfflclencles t o use :
Stripping
Absorbers
Hydrocarbon oils + vapour 33-50 % 15-20 %
Amine units Dlstlllatlon columns
2.2.
, 60-80 %
Hydrocarbon oils + vapour 50-80 % (Arnine towers ucually have 20 actual
trays)
CONDENSERS
.
Condensers are usually installed on the overhead of fractionation towers t o recover llquid product and provldc internal tower reftux. Design of condensers is covered i n shell
.
+ tube exchanger section.
Basically two types of overhead condcnscr txlat, partial and total. When uslng a total condenser the heat load is equal to the latent heat of the saturated overhead vapour. The resultant bubble point liquid is split with some returning as
reflux and
the remaining portion as distillate product. For a partial condenser the vapour withdrawn from the accumulator is in equillbrhm with the returning reflux arfd consequently the condenser is acting as
an "external" additional tray. The vapwr is normally withdrawn under pressure control with a l l or part 01 the llquld returning aa rttlux to the column.
2.3.
REBOILERS
.
Generally three types o f reboiler exist for light hydrocarbon iractionarars. Internal rehoiler
therrnosyphons
external "kt?tltn type external "heat exchanger" type rnmt cases the "heat exchanger".type -
.
furnace, electrical
is preferred for elficiency.
The heat cxchanger should be located 2-3 rn below the exit nozzle from the
column so that sufficient head is available lor thermal circulation.
-
Reboilera may be heated by direct lire. electrical coil, steam, closed !>eating medium or process fluid exchange.
.
Values of U overall (lncl. fouling factor) for various types 01 reboller and deslgn tnethods are given i n the heat exchanger design guides*
-
4/
TRAY CALCULArtOlJ SHEET ~ o l u m mitem :
ray number : to =
1
a b\G
Name :
8
L
Number 01 passes :
Po = I f b a r a
\AaC
I. VAPOUR AND LIQUID TO TRAY
I
I
1
I
I I
FLUID
I I
kglh
I I
1
MW I
kmolfh
I
I 1
T,:
I *K
I I PC I bera
I / I
d I5
b/mS
I 1 I
i
-
i
I
I I 1
I 1 LIQUID I
I
ii6rtoQi 31 L
VAWUR
I I TOTAL I
I
I
I I
1
I
i s
i 304 i
I I I
I
I
1 1
I I
I
I I
I I I
I I
I I
I
Comprcssibillty factor Z
Reduced temperature Tr
R e d u r ~ dPrt!shure Pr
From charts Flgure 1, 2 or 3
Z = 0.6 7
page 15- 1 5 Yapour density
DV =
12.03 x MW Z x (to
Vapour
+
xP
273)
-
12.03 r 3 1 . L
* Ld
0.6't r
actual rate
7
PROCESS CALCULATION SHEET
a 3
TRAY COLUMNS
rc ~ ' D D l ~ b l PXP.$,JR ,i BI
CHU
ITEM
Sheet 1 of 4
3 21d \ i
uo DATE
I ~ o r r ~ r ~I *tf i r f ? t C
ran NO
1
t
i
3.6
2. LlQUlO FROM TRAY to = i a
.c
use flgure 10 page 15-20
= 384 kglm3
DL at to
=kt\
kg/m3
Liquid flowrate = 4 F b s ~ kgth
--
= qgooo = 239 m3fh
C, = & k
DL
All
3. WWNCOMER DESIGN VELOCITY YO bE n
TS =\? =hfo mrn "TRAY SPACING" DL D, = 3% kg/m3
-
-
YD drgo = 3b rn3fh/rnZ From ilgure 2 P a ~ e3.10 System factor KI 1.0 from table 1 Page 3.9 VD dsg = VD dsgo Y K1 = 3 t o rn3/hlrn2 4.
Y APOUR CAPACITY FACTOR CAF T!j .,4.hmm 38 f r ~ m (Fig.3) on page 3.10 from (Table 1) page 3-9 System factor K2 = CAF 0 CAF
50
= CAF x K 2 , l
0
,u.~t.
o.IB
5. VAPOUR EFFECTIVE LOAD V L w d
.
v Load = c . J ~ = m . DL - Dv
=
x
3 r6
=I164m3/h
6. APPROXIlAATE COLUMN DIAMETER DT =!.S-m
from (Fig.4) page 3.1 1
_-__---
__II_______I----------
4Y PROCESS CALCULATION SHEE1
TOTAL
m
ITEM
~EPIWPIOIPIIIIP'SUR
6I
CUY
OhfE
TRAY COLUMNS
wo
1 IOB tart€
100 N O
<~411i-L
4 !,
st!cel 2 01 4
-.-. 3.7 3.2.
COL ,:1N HEIGHT ESTIMATION
-
7
1
i 1 62
1 '1
"a
I
.
1\
' I
[LI
I
1 I
I I
lnnlilion
a. H1 :
5 -
See design details on vertical vapour-liquld separalots. Minimum distance for H I will be one tray spacing. Minimum distance between inlet nozzk and top tray 300 mm. selected H I= 6 0 0
mm
b. HZ: H2 : Tray spacing x (number of actual trays - 11
No.actua1 trays = theoretical traysltray efficiency far tray
= 50%
efficiency see section 2.1 page 3.3. Assume
Actual trays
- if the column ht = q ( # l Note :
=
16
diameter changes over the length, the transition piece will be
long and H2 will increase by this amounl
Selected HZ = Cqro
mrn
$5 PROCESS CALCULATION SHEET
.-.....----.-.-
btrM
T R A Y COLUMNS
3:crG
___
Sheet 3 ut _ ___. --,. 4
-
.
-.
3.8 c. H3:
H3 = h l + h2 hl
=
tray
h2 = h6
spacing x 2 = 900
+ h7 + h8 (see vertical
rnrn separatar sizing]
h6 = hold up time For production flowing to :
. . . . . hb
another column
t
= 15 min 2
storage
a furnace
10
anorher unii
a
5
I
reboiler/heat exchanger
:to00 mm
h7 = ip0 mm
h8 = 300 m m
4 h2 = 2500rnrn
H3 c h i
t
h2 = 3 7 e 0 rnrn
Selected H3 = 37 0 a
TOTAL COLUMN HEIGHT = H I
t
rnm
HZ + H3 = I I 0 f 0 m m
46
Ex3 m2Y
-
TOTAL
PROCESS CALCULATION SHEET ..I _ _ _ _
I I CuK
I
_ ....- Slieet -4 of 4
> lCl<
___I_
11IM
T R A Y COLUMNS
ItPOOPrblP E I I P I S U ~
Cmv
- -
oAtr
1 ronrlttt
TNQ
irnt-*ri
1100 Ha
I
ntv
1
Hev~siurr:
TOTAL
T R A Y COLUMNS 2/85
Wale:
TEPlDPlEXPlSUR
TABLE 1
SYSTEM FACTORS Service
System Factor
.............................................................. BFj. Freon...................................................... 0.9
1.00
Non foaming, regular systems Fluorine systems, e.g.,
Moderate foaming, e.g., oil absorbers, amine and glycol regenerators.,....
.85
Heavy foamlng, e.g., nmine end glycol absorbers
.f
................................... 9 Severe foaming, e.g., MEK units........................................................... .60 Foam-stable systems, e.g-, caustic regenerators.....................................-30
TABLE 2
Minimum recommended Tray spacing :7 5 m m
Column diameter mln
< 1 zoo 1 200 C 2 100 <
I
Q
~ s q cNU. :
< a roo <
4 200
g s
4 200
43.
3.9
P R ~ L S ENGINEEH~NC YESIGN MANUAL
TOTAL
TRAY COLUmS
TEPID PI EX PIS^^^
I
lleVlsJYll
Date
: 2/85
Fig. ~ O A L L A S IT R A V O l A U C T E l (FOR
APPROYlMlTlON
PURPOSCL O U L I )
.a,. Y LO80 -=Ch
low-
*
-
mass : T t
---
21M
-*Dm
PI-
r ?-.I%
----
:
ror r w n oars r n ~ v s
--. ma4 -. -
li.-r.r
-
ISL
-
110
*$O
ODD
- ssa - ma -m v - >w 4 s
-
IOaa
a00
ZlO
-am
-
d
-
--
ISP
?W
-*
-
-
-
*
0
IW
-
w
Ism
5-
-
-
11 Dlrldr Y Lm.4 k l II LnPY LmmL h l 1, D.l.l. dl.n*lW l l r k*.L*.l h.7 Ik* 41 MWIUI,~,
LrnUlO
44
l
.ye
mru
3.11
.
TOTAL
Revision
.
0
Pege Na. :
2/%5
3.12
PACKED TOWERS
TEP/DPAXPISIJR
1. APPLICARILITY FEASIBILITY;STUDY : PRE-PROIECT
Under normal elrcumstances the deslgn of a packed tower would be detailed by a vendor based on process data supplied by the engineer. The detailed design
of packed towers is
complex and requires spcclljc information regarding both packing type and size and mass
transfer data for the fluids contacted. For the purpose of this design guide detalls are given on the general arrangement of packed towers, various types of packing and loading and pressure drop correlations. The determination of the height of a packed tower should be evaluated b y a vendor or determined by the engineer I! required using methods outlined i n design literature (set references).
A detalled description is beyond the scope of this guide end is normally
unnecessary tor Ieasibility and pre-project level. 2. PACKED TOWER DESCRIPTION + NOTES
A general arrangement of a packed tower is shown in Figure I. Packing The correct selection of a tDWe1 packing w i l l normally be made by the vendor M
d on the
required process, klowrates and fpressurt drops srated~Details on pecking are given in :
-
Table 1 Packing service applications.
NOTES AND GUIDELINES
.
Carbon steel towers rnay be lined for corrosive service with rubber, plastic or brick deptnding
an the nature at the iluids being processed and the temperatures encountered.
.
Towers are generally loaded by dumping' the packing rather then stacking. Stacking is !nore
expensive and gives inferlo; liquid distribution but smaller pressure drap. Certain packing types will be stacked at vendor request.
70
-----
TOTAL
II~vi~inll : 9
Date t
.
Packing heights per suppwt platelgrid should not cncted 12' (3,6
15-20' (4.5
..
P a q Nn. ~ .
PACKED TOWERS
TEP/DP!EXPISUR
.
---..
- 6 rn) lor other packing types.
21~5
3.13
rn) for Raschig rings a!
Individual bed heights are normally limited t o 8
column diameters or 6 m msxlmum.
.
GoOd llquld distrlbution over the packing is necesssry to promote adequate p h w cmtact
-
within the bed. The streams of llquld should enter the bed on!3" 6" square .centres for small towers with D < 36". For larger towers the number of streams s h l d not be l e g s than (01612.
.
Llquld re1
tributors should be installed after approx. 3 tower diameters for Raxhlg rings
and 5-10 d: ~netersfor other packing types. Redistributors are not generally required for stacked packing as the downward liquid flow Is vertical.
.
In order t o reduce ceramic errd carbon packing breakage accuring durlng flow surges holddown or floating 'bed limiters are installed on top of the packing. The limiter must be heavy enough t o hold down the bed and be able t o resettle as the bed mavts.
For plastic or metal packing the bed limiter i s boIted i n place and doca not rest on the packing. Packed towers are not recommended
for
dirty service fluids nor for glycol dehydration.
Packed tower should be considcrcd i n preference to tray towers tor :
il srnall columns with fl'< 2 f t ii) acids or corrosive liquids iii) highly foaming liquids iu) low hold up times
v) law pressure drop requirement
.
51
TOTAL
Revisloti
0
PageNo
2/85
3.14
PACKED TOWERS
TEPIDPIEXPISUR
Date :
6. REFERENCES AND
USEFUL LITERATURE
4.1 Applied Process Design for chemical +
LUDWIG
-
Petrochemical plants VOL I1 pp 129-239 4.2 Design I
NORTON Co.
ormation for Packed Towers
Blrllctln DC-I I 4.3 Tower Packlngs
Bulletin
Packed Tower Internqls Hy-Pack
TA-8OR MY-bO
Interlox saddles 4.4 Dcslgn Techniques
TF-78
" I.
to
CI-78
for sizing
Packtd Towers
4.5 No mystery in packed bed Design
John 5. ECKERT
Chcrn. Eng. Progress Scpt. I961 VOL 57 John S. ECKEKT Oil and Gas Journal Auk. 24 1970
4.6 Calculator Program for Deaignlng
Packed f owera
4.7 Packed column Design an a Pocket Calculator
kd Packed Columns
V,I. PANCUSKA Chcm. Eng. May 5 19110
T.J. HtXSON Chem. Eng- Fcb. 6 198U Ptrry Chemical Eng. Handbook pp 18.19 4 18.47
.
f2
J
,
TOTAL
PROCESS ENGINCt+ia~u r-f)KlrBD
%xm3
D8te
TEPIDPIE WISVR
:2/85
( 0, 0.1111
Ir twllhlhw -0
F r r l * M cnlv
mt.l.re hrplr *M Pmribdw .mu
W l u ' a hnl TUN ?h.lH b.. vtw C Irar ilk *I- I.(t*.
--
-
-wh " psk;q
eartsct t&iiney; ewient; hrr-t,
mudly, the tmdlrr
p m u r c dm? in.
TOTA
~ w ~ t:i oa
P~OCESS ENGINE~R~ND DESIGN YAWL PACKED m
P-a No :
W
Dl10
TEPIDP/EXP/SUR
;2 / 8 5
3,16
3,o
Techniques for Sizing Packed Towers Reproducer 'rom NORTW 'Design 111, -matLon for Packed muera ' B u l l e t i n DC-11
hsMIrKw
F
--.-
-
.-.00
W
01Y M
01
02
k
Packing Factors (DUMPED PACKING)
0.4 06
K
tO
ZQ
40 W
2. bnw c m k u m ~ qth. v r l w d K comull th. ElrrrmLTmd pmnw~ drop m h m n .ban. It -I! br noled that h+rm m r r.rin oc m 4 . d pavam*tm PBWLnl tRnn 0.mm 1.5 Imhlln 01 mior pusurn dmp #r lwl at pmcW d.Mh (4 rn 123 mm oi *mrar pmrwe dm@ Wr nwtu d p c h M
.
E%,w. p c m o m m *mu k Owlnod to, at nudmum uonorrJU1 pruswa dm& Th. d n s n mu-
-
n m m w a a t d n m Un b W b . l m m m W w n n h i m a p r b l hrrlrnmni n bnt m m m t rsllt i n IO*. p ~ . bun drap ban. and law clOlul Lmwh~M r*. h4h.r m m ~ can u iw imwn r p n w u wan- p . l r u n a&, O;binmriI,, ~ c h m U mn.W -1.a a m 1.0 huh d n h r o r m m dme F M I d rcW d*Wh (W mm el wrbr pr+uun amp mmtm q mchd 0mL.pth). H M h t pnsnun #OM In pn* rMn rmbMnlaimn is wcn an to mJnWm a mm~lnl mrvsrum amp. -1 rb e n and rclmmrrlan bm W m d la h m w t r bram bns g.00 opiabm, ir. IMU d w a r prrun d.l. p QI wehd kpM (17 a d SO nwn el - M u lmrm d m m d u 01 ~ J m d wptnl. mmmpk.nc w m m v n d ~ r i l h n am d..isrwd h r F..lum dr4m ai 0.50 IO 1.0 W k r rllU gr4llun d w p.r W d p l e k d Moth (a2 mn rn U mm 01 *tar pfwlun d m mr rrulm d p.ehmV dm*). Y . o l u h dhaib !Am nm U ! a c m p l r l r mnm . Ipnwn dmp mnd l a w n d u d an rh.1 tw Um .5cmpllshad .nd w M h u tk lwumbadml)k~glo*.dupnn.nor*haukk a mduer I m p n a m d s*mntan b h n m produd qua*. fhm a n y w r uu m p in m W mrt m. prumurm 8-0 parrm.hn S # J * m tho r e n u 8 l l r . d prruun drop wrmb- in in tm M rbtmr (mm d r b h r l . fh.rdorr. M n a n i g n l q ~dnrmr rlh OUn M ~ a s * .P d m 1 eom~arntlons h a m bo m-n. n & a k w l r n lk. saell[c imvltv d tM b i d h suwunn.Yr i n s ih.m tkrt
tna nublishma the aibmrt.r
01 the tmr *nich. whm lh. ).Chin[ srtuned nnd oprrrtrd r t aaaI#m lkuid earn rmf- d d*rmIb# tnr re1cet.d mnaaurr amp.
nrw ~h
4 mr arplh d h m bw r w u l r d mltl bm d m n d m t upan thr, a#prwch Ia mml m a n trOn*fnr nsurnd r l l h lW% mlr. tnnllY tfmrrlk.lly rmuMI* r b d d innnil* depth.! Rm(ara 1R.m .81 IMPS dnr8n.d 10 owmtm mt m a : nun -1 m m lr*nsIaf. In (re abwrutbn pmblam~.thm, b.d h uwmlw ~lleueyllledlmm the mala mmln c*,
*I&
c
bream4 thr d n w H from th.r u I 0 Mm Hauld ph8n. n i h m ma$¶tm-8.
Or d dnpprn# aperatan m lnrOhM h mar c v ~ r mbecanal: l
fw
-
*.
b c c m ~th ~m. d r il ~Ivq~d la rnq S # I phma. Thm M n i l k t u ol tho t e r n tor the v b v a q u m l k n l lor w nna I..r n r n f0IfC-w k m t M.U tnmia co-.mtient lb. rnom/n.a nr. ~ t m .
h m M H ~mmfn c m m d m t m. rnowlfl.)nr )I s b. tmnsRrdlHr. H n h c droth ~ of towr wchbmL ft. 4 = tcwruwar -1 wmr, Ity C r h m r r u u r h 4tmorWarn v, ;-&tr;pniu%h ItdG. cmupanmnf i itn eh.se m e h m h n of m m w m iLn
I,.
~sui#lrrivnd t h liguid bulk H a w mom lr8dm d &rnpm-d lXB X, t liqul4 ohms# WI rraetipn. eunpovnl i X.* = * I d mas* mob Irmctbn m i tornpnnmnt i I* qrriHtiurn rlth E n bulk phrra motr mmmar CpmW"."t I.I 0
3. anr* h d n # d d m i n e d tha mlu4 oi
X 1s D. mbrchu *r U.p 1 . m d uMld mn o # r r t i y wrrm amp in f e p 2. a r mku at Iha erdlrrrm. I.m q b. datnrmiw by lhr urr gT IM # a ~ n U r m dm w r e or- -Ua. Locrtm thw
-rum d me m b ~ l an s lhil ~ Cr n * . ( t ~ ~ n umtu y the p p m r prbsnum apramrtur a Centme*d: IkW m -tmlV hem rn, paint b (h. WI iund +qr d ttm ehrt m d nM ma v u w 01 w mdir~tm.1411 nkn q - I m this smuv d *.firbin:
rn~
mrrr mu rwbstriptr 1 4nd 2 n l r r to thm mp rM bonffn mi tlw wkrnn r c r p d i w * E l Thm qwllon 01 &XI. ir .n.)qOu¶
ro itm q u r ~ b r lor r av~.i l w n r m .
b a d hr dm* a r m Wmilmbh fofmalt abarDlbn and -ping omnfkm. b K l ~ 8 mIh.I a U On a h a m t b n M COI wilh ~ l u 8 t krod. Mlutlmn mm r w mmvMt* tw mm v-riaua p e w , N k ire( # all I unusual tm me ttm -10 m a I mllo in-m wunm tor orlrgn wilh whar p c Y n p 04MMr nln wn tha. W rmeh OI& inlOmtiOiOn nfltl. Pdlilnlbn unth m ganwrlb d n i p M m tM b.bh ul M T P tnaifh~.~U~Y.IWI10 I~ ~ C O I ~ @ T .I*).~ I numind. d -11. barn n w l r n m l r l studlrs h r w u u r d UI lo cMLa ihbt tnr d n # 8 apturn mu ml. a rtlh tlw H I T ? *I&. (rmacd ihmt jcd d l l t n b u t i in nmntlimd and iha WebM w m ammtao wth p m w n wow d r l hmrt 0.20 mrm @ u r a r p f n w e amp mi IW . I prkdm (17 rnm ot r ~ ornrun n amv uw m& at W e U d mpch). Mars m n s l u tmkl~##elm m p c M Oms. whmR m ) r lubrmmial amd msuvm dmp aalwF.. -11 aecw i n d m r M l * f # I r mull d brbuhnl t0-i . Ip a am %tid miner man 4 r 1 d f i s m n l 00.rvlmn gwmrwd b y Rlm mlutmnCn 11 lhm
*
dlul al r l u 8 h h n l i m n ere*# Iulha nswrty Of r M YqW, 1 l u mckhq l a c l a r m d inn nr nle a. tho viraq c4 Ihr hldd a n C. dat.rmimd FtanNm. uwrlmtm or m m r r m w a Th. W U r I n n o n d bI1 YI.L 61 naelim am i m n m tna an* on p e a 4. Orordb I W a W W U n * mmlkr Uun 1 imh .Inm 4 m t l d . d lor tw.n om trrr or s m l k r dm*-, p r h t n p 1 ,men w L'H inch in un b r ton- mr ow M lo t n m hi 10.3 a 0.9 m a w ) m Mrrnwr urd z ot 3 rwh W P I . I ~ ~ arm u n d la l a r m n Ulrn or mole In(( 0 9 m u n l in awmH N Thc d.rrlrm rnouY urn tha m m i raa of erkmn. Th.
a n d thanlora .----.-..
lk p . ~ p rp u h u n ~f m o r
10
lkrs Rst
eu .n l..M l--.
om. ma told ~ . dgmn d
hmw bt.n amtarm~md.t h damn or
~-&rhurOwr must be rstab1,shd. O1Mral(l. hdlndua4 Dtd damn D hcu 10 csIumn d ~ m e t a r rr fO *nhoucn
n..
..C.,,..lr
3. Har that mH vmrublll hew rmsqnod vrlues. O mar k clkUktW mnd me u~arnelurd ikm te-w aet.rmlnM by
C l O O l lOrw bnimmlls br* rmur4d to r*llltD 1111 lull p l e n tirlol lhm p ~ ~ u m na any .por!crlion. (3.. [email protected] rnanu.1
TA.W.1
4,
HEAT EXCHANGERS
R c v ~ s ~ o: n u
Date:
TEPIOPtEXPISUI
rry:++r
2/85
4.1
1. APPLICABILITY It
is not expected that a hand calculatian of shell and tube exchangers be performed by the
engineer. For the purpose of a feasibility or pre-project study any required rigorous calculation would be performed using computer pr%rams HTRI or HTFS.
A qulck estimation of heat exchange area, shell diameter and tube length should be h e by hand calculation. An example of the procedure is given in Section 3.
A detailed mechanical design is beyond the scope of this guide. 2. DeSCRlPTlON A N D NOTES 2.1.
DESCRIPTION The flow of fluids inside the txchanger varies according to requirements and
can be
single or multi-pass on elther tube or shell side. Figure 1 shows the types of tubular heat exchanger manufactured to TEMA standards ;
The following types are irequently found t
2.2.
-
Exchengers (Heaters)
Candenserr
Reboilers [Therrno~yphonor forced circulation)
-
Evaporators (Kettle)
Chillers luring refrigerants)
SELECTION OF SHELL OR TUBE 510L FOR THE FLUIDS a. Tube side :
-
Most of time highest pressure fluid
-
Cooling water, steam
F w l l n g or corrosive fluid Sea water (it ir always recommanded t o install the sea water on tube aide)
b. She11 side :
-
3
Evaporation (refrigerants in chiller)
- Condensatian - Lcagt fouling Iluid
Most of time lawest pressure Iluid
SELECTION OF TUBES
. .
. 2.9.
Fluid with the highest viscosity
Standard length : 12'. Ib', 201 but longer tube lengths are possible {upto 00') Diameter commonly used :3/0", 1" Pitch commonly u x d : triangular or square. E~tcrnaltube cleaning is possible with square pitch only.
TUBE SIDE VELOCITIES
.
&
.
IIK tube side velocity for most materials and services should be held bcrwecn abour 1.3 to 2.5 mls. Below 1 to 1.2
mi5
fouling w1I1 be cxcessivt, much above 2.5 m/d erosion can
become a problem, 5 q
.
Rc~lsion. 0
TOTAL
'
pap* M~ :
SHELL AND TUBE EXCHANGERS
2/89
TWIOPIEXPIW~
4.2 >
CHARACTERISTICS OF
5
TUBM BWG = BrRMlNtHAM WIRE CAGE
I1
I
I lnmM1 SECTION 1 THICKNESSl R E/ dlamcter lmml I (in el mm) II B W G j (cm) I (cm21 1 1 External 1 I I I I I I 1 l Z i n I 14 I 2.10 I 0 . U 1 0.563 1 0.0399 I 1 (12.7 mm) I 16 I 6 1 0.950 1 0.694 I I I 1 18 I I I l a 2 1 1 0.819 I I I I I I 1 I I I 3jU in I 10 1 3.40 1 I.2Zu I 1.177 1 0.0598 1 1 (19.05 mm) I 12 1 2.77 I 1.351 1 1.435 1 I I I 10 1 2.10 I 1 1 1.727 1 1 I 1 16 1 1.65 1 1.575 1 1.998 1 I f I & 1.2P I 1.6% 1 2.159 1 I I I I I I 1 I Iin 1 10 1 3.40 1 Id39 I Z.7lb 1 0.0798 1. 1 (25.4mml 1 I2 1 2.77 1 1.986 1 3.098 1 1 I I 14 I 2.10 I 2.118 1 3.523 1 1 1 I 16 I 1.6 I 2.210 I 3.136 1 I I I 18 I i.20 I 2.291 1 9.122 1 I I I I I I I I 1 1 1 I 4 i n 1 10 1 ?.PO I 2.994 1 4 0.0997 1 1 (31.75 mm) I I2 1 2.77 I 2.616 1 3 7 I I 1 4 1 2.10 I 2.743 f 5.909 I I I I I6 I 1.65 1 2.845 I 6.357 I 1 I I 18 I 1.2@ I 2.921 I 6.701 I I 1 I I I I i I I 1l/Z in 1 10 1 3.40 I 3.120 1 7.661 1 0,1197 I 1 (38.1 mml I 12 1 2.77 1 3.251 1 8.300 1 I I I I k4 I 2.10 1 3.378 L 8.962 1 I I I6 I 1-65 1 3.4110 1 9.5t2 I I 1 18 f 1 1.20 1 3.556 1 9.931 1 I I 1 I I I 2-6-
External
I
1
1 [nlond
I (kg/rnl l I
0.0266
I 0.W
I 0.0295 0.0321
0.0384 0.0424 0.0166 0.0495 0.OSZO 0.0584 0.0621 0.0665 0.0694
I I I
0.b90 0.384
I t
0397
1
1 1 I
o.orm I I 0.0783 1
I I 2.021 1 1.696 I 1.321 1 lart I 0.~11 I 2.609 2.158
23-
0.862
0.0981 0.102t 0.1061 U.1093 0.1171
I 1
3.185
1 2.635 I 2.039 1 1.622 1 1.237
I
DESIGN MARGlN 10 % on area in recommended.
PRESSURE
.
DROP
n!Jawablc
id
A P varier with the total system pressure and the phase of fluid.
pressure drops of 0.7
t o 1.0 bar per exchanger arc common. The
cquilralent gas drop is about 0.2 to 0.5 bar.
.
hrne cxchangerr have low pressure losses and as rcboiler and condenser tless than 0.1 bar) trpccially those in vacuum system.
&J
I 1
1 1 I 1.682 0.0894 I 1.340 0.0918 I I d 2 4 I 0.0822
TEMPERATURE APPROACH AND PINCH
.
1 I I
1 1.416 I 1.216 I I 0.963 1 I 0.772 I
mlnimum temperature approach 5 'C. minimum pinch for condenser or chiller 3 'C, 2.7.
II
i 1
,
li
TOTAL
SHELL AND TUBE ~XCHANGERS Oat* :2/85
~w/DP/cxPISUR
2.9.
1.3
CHOICE OF HEAT EXCHANGER TYPE (Figure 11 a. Front endstationary head types
.
. .
Type A : Used for frequent tube sldt cleaning due to the easc o f dismantling the cover.
Type B :
Cheaper than Type A but the dismantling of the bonnet is more difficult. To be used for clean products.
Type C : Cheaper than Type A for low pressure. The price increases quickly with the pressure. This type Is pracrically never used.
Type D ; Special for hlgh pressure P > 200 bar. b. She11 types
. .
Type E r . In general the most commonly used.
.
Type F : Advantage
; Fluids flow
.Disadvantage : -
at perfect counter current (F = 1).
Leakage between the longitudial befile and shell decreases in
-
-
value.
Mechanical problems from expansion. Low prcsmre drop t g : < 1 bar (risk of d a m a ~ e
01 the longitudinal baffle). This typt should be avoided. A greater number
oI Type E shells in Series is
preferred.
.
Type G 4 H :Used tor low AP J. 50 mbar as lor thermosyphon reboiler. Vertical balfics are not installed lor t h c x types and due to that the length of the shell must be limited.
,
Type 3 : Uaed for high flow or high
AP for
Type E and also sometimes on
condtnsates to avoid the use of vapor belt.
c.
. Type K : Used for vapor separation i s required ie chiller, some reboiltrs... Rear end, head types - Types L, M and N : Fixed tube sheet, used for clean fluid on shell ride and lor Iow
.
.
.
AT
< 30 ' C . i f AT > 30 * C
use other head types or install an expansion
joint on the sheil. Typc L and N will be used for dirty fluid on tube side. For the other cases the t y p e M wlll be urcd it is the cheapest. Typc P : Generally not uscd.
Type 5 : Used very frequcnlly, no restriction& Type
T : For frequent dismantling, enpensive, she11 diameter larger than t y p t
S far same number of tubes generally not used. Typc U z For ckan fluids on tubrsidc no other restrictions, low cost.
Type W : Generally not uscd. d. Conclusion
Tot most frequently uscd types are I BES, BEW, AES, BEM, divided [low,
6 1' 7
-
.
TOTAL TEPIDPIE"~~SUR
--"- ..-
-
m u . "
PROCESS ENGINEERING DESIGN HANWL
k.i*' : 0
P.g. No
SllELL htJD RlBE EXCHAWSRS a
: 2/85
4.4.
3 DETERMINATION OF ESTIMATED HEAT TRANSFER &REA
I I I
DUTY
I I
Outlci temperature T2
HOT FLUlD
I Inlet temperrturc
I I
TI
4
II
I 1 1
T2-tl
'c
I T1-tl I I TI-T2
I I I I
O.fr10
6
*C *C
13J-?S=g
I I I
I8 16
(fr-1Br+
*C
I 1 3-r I I ?&-ti=? I I st.19=16
'C
1 3b-t5-4
I
-
2/11
I I
q/l
I
=
---
-
I Ir CORRECTED - LMTD - CORR. - Ir i
HEAT TRANSFER COEFF. I TABLE 3 Page 4.10
r-----
I HEAT TRANSFER AREA
ui
.
kcal/h
i
mZ
1
A=+ U.LM D CORR
I
ESTIMATED TUBE LENGTH CT(m) ~ T ~ M A T ESHELL D DlAM Iinr(rnm)
1I I
I 1
1 ESTIMATED WEIGHT Bundle I tonnes
1
1 I 1
f
1 I I I I
I
I I I
r
T
- c-[ -II
,
- rI 7----i
I
t I I 1
-
I
I -
-
-2ifI
sea a.0 ( LOO r S.cC
20
I I
i
including foulin8
I
I I I I
F = D.111
I
(c.1 1
3 1 [tqo)
13hlI
ruh* L
' I& t dY 6
;C 17
tA*s I1
3 .C)
I
L.o
Shell
-------
1
I
----
J tannes I Total I tonne~ I I I
I I t
1
I m2 *C III factor I r ----------I I 1 I I
I I I
I
I I I
I I
~ - F T ~ - carrection !D I factor (3) t
r--
I I I
I 1
l.llf
~TNK-BFROFS ~ELLS------
I
i?
I
o,f
-,---[ L I
I
I I I I I
I
' C
I
I
I I 1
*c
I
a&
I
-C
I
NOTES :
I Indicate temperature I I
tr
I
'C
I I 1 I 1 I 1 I I I I I I I
(1)
I I P-U-tl I TI-tl I I R~TI-TZ I tZ-tl
'C
I I 1
I COLD FLUID I Inlet temperature t l I Outlet temperature t2
formula
kcallh
I I
VALUE
I
I I I
Q
I I . LMTD from I I t2-tl I
I
I I
ITEM :
--
q .o -
--_
1 __---.l
- - -
-
--
I
----
I 63
PROCESS U L C U U ~ O H SHEET ITEM ; i l - ; < . . L . , -
~WQO? MR~KP'SUI
1 I
CI.
I
SHELL AND f UBE HEAT EXCHANGER no n ~ t ri
I lnm rartr
.
a .tz ,?t
L
~ n un n
L*t*',.*
.a%.
,II!, i
rrv I
Revhion ;
TOTAL
0
Page No. :
SHELL AND TUBE EXCHANGERS 2/89
Date:
T€PR)Pf€XPlSUR
4.6
(1) Use following formula
- -- -
if T2
- t l > TI - t 2
- t2) - (T2- t l )
if T i
-
LMTD. (T2 tl) 1T1 tZ) LnT2 t l
T1-t2
LMTD
.
(TI
'12-tl
LnTt
t2
t2 > T2
- t1
Remark : If tht htat exchange curves are not linear the LMTD should be determined step by step w l t h the lintarisation of the curves and with the ponderation of the
partial LMTD by the partial duty on tach Iincar step.
(2) For total condensing TEwmnPJ .c
3y
26
5 hmpratur. *WW+h
I
I
>
I*m l
- 2
Dm
D.np.h*ariw
Eond.amlnp
I d l l Y
/r 1
0
%.tm
In this case -alculatc the heat transfer area for each zone, the sum of these areas is the
surface for the exchanger. (3) See LMTD correction factor (Figures 2 ) the number of shells should be chosen in order to have 0.8 IfF
(
0.8 add shells (2 exchangers in service)
1. ESTIMATION OF SHELL DIAMETER With the heat transfer area, selected tube sits, pitch, tubes I e n g t h ' i t is
possible to
determine the number of tubes and. w i t h table 1 or 2 hereafter the approximate shell diameter. Take maximum shell diameter abwt 60 inches.
6q
( TOTAL I
IROCESS,ENGINErnlNG DESIGN MANUAL
I
Revl$inm :
0
I
Papa No
.
SHELL AND TU8E E X C W W M
-
TEP1IOPIEXPISUR
Dltl
: 2/05
4.B
1
TOTAL
P R O C E S ENGINEEAINII DESIGN MANUAL
TE~~DP~EXP~SU~~
SHELL
R4n.m :
7WBE E ~ ~ ~ ~ G E R S
,-
OLtm
.a
: 2/05
i ayr
IVU
4.9
L
1 I
TLWLI k MI' PITCU
1 I,
u
rruusr~o r v ~ r r r sruar
s
)IDL
I
3
*
I
!I
n
10
>1
11
I
I
C I T ~ A 1-
I
I-
NVMOLIOF C
I
rumS SIDE
~
I
1
r
10
Y
I?
H
31
10
64
%
17
I?
Tb
$8
W
82
76
95
+n
az
161
104
M
IJI
LIb
146
1%
I17
111
12. 1U
131
111
lm
IS I I ~
1%
120
am
nm
13
111 21 .
11 I/* ZJ l i b 13
Z7*
??a
186
JID
MS
ln
JIJ
111
301
H1
Wl
3s
a0 I
W
$70 +Jl
111
*A
*I9
3%
JIC ILL712
119
bm
1% WI
*If
19 I 113
m
7SJ
111
477
I
IS
~fi
I?
n $1
II II
LbU
10.
1%
UY
199
a10
77:
I?> 111
111
170
I67
301
110
1071
917 1017
U Y 1011
lolb
iOJI
3lJ
LrM
ll t l
1129 1110
rni Inr
1172
1/15
t2lZ
1111
ZDI?
m9
8117
1Yl
1111 I0
111J
2JY
tW.1
a
Ib
I7 $7
>a
61 14
37
I a3
Ill
110
11Q
In
I77 115
.I IC
I 6b
nr ).I
151
I
Ma
m
,n
171
a31 117
J>l I10
*I
6lh
131
tbb
*?I
9m IO>I
YI
IIH
lola
llOI
In,
llJS IIS?
I%*
If*?
I I
TABLE I
p
.
kdh. m? Y
rnrrl* vsr.rl*rtr "h. I< l rs
(includinp foul LW factors) nrn#ndtmUq
..
C~~,SS
w-i n r r *
C&3
chlllrr d
It0
r.tsh...,n.C
11 110
.-1wsltr ' I C P
a30 - 6 1 n
1C p
x 0.2047 ' ~ ~ i p f t ~ * ~
r 1 .I62
W/m
*x
>O-)W
r n h m b - v *il
sl.~.rrr.le slE.&nr,
nx. Y'Y""~
* "C"
n.c.0.9 CP n.c. wbc-ibr
(
*imW 1 CP
1 lC P
-
I IW 13 1M m-1-
9 0
Itrsmlral*l ,U,,,,/U'bi
-- bm
H m 100
m-x4
putkmll.*
*.dlu
-w
rm. 190
I.~M HL. I wircsrlr ~I 0 3 c P v.le,..r.,e H.C 0.9 c p c vw-ill
kc.l/hrm2'~
-
W-1100 2-0 Y P
am-w w.m
TpTAL
PROCESS ENGINEERING DESIGN MANUAL
Revhion : o
pwe N. :
SHELL AWD TUBE EXCIIANCERS
Dale
TEPIDPIEXPISVR FIOURE 4 TYPE BEU
WEIOHT ESTIMATE
:2/BS
9.12
TOTAL
Revision : 0
P8gs ?Jn '
AIR COOLERS htc:
TEPtDFIEXPISUR
1.13
1. APPLICABILITY For both the feasibility and preprojcct study i t would gentrally be required to state the requlrrd duty of the air -let, the overall dimensionn yld weight and an estimate of required fan power. A calculation prmedurc sufficient for a preliminary estimatt is given I n section 3.0.
2. DESCRIPTION AND GUIDELINE NOTES Water or Alr Gaoling ?
.
Air cooling offshore is sometimes prohibited due to the modular layout 01 the platform.
This may require installation of the air cmler 1na rcrnoke from the associated equipment. Use clorcd loop watcr cooling.
.
A i r caaling ia cheaper, simple and fkxible when compared to rumter cooling. The cost and
nulsancc of water treating Ii eliminated If air coolers are used.
.
h warm climates
will not be as tffcctlve as watcr which will produce a cooler product stream. Air cooling is apprax 50-70 % as effective as water. gg&ng
Fwced on induced draft ?
.
'Forced draft, pushes the air a t lowest available temperaturc~~highcst f
hence lower
pow-. requirement.
.
Acces billty to motor and driver are better on lorced. Structural and maintenance cmts
arc lower.
.
PassIbllity with forced draft ai hat alr recirculating into suction of fan thereby reduclng efficiency.
.
Induced draft gives better air distribution due to lower inlet velocity with less chance of rtcirculatlng of hat air.
.
Indudd draft coolers can be easily installed
4 h v c piperacks or orher equipment.
Protection is given by induced draft coolers from effccts(oll rain, wind mawlpn&md tubes. Important i f fluid in tubes is sensitive to suddsn tamp change also freezing 0f tubes can occur i n cold ckirnates or heavy snowfal!.
I
0
Page No. :
2 ~ 5
S.lI
Rcvirion :
TOTAL
SHELL AND TUBE EXCHANGERS
TLP~DWEXPI~UR
Finned tube elements (see Table I)
. .
I"OD tubing t most common w i t h 0.5" to 0.625" fins* Fin spacing 7 to 11 per inch. Exten. ' surface area is 7 to 20 times bare area. Standard tube lengths from 6 f t to SO It I2 m t o 15 m). Lonser tube designs are less
costly than short ones.
.
Bundle depth may vary from smaller units. U l c
.
U as first
9
rowr so 30 rows of tubes, 4 or 6 r o w r is common l o r
estimate.
Fin material most commonly AL. Adequate vpto 400 ' C operating. Use steel for higher
.
temps. Fans and motors
.
Fans arc axial-flow large volume low OP devices U s e l o b 1 fan efficiency 65
%. Driver
efficiency 95 %.
-
Fan 0 equal to w slightly less than bundle width. Normally 2 Ians preferred. Fans have 4 to 6 blades. Max fan diameter 14'-16'.
.
Distanct between fan +.bundle 0.4-0.5 01 inn diameter. Ratio of tan ring area to bundle area must nat be less than 0.4.
.
Fans may be electric, steam, hydraulic or gssoline driven. lndlvlduaf driver site usually lirnlted t o 30 hp, (80 Kw), 3110 V.
.
Face velocity of air across a bundle is 300-700 LVmin (1.5-3.6 ms-11. A 10 % change in alr flow rate results in
* 35 % change in power used.
Temperature control (Fig. I )
.
For c l o control ~ of process outlet temperature auto-variable pitch fans, top louvers Or variable spe@
.
. -
rno.tws.are required.
Vmrlablc pltch fans are more efficient than louvers.
Louvers can be manually adjusted for winter
or
night time operation.
For p r a c l s fluids that i r e c r e or gel at temperatures above the winter amblent a recirculation system is necessary t o maintain air temp enreriw the tube bundle.
-
-
General approach temp to ambient air is 20-28 'C. Absolute min is 10-12 'C.
- Air Note
I
coolers are noisy. Keep fan speed as low as posslble and consider relative 1ayOUt
carefully.
72
TOTAL
~ P U I ~ I I I :~ I{J
AIR COOLERS
.
f EPIOPIEXPI~UI
: 2/65
4.0 REFERENCES AND USEFUL LITERATURE 5.1.
Air c w l c d heat exchangers
PERRY
pp 11.23
13.
Air cooled heat exchangers
LUDWIG
pp 1 7 7
3 .
A i r cwled heat exchangers
GPSA
1.4.
Aerial coolers
4 .
Design of air coolers
-A
b t i m a t c air cooler size
HP QICV program
- 193
chapter 9
R. BROWN
Chem. Eng, Mar 27 1978, p 109 N. SHAIKH
Chern. Eng, Dee 12 19S3, p 61-70
73 >
- 11.25
CAMPBELL pp 207-209
Prcrcedure for estimation
1.6.
I*.rcJrc d r j
4.15
4-16
OPERATING CONDITIONS AND NATURE OF PLLriD : Duty
I Q = 11 w to6
Fluid inlet temperature
ITl=l
100
Fluid outlet temperature Fluid iniet pressure Air ambiant temperature Overall k a t transfer cgeff. Table f andlor aruchcd
I T2= I
r0
1
kcaIih
,C I *C I FLUID A r t = TI
- TZ =
SO
-C
l P = 1 10 barabr I I t ] = t 3a *C IINLETPI = T I - t l s 7-0 l U = I zoo kcalfh m2 *C I
C
w w k sheer) (Based on bare tube area)
I
NOTES
STEP I
8
I
(curve N* 4) P:?.
0.8
I 1 I
{curve N. 4)
t * ~ptirnrrmnumber oi tube rows fat U selected 2 R = dt airldt m 3. TI TZ/Tl tl
IN=
4. Y = A t a i r / T i.-, t l
I Y = I 8.35 Idtair.1 1 . I t2 = I S
-
IR- I 1 'qjn 1
-
5 btair r % ( T I- t i ) 6. Exlt air temp t 2 =Atair + t1 7. Average dillerentlal temp. dtm
.*
1- Bare tube surface A
z
&-
1 Idtrn.1
I IA:
10. 11 12.
I
I I 326 I
mz
m2 1 m 1 3, 4, 1, 6 , 7.5 or 9 m are I (1" 00 tubing)
IL= I 7s fubcslrow TR = Fa/LnO.OS 1 TR = I L 8 Cooler width V=TRx0.0635 ) w I jl,l Tube length
-
1 16.
Powerllan F Q ~ N F
17.
Estimated wclsht 4.88 (36.bX9.35 NIxwxL
1 I
I
i,r
Totel lan power ~ F W . 7 9 5 ( Fp = 1 3t I, Number of fans INF*I t Fan diameter I F 0 . l 3.r
3. 4
'Ct
30.d
1 Fa = 1
(curve N' I )
I
.C
I
1 9. Bare tube areafraw Fa=AlN
*C
Q.2IA
m
1
kw
i
I m 1
1 PF r l L I M r I ilrfio I I
kW
common
man. fan diam = 4.6 rn
I (including motors)
kg(
I
Notes : Curves numbers refer t o Process Design Manual Chap. 4.
70 PROCCSS CILCUCATION SHEET H*hl&@,cr*
AIR COOLER f I t f W C Q M X L IUI.
.
av
CWN
DATE
1 INttrit
. ,L
'2
Li'-.
-
UO
LI(A~?PC~-
100NO .
REV
1
4.17
1.
rlQUUCOQLlNG LIQUlD VISCOSITY AT 1 1 + T2
i ;
GLOBAL HEAT TRANSFER COEFFICIENT r U
e
--T-
(Read curve n* I) 2. GAS COOLING MOLECULAR MASS :MU' =
GLOBAL HEAT' TRANSFER COEFFICIENT r U = (Read curve no 2) 3. TOTAL CONDENSATION
71-T2 =
'C
GLOBAL HEAT fRANSFER COEFFICIENT :U = (Read curve ng 3) 4. PARTIAL CONDENSATlON
I . w1Tnou-r L~QLJIDAT inlet gas flowratc
INLET
=
WGl
---
outlet gas flowrate WC2 outlet liq flowrate
-
WLZ
T I T2 GAS MOLECULAR WEIGHT AT T i
+
12 =
2
--
HEAT TRANSFER COEFF. Uc (Read curve n' 3) HEAT TRANSFER COEFF. Ua (Read curve n' 2) GLOBAL HEAT
I
TRANSFER COEFF.
U. W L ~ X U C + W G ~ug X prtl
m
I
SELECTED GLO8AL HEAT TRANSFER COEFF. r U
=
?z PROCESS CALCWPTION SHEET
AIR COOLERS
HEAT TRANSFER COEFFICIENT 108TITLE
ITEM
no. 100 no
rtv
I
kla
4.2.
WlTH LIQUID AT INLET
Inlet liquid flaw rate
WLI
-
kglh
outlet 11quld flow rate
WLZ
I
kglh
=
LIQUID MOLECULAR WEIGHT AT LIQUID SPECIFIC HEAT AT QL =)-I
x
CPl =
-
CPl x IT1 T2)
inlet gas flow rate WG1 outlet gar flow rate WC2
QC c (WGI
-
kcallh
-
kgh
kgrh
I
GAS MOLECULAR WEIGHT AT GAS SPECIFIC HEAT AT
kcaVkg *C
TL + TZ = 2
v. CPg
wG2) x CPg x (TI
*
kcallkg *C
- T2)
kcallh
CONDENSATlON HEAT
-
Qc=Q-QL-QC LIQUID
VISCOSITY AT T
I
kcallh
CPB
LIQUID HEAT TRANSFER COEFF. (Read curve c* 2)
UI
=
kcal/h rn2 ' C
GAS HEAT TRANSFER COEFF. (Read curve n* 2)
Ug =
kcallh rn2 *C
UC =
kcallh m 2 'C
U =
kcalfh rn2 ' C
U =
kcal/h m2 * C
CONDENSATION HEAT TRANSFER COEFF. (Read curve n* 3)
GLOBAL HEAT TRANSFER COEFF. "=
& UI
Ug
Uc
SELECTED GLOBAL HEAT TRANSFER COEFF. :
76
& -
PROCESS CALCULATION SHEET
AIR CQOLERS HEAT TRANSFER COEFFtClENf
lI?IDD?'M?lIW3VR #I
CHk
OAIE
.
10I llllt
nru
106 No
I
arv
I
TOTAL TEPIDPIEXPISUR C L r I~
P I Q E P ENGINEERING DESIGN MANUAL fix4 COOLUIS
- ceoune IIYD~WIRUOH
LIWIDS
I l m v i ~ h: 0 Date
I2/8S
P-
NO: 4,ZO
--
TOTAL
PRDSLS
ENGIWEFRINO DTSIW MAMUL
inision :
o
PW* NO
AIR COOLERS Dotr
TEPIDPIEXPISUR
I.? I
: 2/85
snr/hrft2*r - 2 Fintub. 1.h h r t-in. OD . k h * ~ l l r hl l l ( l k ~ APF. rq k/k
+
3 S8
3.60
AR, q k ~ h
tub. PI* A P Y 13 ,I4 nrrl
kb.1 h*.h)I
14.5
11.1
1 in.3
1% h
11.4
60 4
a
A 2 % in, 3 IQ I I0 1
2% m ,
11.2
80.1 1 1 1 1 107.1 I . 114.0 101.0 id15 1340 lbrrd 134.1 1 178 2 140.0 k ~ A p r t l u r t ~ u r r J w n d f i * r . k i n . ~ nA# r ni. . ~ . w u ~ I * u r b r ~ ~ 4 h ~ ~ino4 Dri . k r r r~ d. ~ d I *hid b u *.MI q R I f L APSCb l k n v r u l a m in q hrb 01 b.nd& I- w.8,
.-
I
*-
. ". .....
2r....,.
-.
U*.m I . . " , . 1m.1n-
",
I*#* -,> 98.-1.2
4-.1 r - a
I,,
-a*
u, %I,#
I
FII
_.___.I-
TOTAL
p ~ l r f E H.
GK
Revis~on: 0
Page No. .
dric d a o k m
Date: 2/gs
l~p~~~~EXPfSUn
4.29
C
1. ~~PPLICA~ILITY FEASIBIL~TYSTUDY r PRE-PROJECT
Under normal c i r c u m s t a ~ t s ,the design wl plate type exchangers wwld be detailed by a vendor b a d on process data supplied by the eqinaer.
Two types oi plate exchangers could be used z
.
. or
Plete i l n exchangers ;
Plate exchangers.
the purpose of this design guide, only a quick description and
some charseteristlcs are
sivtn. For plate fin exchsngtrs, the size could be done only by a vendor.
For plate eschanger3, the size could be estimated if some vendor {ALFA-LAVAL, APV, VICARB) inlormation are available. An estimation of the heat transfer area could be done i f the hcat tranrier coefficient is known using the same formula as lor 8hil mnd tube hcat exchanger w i t h factor
= I.
4
LMTD correction
The heat transfer coelficient is difficult to clrtimate; it depcnds on many factors
as flow rate 01 different iluids, pressure drop, plate spacing, etc,..
2. DESCRIPTION AND NOTES 2.1 PLATE FIN EXCHANGERS
Thee exchangers consist of stacked cwruyttd shrcls (lins) separated by flat plates and an outer irarne with openings for ihe inlet and outlet oi fluids. This core Is immersed In a liquid salt bath t o b r a z ~all the separate parts together. Flow in adjacent iluid passages can be coeurrent. counter current, or crossflow and Sever?
uids can be erchangin~heat at the $am time.
In case of the inlet fluid & a
two
phases flow a drum is requlrtd to separate the two
phsses in order to hsve a good distribution.
These plate iin exchangers arc used only with clean fluids.
L
81
TOTAL
Rwision : 0
Paga No.:
AIR COOLERS
TEPTZIP#XP~UR
Qstt :
~fif
1.25
Figure I ahowr *t principle of coratruction of a platelin exchanger. A large amount of
surface can be accomodatcd in a small volumt (1,000 m2/m3). Maximum design pressure r
59 bar&
Temperature range
r
- 195 'C
Size rnsx.
I
1,220
Ttmpersture approach
Applicability
2 :
t o t 6 1 'C
m m x 6 096 m m x 1 340 mm
*C
LNG, LPG recovery,
...
Prc~sur top as for shell and t u b heat exchangers. 2.2 PLATE EXCHANGERS
Plete exchangers a r t an assembly of metal plates stparated by gaskets to give a small clearance between each plate. The two fluids pass in opporha directions each thrwgh every alternate plate. Refer to flgure 2.
Tht exctmnger Is easily dismantled for cleaning ii required. A good overall heat tramfer cotfiicicnt is obtained and small tempcraturc differences can be u e d . The plates can be made from exotic malerials such as riianiurn which are redstant to
corrosion and u e used for sea water coolers. They are v t r y compact eschangerr find aeupy small i l w r area.
Maximum pressure
:
Maximum temperature
: 250 'C
10-20bars
(Need spcelal gaskets) Overall heat transfer cotfficint
-
5 000 k c a l h m2 ' C
Vatcrlwatcr
: 2 000
Maximum surface
: about 1 MO m2
Maximum ilow
: 2 500 m31h
Applicability : Sea water
.
Prtswrt b o p s
I
- service water, water-TEG, TEG-TEG,..,
allowable pressure drops vary according to the total system
pressure and the ~ r v i c otf the flulds.
-
-
water #ervict water r 0.5 to 2 &r (high transfer caeflicitnt), lor sea
lor water-TEG or TEG-TEG the dP cwId be very low such as 10 to 20 mbar.
3. REFERENCES AND USEFUL LITERATURE +
>
A P increase the overall heat
Vendors iniormatlon.
2?2
/
~0Tf\ '
-
PROCESS ENGINEERING DESIGN MANUAL
Rwision :
0'
Pwp tdo :
1
p=m U C n m C Z R S
cww
~~P~DPIExPISUR
: ?IB5
4.25
PMTE F I N EXC-ILS
!
IIWCIPU OF mnstnucTKm 1. A . u * ZV d Y 14. *.dm I.-.1
I.*m t
slaw hrm
I. LR) 1.P W W ovtW 10. El-
ih.t
i l . P * M I Z M U W ~ W *
I2.wmMbr 1b.-II
Llr**r
i
Y'3
D r n I t S OF PU'PE
TYPE EXCR*NECR
. TOTAL
--Rcvirlon : 0
Pmp. Nc. :
FURNACES D a a : 2/83
~ ~ ~ ~ o P I ~ x ~ ~ S U ~
4.27
1, UPLlCABTr'TY i s not exy. -tcd that hand calculation of furnaces be performed by t h t engineer. It is normally done by 4 manufacturer based on p r m u s data suppllcd by the cn&inecr. Furnaces are
used
to transfer heat directly to the process fluid md generally have a large
duty and produce high process tcrnpratures.
OESCRIFTION
2.L.
A iurnact consists of the Iollowlng :
. .
A cornbustibn chamber lined with refractory shd burners
Tubes which .re located within the combustion chamber and where heat is transferred to tht process fluid by radiation
. Tuber which is also . which
arc I ~ a t c dexternal to rhc cornbusion chamkr in a convcctian zone Iintd with refractory.
Stack for dirpasal of flare gas.
2.2.
.
Alr supply system by tan ar induced drajt.
+
instruments and controls.
TYPES OF FURNACE 23.1.
Cabin furnace
.
This
ifia
rectangular furnace and contain$ t u b a which can be horlzmtal or
v t r i i c ~ l .The burners are rituated in the walls o r floor, and the cmvectlon
zone is laated above the furnace.
.
Flue gaser discharge to a stadt tither directly ar arc driven by an induced
drait fan.
.
Burners are normally arranged in raws on two wails and a r t spaced SO provide a rad~atlon zone of constant tcmpcratun a d avoid
aj
to
flame
impingcment'on the Tubes. An alternative arrangement i s burners located In the floor ai the furnace as shown in Figure I .
.
The connection bsnk conbins raws of tubes acrms which the flue gas
.
leaving the lurnace 1s d i g e d to pass A small negative preswrt is maintained to prevent hat gas leskagc.
,
There
is a pressure lw in the flue 8as syste~nand this h l s to be made up
either by we ot
fan discharging to a s b r t stack or by natural bwyancy creating drait in a tall stack. +
&
$5
TOTAL
nrv~rion:
0
~ a g ~ ~ o . :
FURHACW
tEPIDPlEXPISUR
Date :
2/85
b.28
1.2.2- Cylindrical furnace (see Figure 1)
.
These furnaces arc vertlcal and contain rndistion and convection zones or
KI~CIJ
. . 2.3.
4
tadistlon zone.
The burners are h a t e d in the bottom and the radiation zone tubes can be vertlcal or hcli&~dal. The convection bank is located above the radiation zone and contains rows of horizontal tubes. Cenermlly the stack ls vertically above the convection bank wlth no f u k
BURNERS
.
Two types nf burner are used in furnaces, induced air or natural draft burners and lorccd drait burners.
2
. Induced air burners These can burn gas or fuel oil simultane~uslyor independently. Excess air required 1s 15 % to 20 % for gar and 30 % t o h 0 % lor liquidsl If fuel oI1 is burned 0.3 k@g
2
oil of steam is required for atomisi*
Pressure burners
The air far prrs8ure burners is supplied by fan. I t is therelore capable of control and the burner can operated wlth less excess air 5 to iS '16. 3. EXCESS AIR
.
Determine the excess air recommended by the burner manufacturer and the type of burner air system proposed. k t 1 2.3.
.
From thk determine the kg of flue 68s per kg of fuel fired remembering that air
contains 21 96 Vol 01 oxygen. I.f TACK GAS TEMPERATURE
This i s controlled by 2 iactors :
. .
The process fluid inlet temperature w i l l dewrminc the temperature of the gas Jeavhg I h t convection bank. Condensation is to be avoided. If sulphur 1s prcaent in the fuel the stack temperature i s raised to avoid the possibility of production 01 corrosive sulphuraus wid. This would result in a minimum e x i t temperature of about 120 ' C .
5?6
Rev~sion: 0
TOTAL
Pagc~o.. :
FURNACES Date:
ITEPIDPIEXPISUR
2/85
0.29
t
-
EFFICIENCY
\I
3 I f Hc =
-
IOD IOSWS,
-Tbb.
Hf
- HC
Hf
flue gas enthalpy at exit
Hf = enthalpy of combustion (net calorific value + sensible heat in futl and air) + heat bclng furnished by atornisalion steam if required. L a s x s include radiation and unaccounted, e.g. unburned fuel (2 % is a good figure). For a furnace which is all radiant duty the efficiency is of the order of 50 to 55 %.
.
.
A furnace with a convection bank will be from 75 to 8 1 % efficient.
P R W U R E LOSSES
Pressure is lost in :
.
.
: 3
Burner air regulation Convection bank
: 5
- I 5 mm water
- I$ mm water
.
Ducting Stack
:
variable : variable
Pressure is gained by natural buoyancfof hot stack gas. For r system using natural draft burners a low pressure loss is required across the burner and the furnace operates under negative pressure. FLUE GASES VELOCITY The flue gases should leave the stack a t LO
- 70 m/s velocity to ensure safe dispersal.
CHOICE OF TYPE OF FURNACE
.
Above
a capacity of
60 r 106 kcallh the cylindral furnace gives construction problems as
t h e maximum diameter is about 10
.
- 11 m.
A cabin furnace requires much more floor area fian a cylindrical furnace the length can b t as much as 27 m. If the tubes are horizontal then a withdrawal space for tube
replacement will also be required. However for offshore applications the gpace requirement tends not to favour the cabin furnace.
.
With a cabin furnace it is possible to obtain a uniform heat reicasc across the radiatlon Zone. The helght can be a b w t I 5 m.
-
With e cylindrical furnace it is not possible to obtain a uniform heat above release across
the radiation zone. The height can be about 25 m. For remote locations in oil field sppljcations water bath fire tube cyl~ndricalheaters a r t often used (consult vendors NATCO, 85 & B etc...)
g?
-
The I o l l o ~ ~! is lor a very preliminary sizing
D in m Qa =
absorbed heat in 106 kcalfh
9 H
Dtlinm 2.5 D in rn util radiation bank
r 5
/ TOTAL
PROCESS ENClnlERlNO DESIGN MANUAL
1 ~EPIDPIEWBUR
Aarklsn : Dmra
I
5,
PUMPS
:u85
Pwe No :
rOTAL
Revision:
0
Page Ho. :
PUMPS
-
TEPIDPIEXIISUR
Date:
2/83
XI
1.0 APPLICABILITY
For both the feasibility study and a pre-project study the engineer will be required to cvJuate a pump selection and fill ln a data sheet with the basic Information. In order t o provide the basis of a good cost and layout estimate it is important to understand the type and number of pumps-for the service in consideration, and the associated power rquirements.
2.0 DESCRIPTION AND GUIDELINE NOTES TYPES OF PUMPS
.
Generally there are three classes of pumps : Centrifugal I . Centrifugal 2. Propelkr
3. Mixed flow 4. Peripheral 5. Turbine
.
Rotary
Reciprocating
I . Cam 2. Screw 3. Gear
I. Piston 2. Plunger 3. Diaphragm
4. Vane
S Lobe
A pump select~onchart is shown in Figure 1.
GENERAL USAGE Centrifuga!
. . . .
~
U
(Process J Pumps)
Medlurn t o high capacity far low t o medium head requirements. Higher head requirements can be met by using multistage impclltrs. General service for all liquids, hydrocarbons, products, water, boiler feed.
Simple, low cost, even flow, small floor space, quiet, easy maintenance.
s/
1
Revision : 0
TOTAL
Pag4 No. :
PUMPS Data : 2/85
TEPIDPIEXP/SUR
5.2
Rotary pumps
.
. . .
Many proprietary designs available for specific services. Essentialty can handle clean fluids only with small suspended solids ifany. Can pump liquids with dissolved gases or vapwr phase.
Can handle wide range of viscosities
- upto 500 000 SSU at high pressures.
Typical fluids pumped : mineral, vegetable, animal oils, grease, ~lucose,viscose* paints*
.
molasses, alcohol, mayonaise, soap, vlnegar and tomato ketchup 1 Generally specialist pumps for specific requirtrnents.
Reciprocating pumps
.
Pumps p r d u c e virtually any discharge head upto limit of driver power and strength of
.
pbtonr:
.
.d casings.
Overall ~.Iicicncyis higher than centrifugal pumps. Flexibility is limited. Piston pumps : can be single or double acting. Used for l o w pressure light duty or intermittent services. L a s expensive than plunger design but cannot handle gritty
. .
fluids. Plunger pumps : high pressure, heavy duty or continuous service usage. Suitable tor gritty or foreign material. Expensive. Diaphragm pump : driven parts arc scaled from fluid by plastic or rubber diaphragm. Ng
seals no leakage. Ideal for toxic or hazardous rnaterlal. Can be pneumatically driven at
.
slow speeds for dellcate flulds. Triplex pumps :commonly used for TEG circulation.
4. REFERENCES
AND U S f f UL LITERATURE CHAPTER 3
4.1.
LUDWIG VOL I
b.2.
PERRY CHEM. ENG. HANDBOOK
1.3.
CAMPBELL VOL 11
4.4.
"Centrifugal pumps and system Hydraulicsn Ugor
4.5.
I.
CHAPTER 14
Karassik Chem. Engrng Oct O 1982
"New Program Speeds up Selection of r Pumping unit" M. Seaman
4.6.
CHAPTER 6
O i l and Gas J. Nov. 12 1979
"Rapid eslculation of Centrifugal-pump hydraulics" W. Blackwell
Chem. Eng. Janv. 28 1980
f2
Revision : 0
TOTAL
Page No. :
PUMPS Date :
TEPIDPIEXPISUR
21g5
5.3
1. FLU10 CHARACTERISTICS
.
Always quote at pumping temperature ie : normal suction
T.
2. SUCTION PRESSURE ,
Evaluate at pump suction flange
-
Ps = Pop + Static head line 1 0 s Pop = minimum vessel operating pressure bara. Static head :evaluate a t LLL always,take statjc head above pump centreline. s u l f ~ cravlt Static hcad (bar) :h2 (m) x w Line loss I evaluate APline for bends, fittings, e t c I for estimate use 0.1 barl100 rn.
3. NET POSITIVE SUCTION HEAD
.
NPSH available (NPSHA) is evaluated by the engineer. NPSHR required is stated by the vendor. Always try to providdp.6
.
- 1)rn NPSH more than vendor states.
Vapour correction is calculated by substracting the Vapour pressure of the fluid being pumped from the calculated suction pressure. Convert this to rn head. For a fluid a t bubble point the vapour pressure r Pop head (m)= bar x 10.197/SC. NPSHA :static hcad line loss + vapour correction
-
.
DISCHARGE PRESSURE
. .
.
Delivr pressure :use maximum Pop of destination vessel Static head h3 : height of delivery point above pump or if a submerged discharge into a vessel the height of the HLL. A P discharge line : calculation based on line length, fittings etc or use minimum of 0.5 bar. D P exchangers, heaters, etc I use allowable AP from equipment data sheets. Estimate 0.7 L.0 bar ii not available.
-
b
P
Rev~sioti: 0
TOTAL
PUMPS
TE?IOP/E)[PISUR
.
. .
Page No. :
Dale :
A P orifices I for flow meters use 0.2
2/65
5.0
- 0.4 bar.
A P control valves :use maximum value of 0.7 bar, or 20 96 of dynamic Irlction l o s x s or 10 % of pump
AP.
TOTAL DISCHARGE PRESSURE :sum of ail above A P values.
5. DIFFERENTLAL HEAD
. .
-
Differential pressure -. discharge preswre suction pressure Differential head = Dif ftrential pressure x 10.197 Spec, gr.
6. FLOWRATE
. .
.
Normal flowrate is maximum long term operating flow (rnllh) Design Ilowrate is normal flowrate + design margin.
Design margin
I
10 % for feed pumps or transfer pumps 20 % ' r reflux pumps and boiler feed water pumps
Use
7. POWER REQUIREMENTS Note :although the term "horsepowtr" i s still used,power requirements a r e given in kW for metric calculatlonr
.
Hydraulic horsepower
I
theoretical fluid HP = design flow x Diff. press136 (kW)
Brake-horsepower (BHP) = hydraulic HPi q p pump efficiency IkW)
.
Optrating load =
.
Connected load :electrical power to motor a t cated motor qize (kW1
+
Note pump s p e d are either 1 450 rpm or 2 900 rpm
electric& input to electric driver a t normal pump qxrating load = BHP/ motor efficiency k W
vrn
UO HZ electrics1 frequtficy)
8. MAXIMUM DISCHARGE PRESSURE (shut off pressure)
.
Estimated shut off pressure t max suction preswre (design pressure of upstream item head calcuiatdat HLL and SG maxi) + 120% x(norma1 pump AP) 9+ PUMP MINIMUM FLOW
.
For an estimate
use 30 % of normal flow.
10. PUMP WEIGHTS For an estimation purpose only Flgure 9 can be used to determine t h e welght of centrifugal pumv package.
.
.
$?f
a
+
-
--..
6-5 ' 5 0 4, 1
HLL
~ Kq!-i:~
.
--7 .
4,3.4 :er c
I4 m
CCL-
i ? -~ ~
rnr2
i . i~ : :-a
Pump - A .CC-.Xw
Indicate pressure, elevations and system sketch
LUlD PUMPED :Liquld : Pumping temperature T I .par pressure at T r entity at P, f dpedfic gravity a t P, T :
1
.C bara
40 i,04
305 kdm3 0,395
I I I
SUCTION PRESSURE kin. Origin Pressure. ,Static head at LLL = (rn x sg x 0.09S11 L A P suction line
PUMP TYPE : Z L I I - b Speed : 1232 Z.iV
CtuDE 3 i C
baral rn 1 bar1 bar I
I
-
TOTAL AVAILABLE NPSH
m m
m rn
MAXIMUM SUCTION PRESSURE Vessel PSV setting Static head at HLL
25
%
<8?
m3/h
.
(I):
DISCHARGE PRESSURE
I I 1 bsra 1 bar I bar bar bar bar bar
cP
I NET POSITIVE SUCTION HEAD I Static head a t LLL' L l m loss + vapour pressure correction
Design margin DcsignflowatP,T
1 APorific s) AP II dp 1 Other ; :oht:r,;r-.%l)
42
4,20
I
!,I7
I I
z
I I I
bard1
bar1
Q,5?
I
-
I
I I
I
I
I
TOT DISCHARGE PRESS bara
I
I
DIFFERENTIAL PRESSURE
1
I 1.43 11 I I I 4,5Q 1
1
.
I
bar
1
I 1
:-:;= CP {WC. cnnd 1 m3lh
I 1 Delivery pressure 1 Static head 0 3 I A P control valve(s) C , !O A P exchan efts)
I
~;r.
Viscosity at P, T ?, 2 Spccif ic gravity a1 8:: ._,_ 0 a?? Normal flow Q at P, T : 151
l ,D! 4,20
1
PUMP SUCTION PRESSURE
:
1
I
Suction pressure
bara bara
Pump AP
bar
m
1
1 I 1 1 I
I I Brake Horse- wer = (t)x(Z) k W 1 MAXIMUM DISCHARGE PRESSURE I I kW I Max. suction pressure baral 5,03 1 Estimated motor slzc I Normalpump A P x 1 2 0 % bar( 3 , 3 ~1 1 Design operating laad (4)lrlmkWI 1 L (Fis3for 9,) I net bara I I I 6,53 1 kg I I Estimated weight I 5,03
0,75
1
I
I
2,Y I 4 3.50
1 I I 1
I 4.42 11 I
I
1 POWER REQUIREMENTS
net bara 1
1,O.I 1 ,
I I I I
<.Zb 4.d?
I I 1 1 I
3.16
((2)
40,o
I I 1
1 I 2 3 1 1\31
j ~ + I , I 1
-
75
30
1141
34
H51
4230
I I
1 I I 1
PROCESS CALCULATION SHEET T X b ~ , S T E i . PLlWF
lttM.
PUMP
~EPLWliOlPltVlSUm
v
i
CHX
D~II
1 tor
~ITLE
~ - X A L : ~E:
'
NO.
JOB ~o
.
2270
A l t
I
MU
(0
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
n * ~ i :~ 0~ n
wm5 TEPlOPlEXPlSUR
: 2/85
Datr
5.c
*IC* Y I l O CI*IaHUCIL .LAN-.
C"I"LC.L WICYIO*
m m
loo. nncwnw.lla= r m a n r # rwf
7
b
b-*
-_-
-*
,a
~ l l l
-.._ _ --._
..OTEY
CYYl
2 #1bGESn 3-a
a*m
. R X I Y NIYI I I I B C I Ill.Y
z Y
I.
-
+
I
I FIG. 1 - * & I
FIG. 2
I0
w
m
llD
A ~ ~ N C E0Ss I P P C I C ~ ~ I FOO~R O l f f
01-
l L l M IY'IHL
EeCnl PuuP 1 Y P U
ESTIMATlON OF CENTRIFUGAL PUMPS EFFICIENCY
a I m m m n l I m I m m I DOTTED LINE FOR PUMPS WITH H ,I
7
H III
(96
TOTAL
P A O C E U ENGINEERING DESIGN MANUAL
Revision :
Data
TEPlDPlEXPlSUR r
701
: 2/85
Pwpa NO:
-
--
OTAL
----Revision : 0
-
Page Ho. :
GAS TURBINES
WDPIEXPISUR
Date:
2/85
6.1
1. APPLICABILITY Fearlbllity and Prc-Project study :
.
The purpose o f this design guide is to give some information
to the engineer in order t o
be able t o select a suitable gas turblne.
. .
The' gas turbines do not cover the f u l l range of power and sometimes the process is adapted t o the choice of the engines. The ioca
bn is an important factor.
INDUSTRIAL APPLICAT!ONS OF GAS TURBINES
The two major industrial applicatior!s of gas turbkne drivers are power generation and gas compression. The gas turbines are also used for liquid pumping [crude oil, water injection, .I but these applications depend on thc ratio between power generation and pumping station capacities. In Industry, three types of gas turbines are available :
.
.
.
heavy-duty (one shaft, suitable for power generation not recommend for comprtswrs or two shaft3)
jet engines or aeraderivativc (two shafts) turbines light industrial
Heavyduty turbines are generally used for large onshore plants where weight and space are not a problem. Aeroderivative turbine or light industrial are predominant lor smaller installation$ offshore where compact, light-weight drivcra are required.
BRIEF DE!5CRIPTION OF THE TURBINE There arc two parts for the gas turbine : a. main system b. auxilliary system.
3.1.
MAIN SYSTEM
- Figure I(two shaft machine gas generator)
It is composed of :
..
.. .
the air filter air compressor combustion equipment
183
HP turbine LP turbine Exhaust
-
TOTAL
Revision : 0
Page No. :
Date: 2/85
61
GAS TURBINES
TEPIDPIEXPlSUR
3-2- AUXlLLlARY SYSTEMS These are :
3.2-1.
. . .
fuel gas or liquid fuel system lubrication 3yatem
. .
hydraulic system start-up system
air cooling system
Fuel aas system
.
A gas turbine i s designed for a certain heat release. It is recommended to
- 10 % magimum) of the design value. avoid large flaw fluctuatians (+
.
It i s also recommended t o provide a safety margin above the gas dew
point (generally
.
+
I5 * C ) and t o have a minimum temperature of + 5 'C.
The fuel gas pressure depends on the gas turbine, a range of 15 t o 20 bar g a t turbine inlet flange is common. For the new generation of jet engines which have high air compressor pressure ratio the pressure could be as high as 30 bar g.
.
Certain trace components must not be present i n the fuel gas in order to avoid corrosion in the hot parts of the turbine :
-
-
Vanadium : less than 1 ppm
Sodium and Potassium r less than 2 ppm Calcium (not corrosivt but causes deposits) : less than 2 ppm
Lead: less than 1 ppm
-
Remarks : a. The fuel gas quality and net heating value range to be specified to the vendor.
b. It is recommanded to install a K.O. pot and filtration (10 F) at the fuel gas turbine inIet (most of time a rafety filtration is included i n the vendor package)$the basic filtration is normally included in the fuel gas supply Skid.
3.2.2,
Llquld fuel system Filtration is required depending
on the gas
rurblne type and manufacturer.
Generally the required level of filtration has a severity higher than for diesel engines. The liquid fuel pressure at the turbine flange is about 3 to 5 bw &
10 4
-
-
TOTAL
Revision :
---
0
Page No. :
GAS TURBINES
TEPIDPIEXPISUR
3.2.3.
-*
Date :
2/85
6.3
Start-up system
A gas turbine cannot simply start-up by firing fuel i n the combustion section : for its gas expansion power after combustion t o be effective, the turbine must attain a certain starting speed first using a starting motor. There arc several kinds of drlvers whlch are used t o start the turbines:
. . . . . 4
electric motor, pneumatic expansion turbine [air or gas) diesel engine or gasoline matar hydraulic expansion turbine hydraulic motor.
OPERATING ASPECTS The powcr is generally defined in cataIogues by 13.0. that means power at
. .
t
Temperature air in take I 5 ' C Atmospheric pressure 101.3 kPa (sea level)
No loss condition on intake and exhaust ducting No auxillarics driven by the turbine (except lube oil pump required by the turbine itself) The main external criteria for the performance of a gas turbine are : the site conditions (location, air temperature) losses on intake and exhaust ducting, operation of the machine at conditions other than design, mechanical powcr to drive auxillarics.
4.1.
AIR CONDITIONS The compression powcr requirement l o r the air increases as the air temperature increases. The consequence is that the available power recovered from the LP turbine decreases as the air temperature incrcaxs (+ 1 ' C 01 air
=
0.8 % of power :average
value). See Flgurc 2 for an example* 4.2.
LOCATION
If the turbine is located above sea level, the site pressure and the available power decrease by about 1 % per 100 metres e l c v a t i m See Figure 3.
/Q6
TOTAL
I
Pbgs NO. :
Date : 2/85
6.4
CA5 TURBINES
TEPIDPIEXPISUR
4 3
Aevlrio~i: 0
LOSSES ON INTAKE AND EXHAUST DUCTING Under certain conditions plugging of the airintake t o the turbine may occur. This w i l l result i n a drop in available turbine power. A similar drop will be seen if the exhaust duct pressure also changes average figures are :
.
.
Inlet duct :pressure Increases by(l0o mm i-120)~owerfalls by 1.4 % Exit duct : pressure increases by 100 mm
H20 power falls by 0.6 %
For estimation take 100 mln HZ0 d p for inlet and exhaust ducts (2% losses)
I
4.4.
DESIGN CONDITIONS I f the power turbine Is running at 80 % of the design capacity, the reduction in efficiency is about 6 %. If the turbine 1s running at 60 % design the reduction in efficiency is about 17 96. Since fuel gas consumption is very much affected.
I
II
Fir.
tpproximate for t alnbiant
P site =
t
-
H =
P lso x
>
I5
O C
1
m~15x*1
l+O.OlH
ambiant t e m p t r a t ~ ~ in te-C elevation above sea level i n metre divided by 100
5. IELECTiON OF C M TURBINE For preliminary selection use table 1 which give 150 turbine shaft power. Table 1 gives the commonly used gas turbines but for more information consult the "GAS TURBINE WORLD
PERFORMANCE SPEC" published each year.
I
6. THERMAL EFFlClENCY AT 1-
RATUK.
Thermal efficiency depends on tlrc gas turbine but for a preliminary fuel gas estimation the followjng v'alues could be taken
t
7. REFERENCES AND USEFUL LITERATURE 7.1. 7.2.
CA5 TURBINE WORLD PCRFORMANCE SPEC VENDOR documentation
7.3.
CAMPBELL VOL 11
7.4.
"Consider Gas Turbines for ilcavy loadp
each year
- K. MOL~CHChem. Eng. August 23. L980
-.
TOTAL
P I O C E ~ ENGIHEE~ING DESIGNMANUAL
P q e NO :
GAS 'NRB1m.S
Dmte
TEPIDPIEXPISUR
1
R ~ * * i o n: 0
FIGURE 4
: 2/05
6.6
3
.
-
**
--.
--*
Revision
TOTAL
0
Page NO :
STEAM TURBINES
TEPIDPIEXPISUR
Date : 2/85
6.8
1. APPLICABILITY For either the feasibility study or the pre-project study the engineer may need to estimate
the required steam consumption of a steam turbine. Details of turbines for guidance and consumptons art detailed in section 2 and 3.
2. DESIGN NOTES
. .
Single stage turbines eenerally used for small applications, multistage for larger. Conslder using steam turbines far pump drivers if residual HPlMP steam from larger drivers (compressors, gcntcators)
.
is avallable.
a
w'
Small
1
Standard size turbines :
Medium
1 or 2
Large
2
+
.
Speed range : usual 2 000 rpm to 15 000 rpm
.
Efficiencies :
Power r a t i n ~kW
Power kW
Steam k ~ l h l k W
0.5-190
350-30
9-2980
30-9
370-7Q50
15-3
Efficiency %
kW
%
L -40
20
750-1500
60
40-250
30
1500-2250
65
250-375
40
2250-UP
70
375-750
50
3. CALCULATION OF REQUlRED STEAM LOAD 1. Theoretical
wt=
kg,hikw
(hsr860
steam load
2. Actual steam load Was Wt
r
100
= steam inlet en4halpy kcallk = steam outlet kcallkg ( ! a tboritical urntropic ph brtwun inht a d outkt WW)
EFfirienq (%I 3. Required steam Ws = Wa x kW I 4. USEFUL REFERENCES AND
4.1.
4.2.
d
wh
LITERATURE
LUDWIG VOL I11 CHAPTER 14 pp 422-435 "Use steam turbines as Process Drivers" Richard F. Neerken Chem. Eng. Aug. 25 19110
-
110
TOTAL
PR~CEP'ENGINEERING DESIGN MANUAL
I
:
P*.
NO :
ELECTRIC MOTORS
TEPIDPIEXPISUR
I
'
R v i i:
Oat*
-
, Z/ZS
6.9
1. APPLICABILITY For both feasibility and prc-poject studies the engineer will be required to estimate
electric loadings for utility consumptions. Fig. I details motor efficiencies for varioufl pomp horsepowerr.
I
I
2. POWER ESTlMATlON
I
I
.
For pumps the driver horsepower is estimated en the pump data sheet.
.
For rcsptciiying of drivers or checking purposes use Fig. 1 to rate power.
.
Power rating at 380 Y 3 phase 50 hz. ffiUPf
1
~CTRIT MOTOR* RECOMMLHOED azt a rmc~urcr (11
Pump RequCemcnr
Prab.blr
A~. t b - a..h n
Mara
~
-
Cdh?io;\r OHP
-
Norart ( I I
(11
-
nl;is
&YAW
EIflcienq
% - a l~Cull -.- LMd
Pawcr ractsr(2) S oi full Lord
BHP
Applies 14 tvtully cndor
cap4c1r)
100 -
I I
--
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
TEP/DPfE)(P/sUR
Rwvirion r
08tr
7. COMPRESSORS
113
: 2/83
Paw No
;
Reviyion : 0
TOTAL
Page No. :
COMPRESSORS
TEPIDPIEXPISUR
Date :
2/85
7.1 7
1. APPLICABILITY For both ftasibility and prt-project studies the engineer w i l l be required t o evaluate a compressor selection, discharge temperature, power and complete a data sheet. To evaluate thc discharge temperature and power i t i s more accurate to use 551 instead of the manual method presented here. I n order to estimate the basis of cost and layout i t i s important t o understand the type of compressors for the service i n consideration, and the associated power requirements.
2. DESCRIPTION AND GUIDELINE NOTES 2.1,
TYPES OF COMPRESSORS The principal types used l n the 011 and gas processing industries are :
. .
reciprocating (volumetric) rotary ~volumctric)
. .
ctntrifugal
axial
A compressor selection chart is shown in Figure 1.
2.2.
GENERAL
2.2.1.
USE
Reciprocating compressors Reciprocating compressors arc widely used i n the oil and gas industry f o r s ~ d l i o medium gas flows and high carnpresrlon ratios. For example :
. .
2.2.2.
Instrument and service air compressors Low capacity/high pressure gas compression for maintain the gas l i f t capability.
re-injection of field gas t o
Rotary compressors The types o i rotary compressors most frequently employed i n the petrolcum indudtry arc as follows :
.
. . . . 2.2.3.
Lobe compressors ("ROOTS' type) Screw compressors The reliability factor is generally higher than reciprocating machines. "Roots" type compressors are used where a high flow rate wlth a relatively low-pressure is required. Screw compressors arc sometimes used in low flow gas service or for instrument and service air for instatlatlons of small t o medium size.
C e n t r i i u ~ acornpressars l
.
Thcse Centrifugal compressors have become very popular offering more pQw?r pcr gnit weight and esrcntlallv vwation-lrcc, lnitial costs normally are %than rcciprocatlng comprtswrs but efficiency Is Its? and utility c W may be higher. Frequently used in the o i l and gas process industry.
Revision : 0
TOTAL
Page NO.:
COMPRESSORS
TLPIDPIEXPISUR
Oste.
2/85
7.2
Axlal compressors
2.2.0.
Thew machines are particularly useful where a very high gas ilow at moderate pressure increase is required. Such applications remain relatively rare in the industry, the exception being LNG plants. DISCHARGE TEMPERATURE LIMITATION
2.3.
,
Discharge temperature is limited either for reasons of gas stability, gas condensation or compressor (or upstream equipment) mechanical resistance
limit.
.
For reciprocating compresxrr the maximum gas outlet temperaturc t o be d h d
is usually between 160 to 180 * C .
.
For centrifugal compreswr used in gas and oil extraction industries the discharge temperature is limited t o 1701190 *C.
.
Normally intercoolers are used t o maintain temperatures within t h t above limit$.
DESIGN MARGINS
2 4
I f the ilow is constant, no margin, but i f the flow is coming from a production eparator a margin of 10 % is recommended in order t o take i n t o account the possible slugs at the inlet of these production separators.
5. WEIGHT AND SIZE For weight and slzc wc rccomrnend to ask the manufacturer as vendor catalogues detail
only the size and weight of the compressor itself. As the compressor package also includes also the seal and lube o i l console^ control cabinet and sometimes the driver and gear box, the use of vendors catalogues could be misleading in estimating the installed weight.
Figure 4 could be used for a very preliminary estimation. It is established for the dry weight of a centrifugal compression package including :
.
.
compressor skid (aeroderivatlve gas turbine technical room
, overhead tank (seal oil) 6 REFERFNCW AND USEFUL LITERATURE 6.I.
LUDWIG
Volume3
Chapter12
6.2.
CAMPBELL Volume 2
Chapter 14
6.3.
GPSA
6.4.
SSI Program
Chapter 5
1979
f/6
+ compressor)
c(mPwss0Qs TEPIDPIEXPISUR -
-
-
_
_
_
l
_
_
_
Data _
_
l
_
_
_
l
_
_
_
_
_
_
_
I
_
C
_
_
_
_
_
_
_
:2/BS m
_
C
.
4% C .-
en
i r, 33
___________________---_-----___
3
$ 2E
A d
v n
3 v
-*- _ - __
-5 --
Y
_
5
zg
-
-
-
- - -
!m
4
~~~~~~~~~~~~~~~____
-------rO
-----------------
r?
I1
x
.-x
'-
3
E
--_---.--------------
c
2s r u
I-"
----------------
..
~8 ?Irn
N
v\
a
1.; E
x
E
11
3
z
L
E
-----
F -u =a
X
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - - - + - - - - - - - 4 - - - - - - - -
5; s
______---_-___---------------------+ B
NA 5 0 I ----------------d-------------------
-- E u
t11
C
-2
3
0
E
i;
- - - - - - - _ ----------------------
s)6
c.
-?! Y
u:5u
CI r
0
2
-------._-----d----------------d----
A
113
I
OPERATING
I I
.
7.0
IlDlTlONS
PI = 7.a bar a DISCHARGE PRESSURE P2 = 3 , O bar a
SUCTION PRESSURE
I
5'3 *C #It
SUCTION TEMP-
TI
SUCTION FLOW ACTUAL VOL F L O W
W = 5b000kbh V = 9400 m Ih
I
z
= 32:
GAS DENSITY fir SUCTION = ', 36
.,
I . GAS PROPERTIES
pe ~c
= =
45.9 230
2. POLYTROPIC EFFICIENCY
3~
=
0,79
3. AVERAGE 8 = MCp/MCp-1.99
8
=
4.
3
DLSCHARGE TEMP 12 =TI(%)
5. DETERMINE Z AVC
5UCT DlSCn
84
=
15014
21
r
0.91
22
=
0
=
AVC
bara
.
'K SEE
IdlG
E S T LTZ~ ~ ?5oU~'i r ~ dBL
*21
T2 =
.
kg/m3
REIII,hT STEP 3-Q If TZ IS D1rfI ~ R E N TFROM ONE "'I'I I IN STEP 3
K 'C
a37 0,975
6. CALCULATE GAS HORSEPOWER
C H ~ = Z X R X W X ~ X ( T ~ - T C! ) H ~ =32h0
' 11,314 k3/ kgMOLE
kW
-
MWx3600x(g-1)
7
CALC SHAFT HORSEPOWER p5 = CHP x (1
F
+ F11001 x 11 7,
taker : Fr 3 5
.
*C
4
PS im * 5.97
=
3d80
kW
C ' l l l kW ~ ~ 5.0 ~ s(ht I <( ~MW 3.1 )LO MW 1.0
'lm 0.96 0.97 0.90
8 . ESTIMATE DRIVER POWER
PS x K PO -GAS TURBINE PS x (1.14 + K) PO =
kW
ELECTRIC MOTOR
4040
kW
' 1.15
41.02 TO 0.04 WlTH
1
GEARBOX
-
3:
2 32
9. E S T ~ ~ A T EPACKAGE D WEIGHT
I
= 9° Oo6
M
COMPRESSOR-DRIVER-LUBE
($1:(1~16 4)
kg
NOTES :
CENTRIFUGAL OR AXIAL Tt?~O?mVffXMUU
-nr
JJ;~FJ
cnr
I
;&z
CoMPRWS?R O~TI
\ rornrir
.
no.. 1om WO
i~ibt
//g
XMF~~,S:~C
It. :,>I6 ItV
'
7.5 OPERATING L f4DlTIONS
SUCTiON PRESSURE PI = 0.0 bar a DfSCHARCE PRESSURE P2 = 27.0 bar a SUCTION TEMP.
T1
PRESSURE RATIO PZ/P1 =
40 *C = 3 3 +K
:
d
GAS DENSITY AT SUCTION s 7 5%
= 549 rn / h
V
?5,0
MW
W = 41DP k h
SUCTION FLOW ACTUAL VOL FLOW
STEP
kglm3
NOTES
L G A S PROPERTIES
Tc PC
2. AVERAGE 8 = MCp/MCp
3 . 33
- 1.99
-
= 247 45,s
mK bar a
8 = l12D
AESUW..~? T 2
2
It7 'C
orl
3. CALCULAT f DISCHARGE TEMP T;L
s
TI x
5. DETERMINE Z AVC
-
T2 = 383,4 'K
m)+J
(PI
=
SUCT DISCH AVG
Repeat 2 3 ti T2 differs from that used in STEP 2
44
21 22
s: s
0.97 0.45
Z
=
0.5%
3g =
O,@?
6. DETERMlNE OVERALL EFFICIENCY
'IS
See Fig 3
7. CALCULATE GAS HORSEPOWER
* *
CHP = Z ' R 5' 5 x (T2 - T I ) m W x 3 6 0 O x ( $ - 1)
8 . CALCULATE SHAFT HORSEPOWER
= 454
kW
PS=14?
kW
CHP
PS = GHPlf x r)g
R = 8.314 kJ/kgmole.*C
i = 0.96 to 0.97
9. CALCULATE DRIVER POWER Electrical Motor
Po = [.I5 K PS
#!'+#(
PROCESS CALCULAIION SHEET nLH: FUEL GAS COMPRELC3K
RECIPROCATING COMPRESSOR
I~CIWCOPPRXCI%UR II
cnu
Po + ?-Z"~W
DArc
Ilorn r ~ t i .r
E xs, M P LE
no
.
IODMO
K 7323
I arv
19
-
-
TOTAL TEPIDPIEXPISUR
PROCESS ENGlNEEAlNG DESIGN MANUAL
ddcs
Rodlion :
Dare
120
:
Pwm No :
7 a6
-~ ...
TOTAL TEPIDPIEXPISUR
P D C E S S ENGINEERING DESlGN MANUAL
Revision : 0
PW No :
~ R E S S O ~
Dale
:lies
7.'
8,
EXPANDERS
-..,..
Revision : 0
TOTAL
Pngm No. :
EXPANDERS
TEPIQPIEXPISUR
Oatc :
2/85
g.1
1. APPLICABILITY
For both the feasibility study and a pre-project study the engineer will be required to fill i n a process data sheet with the basic information and to estimate the expander horsepwer. Outlet conditions and horsepower estimation r a n be calculated accurately by computer. Hand calculations for pure component systems using a MOLLIER diagram are OK.
2. DESCRIPTION AND GUIDELINE NOTES
.
The turbc-expander i s a mechanical device which is designed according t o the laws of thermodynamics end aerodynamics. I t remover energy from a process ga; which results i n a drop in pressure and temperature of the gas. The energy removed i s converted into mechanical energy which is most often used t o drive a single stage cornprcsm.
-
.
T urbaexpanders could be used for : +
cryogenic pressure let down
.
dew point control
.
. .
CZ recovery ethylene processing, etc...
C3ICl recovery
Thermodynamical principal. See Figure I.
, Expanders efficiency The expander efficiency is the ratio of the actual energy removed to the maximum theoretical energy on Figure 1 :
-
'I=H B A A
HBI-HA
Expander efficiency depends on :
.
-
mass flow rate
-
inlet temperature
-
inlet pressure
discharge pressure gas composition speed
Generally a value of 80-85 %can be used for estimation purposes. See Figure 2. Liquid content a t the outlet of the expander varies from 10 t o 30 % (weight) Inlet gas must be free of solid particles and water (sometimes COZ), ice formation is prohibited.
.
Maximum horsepower of the manufactured turbo expanders is about f 2 000 HP. This figure should not however be considered as a limit. Turbo expanders can be used in series. Efficiency Is a f l u t e d by the variation of the design flow rate See Figure 3 for an ntlmarion.
/>'
--
"
*
TOTAL
Revision : 0
P a g l NO. :
Date : 2/85
8.2
EXPANDERS
TEPIQPIEXPISUR
3. REFERENCES AND USEFIR. LITERATURE CAMPBELL VOLUME I1 Engineer's guide to turbo expanders
HYDROCARBON PROCESSING APRlL 1970 Pagc 97...
Turbo expander applications in
JOURNAL OF PETROLEUM TECHNOLOGY
natural gas processing
May 1976 Page 6 1 1 etc...
What you need to know about gas
HYDROCARBON PROCESSING
expanders
February 1970 page 105...
Turbo cxpanders offer processors
THE 011 AND GAS JOURNAL
a way to conserve energy
Jan. 23, 1978 page 63...
Use expander cycles lor LPG
HYDROCARBON PROCESSING ~ o c 1. 9 7 ~ Page 89...
recovery
VENDOR DOCUMENTATION
i.c. : ROTOFLOW, MAFI-TRENCH..;
la 6
PROCESS EMGINEEHINU utslun MfilUUl&L
TUTAL
t$evrrroft :
rb
I
d y I~U U
EXPAtfUEW
Datr
TCPIDPIEXP18UR
: z/n<
8.3
FIGURE 1
PRESSUAE
t
H ~ l H~
PA Inlet prssaure PB Outlet prusure f Bl Outlet theoretical tsmpcrrruw
HA
TA Inlet temperature Tg Outlet temperature
ENTHALPY H A , tnlot enthalpy HB Outlet enthalpy
ktBI Outlet theoreticel tnthstpy
FIGURE 3 ESTIMATED PERFORMANCE AS A FUNCTION OF DESIGN FLOW RATE
FIGURE 2
PERCENT OF DESIGN FLOW RATE
I
APROXIMATE PLANT FLOW RATE M M X F D
.
IIUIMb
~ ~ U L C W CN~IN~LI(INV U L S I ~ NMANUHL
TEPIDPIEWISUR
9.
FLARE SYSTEMS
'2 4
HIYIIIQO
:
Date
: 2/85
r80lN O
:
TOTAL
Revision: 0
Page No. :
FLARE SYSTEM
TEPIDPIEXPISUII A
Date:
2/85
9.1
1. APPLICABILITY For the feasibility and preproject studlcs, a detsllcd design of the flare system is not needed. Required information for either study will include ;
. . . .
.
Evaluation of number and levels of flare system Determination of maximum relieving (and hence flare design capacity) Flare KO drum
Design
Estimation of height of flare stack or boom length and type of t i p required
PSV sizing (not always required, depends on project). For further more detailed specification and design requirements consult thc CFP DESIGN GUIDE ON FLARES-YENTS-RELIEF AND BLOWDOWN SYSTEMS.
2.
DEFINITIONS (see section 3 i n DESIGN GUIDE)
-
Relief system
includes any prtssurc rsjirrf valvelrupture disc downstream piping
t
and liquid separator
-
Blowdown system
I
includes any depressurlng valve, downstream piping and separator (normally the pressure relief and depressuring systems utilize common piping and separator)
-
Flare system
: a system which ensures the combustion of hydrocarbons
Vent system
:
the
rdcasc
of
hydrocarbons
to
the
atmosphere
without
combustion
-
Design pressure
:
the pressure used to design the vessel and calculate the wall thickness (see section 1.0.)
-
Set pressure
:
the pressure at which a safety device is adjusted to open under service conditions. Usually equal t o the Design Pressure
-
Accumulation
:
maximum allowable increase in vessel pressure during discharge through the safety device. Normal accumulation is 10 % but 20 %
is allowed for external fire due t o hydrwarbon liquids. For HC gas fires an accumulation of 5 % is recommended.
3. FLARE 5)'ITEM ANALYflS AND GUIDELINES This section details how t o determine the number and levels of the required flare system for a feasibility or preproject study and other guidelines.
.
-
A system of items of equipment and piping can be protected against overpressure most economically by considering it as a single unit when calculating the relieving capacity
/21
TOTAL .
Revision : O
FLARE SYSTEM
1EPIDPIEYPISLIR
. .
Page No. :
Ostc: 2183
9.2
Block valves should not be present in the system so as to isolate a unit irom its relicvine point. Special casts may warrant a car-sealed open or locked valve. However such a r r , .ements should be avoided if possible Interconnecting piping should be of adequate sire and not subject t o plugging. The system should not be of such a size that t w o separate systems would be more economical
.
tn specifying the design pressure of the individual items and safety valve setting there a r e two approaches
-
Set t h e design pressure of each item independently. Then specify safety valve
scttings to protect the weakest link in t h e group of Items
-
Study the items as a single system initially. Thls is preferable as it avoids having an unexpected "weak link" limit the operating conditions.
.
Consideration should be given to possible abnormal conditions viz :
-
Light hydrocarbon systems can reach low temperatures during depressurization Heat exchange trains may be bypassed resulting in higher than normal downstream
temperatures
.
-
Fallure of cooling medium can cause excessive downstream temperatures
-
Production separators may have a varying feed temperature, especially offshore.
I t i s often required or beneficial to provide two or more separate piping systems from
t k items of equipment t o the flarc $yatem eg I high and low temperature headers. Consideration should be given to the following
-
-
Relief gases below O°C must be kept apart Irom warm moist gases t o prevent formation of ice within the flarelines. Thia could cause a system plug up Segregated systems may be economically desirable to minimize the extent of low tcm+rarure piping
-
-
By segregating t h e flows irom high and low pressure sources into two separate flare systems greater use of the high p r e s u r t drops can be achieved without lmposing severe backpressures on the low pressure systems The molecular composition of some streams may warrant their segregation irom other streams. eg moist C02 or H2S is corrosive. I t may be cheaper t o fabricate a second smaller vent system to handle there rather than fabricate the entire system in corrosion resistant material.
02 A
---
TOTAL
Rerrs~on: 0
Page NO..
FLARE SYSTEM
TEPKlPlEXPlSUR
2/85
Dstc:
9.3
Determination of t h e flare system and levrl can be summarized in the following step by Step analysis.
I. Does the facility contain process areas with distimt pressure levels eg :HP compression, LP c o ~ -ession, atmospheric separation ? If so, c sider two or more flare levels if sufficient limitation is imposed by the LP section
2. Does gas exist at high pressure that on depressuring will fall t o below 0 vC.Lf so, it must be segregated from warm relief gas. If the temperature falls below 29.C may have to consider low temperature steel headers
-
3. ldentify any corrorlve relief sources and consider if n t e d to pipe up separately 4. Is a vent system required for tank breathers, regeneration vents etc... 5. Identify on the PFMs) the set pressures of each PSV anticipated and consequently its maximum allowable backpressure [MABP usually 10 % 01 set ~ r e s s u r e ) .Locale the "weak links" in the process i.e. :the low design pressure vessels. If only 1 or 2 exist within the
system conslder installing balanced relief valves IMABP = bD % set) so a s to incorporate them into a higher pressure flare system, or even alter the design pressure of the weak links to acheive t h e same. This may be more economical than specifying two flare levels. Having determined t h e configuration of the flare system, it is necessary to size the headers only and t h e flareline itself. For thls, an idea oI the maximum relief load gcnerattd will be required. For the studies a full "risk analysis" af upset conditions is not necessary neither 1s a listing of every relief load and condit~ons. The sizing case of t h e flare system can usually be judged by inspection. Invariably, the largest vent flow will be s full flow reliel off the first separator or compres~londrum or a total electrical failure. This may be supplemented by a simultaneous depressurization of a compressor or equipment loops resulting in a flare design flow higher than the normal plant throughput. Generally fire generated loads do not dictate the sizing of the flare system, but may influence the sizing of laterals and subheaders. A certain degree of experience will help
in identifying the possible one or two cases ihat will size the flare system without havlng to perform a fuH plant rlsk analysis. In some cases, the resulting flaring loads may be minirnised by using ESD isolation valves or autamatlc controls t o start back-up equipment.
133
Revision : 0
TOTAL
Page No. :
FLARE SYSTEM
TEP~DPIEXPISUR
Date : 2/85
9.4
I.HEAOeR SIZING 8 STACK AND TIP CHOlCE I n order to estimate the main flareline and header slzcs based on backpressures, 3 pieces ot inlotmation a r t required :
-
9.1.
Design llowratc,temptraturc,MW Length of flareboom or height of stack Type o f t i p and stack t o be used.
DESIGN FLOWRATE
TEMPERATURE AND M W
This has already been determined from the previous sectlon. 2
TYPE OF TIP + STACK T O BE USED (see section 10 in Flare Design Manuay The rhoice of stack and tip type wilI obviously be dictated by the location of the prar,
nder design.
For onshore plants in remote areas i t is usually suflicient to use a remote vertical
stack with a conventional pipeflare tip. The height of the stack will be determined by the radlation limitation on the designated sterile area round the stack. For non occupied areas, this figure could be high as 5000 BTUI~.!~~(15 700 ~ / m 2 )resulting in a short stack height. For cases where high flaring loads s t i l l result i n a tall stack,
a further reduction in height can be achieved by using a Coandaffndair or similar type high pressure sonic flare tip (see section 10 i n FLARE DESIGN MANUAL for dixusslon o f each tip type). Offshore the choice is somewhat more complex in choosing between a remote vertical
flare or similar, or an Integral 45' mounted boom itare or even on board
vertical sta&.
The decision between these is more often than not governed by
economics, structural considerations and specifics pertinent t o each platform Iocation eg r water depth. Generally, however sonic flare tips are used where pressure levels allow (2-> bars) a t the tip entry i n order to reduce stack/bom lengths, by reducing radiation levels, and associated support structure weights.
4-3.
FLAREBOOM
- FLARE STACK SIZING
The flareboom or stack (hereafter termed flare) length
Is determined by the
maximum allowabIe thermal radiation tolerable on the platlorm or surrounding area.
A detailed calculation of this value for vertical or inclined flares on or offshore under a variety of wind conditions and temperature5 can be performed using the computer program SUPERFLARE. For itasibiliry and preprojecta, however an estimate of radiation level can be determined using the method as derailed in AP 521. Set Appendix 1.
134
.
,-
TOTAL
Revision : 0
FLARE SYSTEM
TEPIDPIEXPISUR
Date : 2/85
Recor~ nnded Radiation levels are given
I1I
Condition
1
I Allowable radiation 0tulh.ftZ
I I
I
1000
I
I
I
I I I
1
Exposure
period Infinite
I
I
2000
1 I
L minute
1
I I
3000
I
(Emergency flaring only)
1
I I 1
5 seconds
I
1 1
r DO0
I I I
I I 1
I I I I
1
I
1 I
I
I I 1 1
I 1
1
I1
I
1
5000
I I
I I
1
I 1 mediate shelter i s available 1 1 I I I I Areas where personnel are not 1 I permitted during operation I I t Helideck
I
I
I I Arear where personnel may be 1 I located from which escape is I I possible and shelter is 1 1 attainable 1
I I I Areas where equipment is I located and personnel are not I normally present during opeI ration, but if present im-
9.5
below :
I1
I 1 1 Areas where personnel may be 1 located and expected to per1 form rhejr duties continuously I
I I 1
Page No. :
I
1
I I
I
I 1
D
I
I
The above figures are maximum allowable radiation lntcnsities inclusive of solar radiation t 250 BTUIhr ftZ). I t should be noted that the following recommended values o f F radiated and mach numbers at the ti^.
-
Fraction of heat
a) Pipe flare
LOWM W gas F = 0.2
-
Ethane
F
:
0.25
Propane
F
r
0.3
F
i
0.1
Mach I
F
s
0.05
Mach 1
Velocities
-
max at design relief
normal continuous
0.5 M = 0.2 M 8
b) IndairICoanda
All gases C)
Mardair
Having calculated the flare length bawd on radiation analysis and c3rabllshed both the design flare rates and tip type the main header can now be sized.
i3 i 7
Atvision : 0
TOTAL
FLARE SYSTEM 2/85
TEPIDPIEXPISUR
4 .
Page No, :
9.6
HEADER SIZING T h e major criteria governing the sizing of the header are backprtswre and gas
velocity. Flare headers must bt both large enough to prevent excessive backpressure
on the plant safety valves and to limit gas velacity and noise t o acceptable levels. Sizing procedure I)Identlfy "weak link" wlth respect t o MABP on safety valuea. (this should have been done when determining t h e levels of relief). This is the maximum upstream pressure tolerable in the rystcm2)
culatc the
4 P acrws the
flare tip for the relief design flow. For sonic type
ti1 the backpressure will be 2.0 t o 5,O barg depending on
For plpeflare tips use :
- 2.0 0.2 - 0.5 0.5 - 1.0 0.5
Flare tip Fluid seal Molecular seal
load.
-
psi
(0.034 0.lb bar)
psi
(0.014
- 0.034 bar)
psi
(0.034
- 0.07
bar)
3 Estimate the equivalent length of piping from the tip to the flare KO drum. (Allow generous margins, flare headers are complex and rarely straight). 4) Calculate the mnlc velocity of the relief gas
Vsonic
= 91.19
c -
K :CP/CV T : *K
rn/s
This will gTvt a first estimate of required pipe id based on maximum relief flow.
The stack diameter should be one or two slzes less than the tip diameter. LIMIT
VELOCITY JN STACK TO 0.85 M A T DESIGN FLOW.
AP
5 ) Using thc estimated D calculate the from tip to flare KO drum. The Conison equation is recommended for isothermal f b w : 2
P, Where :
1
:
p2
+
4 V p22 (39.4
= upstream conditions
2 = downstream p + pressure bar (a) u
=
relocity
f
fL -
9
= moody frictlon factor
1 = equivalent length rn d = pipe id inchs
= s p u l f i c vol m3/kg This calculation requires a degree of trial and error as- y
I, 9 6
2 in
"1
mls
v
+
-
lo-'
.
. TOTAL
Revision : 0
PqcNa: .
FLARE SYSTEM Oat@: 2/83
TEPlDPIEXPISUR
9.7
6)Examint the P l (calc) at the relief drum and decide if the stack + header diameter is adequate I t is PI (cak) drum approaching the maximum upstream pressure allowable at the plant ? if so increase the diameter and repeat the AP calc. 7)Oflcc sathfied with the drum-tip line,proceed can
back up the flare header and
late the next section of Une diameter.
8) Continue along the headers, adjusting flowrates as necessary if sources disappear,
untU t k '*weak link" criteria has been satisfied. 9)lf the project requires,sub headers and laterals can be egtirnated from the main line static backpressures calculated above.
EXAMPLE :
@ PS$
I
0 B
-t
Fn4 Hrbr
.
h3 1.1 br:,
0P< t.2 k3 I 1
L. l o o n
4
I a.?
0.6
I. Flare design is based an vent [low from source (1) 2. Weak link in system 1s set by PSV a t source (2)
3. System must be designed for a design flow from source (1) not giving a backpressure at point (3) of more than 1.2 barg. 4. Size line from tip to drum (1 = 150 m) to give P drum O,5 barg (say) site lint from drum to point (3) (L = 100 ml to give PI < 1.2 barg. 5 Check that source (1) can flow from (I) to (3) with pressure drop available.
73
a
.
TOTAL
Rev~sion: 0
P C ~ No. R :
FLARE SYSTEM
TEPIDPIEXPISUR
Date : 2/85
NOTE I ) :
laterals
--->
sub headers
--->
9.8
headers must increase in diameter
as the system progresses to the tip.
2)
Max velocity in a line is
3
When calculating
AP
MACH 0.7
for short duration
rdiefs only.
for flare systems isothermal flow is
assumed for each section. For high source pressures with low MW
a
AT v6 AP profile
will yield more accurate results, i.e. adlust
temp a t specific points in the system to account for accurcd.
A
P
5- FLARE K O DRUM SlZlNC A f l a r e KO d r u m Is provided to drop wt and collect t h e liquid part
of
the f l a r e vapours in
order t o :
5.1.
prevent
quid accumulation at the base of t h e f l a r e boom or tower
to mini11 e t h e risk of burning liquid [golden rain) emerging from the tip and falung on personnel t o recover and reclaim valuable product materials. DESIGN CONSIDERATIONS
-
s e p a r a t e knock o u t drums a r e generally required lor earh level of flare system installed i.e. :a n H P KO drum, LP K O drum, LLP drum
-
cold v a p w r lines Le. < O'C) can be introduced immediately upstream of inlet line to a "warm" drum providing t h e resultant temperature in the drum does not caH below design. This precludes t h e need for two independant drums.
-
FLARE KO DRUMS SHOULD BE HORIZONTAL AT ALL TIMES. Mist eliminators a r e not to be installed. Min design pressure of drum is
3.5 b a r (6)
-
Heating coils should be installed in f l a r e KO drums to prevent freezing of residual liqulds. Typical is to maintain a T min = 4.C LIQUID 3ROPLET
SIZE (per AP1521)
Recommended particle sizes are : VERT lCAL FLARE
INCLINED BOOM
REMOTE FLARES
110
> 45' < 45.
(offshore)
150
I*
boo
I,
600
ug
Revision : 0
TOTAL
Page No. :
FLARE SYSTEM bate :
TEPIOP/EXPISUR
2/85
93
DRUM SIZING
5.2.
Bawd on the above design considerations the flare KO drum can be sized using the
method outlined in section 2.0. VESSEL DESIGN.
For a flare KO drum, t h e normal liquid level should be kept in the tower part of the drum 1.e. : utHise as much space as possible for the vapor-liquid dt-entrainment. If a large diameter drum results consider using a split flow arrangement with the cxlt noz. r mounted on t h e head. This will rnaxirnise the L/D ratio and give a smaller Iighit drum. This is especially useful offshore where weight + space are a major concern. An LSHH will normally be installed in the flare drum to Initiate a plant shutdown (or wellhead shut in oiishore). RELIEF DEVICE SIZING (For more detail see API 520.521)
6.0.
6.1.
GENERAL
- Safety
valves are either termed balanced or conventional depending upon the
backpressure limitation
-
Rupture discs are less robust than an equivalent safety valve and rannot be relied on to function accurately.
6.2
It is recommended that rupture discs arc avoided
BACKPRESSURE
- Backpressure exists in two forms I
. flowlng backpressurc is
the pressure on the discharge side of a PSV that is
blowing off to the relief system
. superimposed
backpressure, or static backpressure is the p e s s u r e on the
discharge side of a PSV caused by another relief source in the system venting to flare
- For conventional valves the
Maximum Allowable Backpressure (MABP) for either superimposed or flowing is 10 86. For balanced relief valves up ra 40 % can b t allowed for without a reduction in the valve capacity.
6.3-
LIQUID RELIEF
The formula for siring liquid relief A=
gpm 27.2 Kp. K,.
Kv
valves is :
G li 7
Revision : 0
TOTAL
Page NO. :
FLARE SYSTEM 2/85
Date :
TEPIOPIEXPISUU
4-10
Where :
-
A
gPm G P
=
-
Flowrate, u.3, galIons/mIn Specific gravity a t flowing temperature
=
Capacity correction factor due to over pressure (from figure 6.5) Relieving pressure minus constant back pressure (PSI) Capacity correction factor due to back pressure when balance belows value a r e used (irom figure 6.4) Viscosity correction factor (from figure 6.3.)
"d
-
Kw
x
Kv
--
6
Effective discharge area, ins2
VAPOR RELIEF The formula for sizing vapor relief is :
W
A:
Where W
I
T
:
C
=
=
M 6.5.
C K PI Kb
Relief flow, lbslh !i = Compressibility factor Inlet vapor remperature, 'R (1.8 'K1 Coefficient (from figure 6.1, 6.2) Coefficient of discharge (0.975 unless vendor data available) Upstream pressure, psis. Set pressure x 1.1 for blodted outlet, CV failure or 1.2 for fire plus 19.7 psia Capacity correction factor (from figure 6.6)
:
K = PI = Kb
inch2
=
Molecular weight of the vapour
RELIEF FOR GAS EXPANSION DUE TO FIRE (DRY VESSEL) A. A A,
A,
4-F F'
F' =
.
0.1406
CK
effective discharge area of valve ins2 = exposed surface area of vessel ftZ
=
~1.25
~0.6506
T
= 1560-T,'R
T
= temp. a t relief pressure R ' .
C and K as in 6.4 6.6.
STEAM RELIEF
r
A=
inch2 SO
PI K&,
/ 40
-
TOTAL
FLARE SYSTEM Date: 2/85
TEPIDPIIXPISUR
PI
l
Klh
I 6.7.
1
9.11
= Set pressure x 1.03. (ASME Power) or 1.1. (ASME Unfired vesseis)
- superheat correction factor table 6.1.
STANDARD
RELIEF VALVE ORIFICE SIZES
The following table may be used for estimating tho relief valve size based
effective discharge areas calculated
6s
in paragraphs 6.3, through 6.6. :
Nozzle Orifice letter
Effective Area sq. inches
Avoid using 2 1/2 inch outlet flanges
**
Page NO. :
R e v i l i ~ n: 0
Normal size Designation
(F and C orifices)
Avoid using 2 112 inch inlet flange (3 orifice)
won the
TOTAL
FLARE SYSTEM Oatc:
TEP/DP/EXPISUR
7 .
DESlCN CUlDE Flares-Vents-Relief and Blowdown systems CFF MAY 1989 - TEPIDPIEXP
7.2.
API
520
AFI I b C
A
521
API 14E
7.3.
Page No. :
Revision : 0
9.12
2/81
Det Ncrske Veritas :Technical Notes fixed offshore installations
Norwclgen Petroleum Directorate :Guidelines for safety evaluations of platform conceptual designs.
---
-
-
YI
LIO
~ I J
111 1p2
1x1
449
141 733
WB
7 3
141
701 191 131
11+
1.2
141
39923
741 7 n
YII
197
if)
m
rlr
tro
nr
--.
TOTAL
PROCESS ENG~NEERIHGDESIGN MANUAL FU.kE
TEPIDPIEXPlSUR
AND
RELIEF
P W NO :
ierision : CI
Date
:2/05
I
9-13
Rerision : U
PROCESS ENGINEERING DESIGN MANUAL
TOTAL
F U R L UJD RTLlEF
Dl#*
TEPIDPIEXPISUR
I
:
The
lrcornlnrnJ,#
.
curre ma, k Whtn a h mrbr rot ~ h c LOIICCIU~ pigYm
. .
.
Page No :
: 2/05
9.11
NOT,: ~ h. b t d ~NW. *LOW t h r ~up to and i ~ l u d i ?LJ~pi. e*rrpl-rm, caprcilp 11 r l e c t d by L IK chbnlr m lilt. lh* cur.* rtpt#nn#rr sornp~ornirrof lhr *llWr ~ i kdri ~ h v r pr w f i i e r n . rnd hr shrnw in ow*I numb.r 01 rrlet.ralws m r n u i x l w m . This c l d df LI lh. 1 *hmn tha ma** or lb v * I w nc4 bnfiwm p,=~,.,.. A b . . 21 p ~ s e n l .csp.cily It rlllnll in o*.rplrUUIe. \nOwll. I h l ~ b n u l r r l u r tll h d d br C Q I~ IU~~~ Vrlvrr -ratin# low ovsrprruurrs und " c h ~ k r " :l ? r r r latiw for,. orarprnrur.r 01 k r c l h r n 10 p r c m l muuld br r*odcd
ar Censrant Barb.?rrssur~ Silin9 Figure for 2) plrtr"t arrrpr.,~~r. on Ilabnr.d B b l l o r s s o f a ~ ~ - l r l iVdO ~ * * S
.votiobl.
torlorI ( .
(Liquidr Only)
*I
&5
.Capocity C o r r t c l i o n l a c l o r - Due prcrlur.
Volr.1
lor
Rcli.1
ond
in l i q u i d Scrrlcr
10 0v.r. Salefy.Rrliel
I
. -.
TOTAL
Revision :
PROCESS ENGINEERING DESIGN MANUAL
0
P a ~ s N o:
: 2/~5
9.15
FLAW AND RELIEF
TEPIDPIEXPISUR
Dbrc
I
1
I;:
5
0
I P
LO
15
20
GAGE BACK PRESSURE
x
25
30
35
BACK PRESSURE
40 PSlC
45
50
,IPSIG
Norr: Thc abov curvcr trprrprnl rn romprnmlu or lhr ralun rcromnnded by a nvrnkr 01 rclicf wal*e mrnvi=rlutcr~ehd may be uwd when lhc mabr or ral-e or the aclubl trilical.l?aw presrvre p i n t I01 ihr rapor or # I 3 i5 unknown. When thc makc i l Lnom. Ihc manufacortr nhwld h comrulrd lor Ihr corrcLlion f ~ c l e t T l n r curves r r r tor rt pnrurc. of 54 pounds p l r sqvmrr #nth *oar and abort. Thty art lirniled to h c h prcnurc klm cril*alnow p*.rure ter r ~ i w n r r pwsure. Fw wbtrfilaczl.flor bmct presrurm b l o w SO paundr p r quare inch -PC. rtu manvfrctu~rr mual br cmsultcd rw ihr v r l u a of K..
I
Figure b,(k-~.r~abl. o r Conrioni 8ack.Prcrrur~Sizing Focror K. for Bolontcd Bellows Sofr!y.R*lirf pars and Gases)
VaIvrr (YO.
1 .o
0.0
09
0.4
0.2
0
0
60 70 80 90 100 BACK PRESSURE. PSI* ABSOLUTE BACKPRESSURE' SET PRESSURE OVERPRESSURE. PSIA XI00 = r X
10
./0
Figure 6 * 6 L ~ o n ' l o n i 8o.k
Only1
20
36
40
50
+
Prelrurc
Siring roctor I(* Far Convrntio,ml ~ . h ~ ~ . r ( e l i sVolver t (Vapors ond Cares
-
TOTAL
PROCESS ENGINEERING DISlQN MANUAL
R n l ~ i o n: Omtm
T EPIDPIEXPISUR
10.
Prp* NO :
: 2/83
?SPES VALVES + FITTINGS
/4Y
A
TOTAL
Revision: 0
PROCESS AND UTILITY LlNE SIZING
TEPIDPIEXPISUR
1. APPLIC,
. -
Datt ;
2/85
'UTY
For a feasibility study a quick e s t i m a t e of the line size will be required. For a pre-project study a b e t t e r estimate of the line s l z c will be required.
-
The purpose of this guide is to size only the lines in t h e process unit.
.
For t h e both the feasibility and prc-project studies a b a q w s AFTP c a n be used :
.
Pmge No. :
.
"Pour le cslcul d e s p e r t c s dc charges des liquidts dans les conduites"
.
"Pour le calcul dcs pcrtes de chargcs dcs g a z dans Its conduitcs"
The line sizing depends on t h e service :
.
F l a r e lints, pipeline end riser sizing a r e not included on this chapter.
2. LIQUID LlNES SIZING CRITERIA S e t Table 1.
3. VAPOR AND STEAM LINES SIZING CRITERIA Table 2.
See
5. T W O PHASE PLOW LINE SIZING CRITERIA The
PvZ c r i t e r i a
f
=rm
as
s t a t e d for vapor lines to be followed with : W
in kglm3
*
W =
WJ + Wv = t o t a l f k ~ wr a t e in kgfh
fl =
W1 =
liquid flow r a t e in kg/h vapor flow r a t e in kg/h
pv
Wv =
and V = Vrn =
=
liquid density in kglrn3 vap?r density in kglm3
mls
Pi = internal diameter of the Line in m. om a n d Vrn a r e respectively the apparent density and velocity of the fluid.
10.1
-- --
.- - Revision : Q
TOTAL
un,,,,
nzlnc
TEPIOPIEXPISCIR
.
Page t4o. :
Datr:
2/83
10.2
The flow regime t o be checked on the figure I for horizontal lines and on the figure 2 l o r vertical lines.
,
For horizontal lines slug and plug flow regimes should be avoided.
, For v t r t i c a l lines slug flow regime should be avoided. Remark : Flow chart fig. 1 and 2 are based on author's experimental results.
5. PRESSURE DROP CALCULATIONS 5.1.
MONOPHASIS FLLID (GAS OR LIQUID1 5.1.1
''ABAQUES AFTP" could be used w i t h the correction of the line diameter
rch as indicated on there ABAQUES.
5.1.2.
Method using MOODY or "regular" Fanning friction factors. a.
Calculate Reynolds number
. -$
R ~ fli . V
Pi
=
line internal diameter in mm
PV
= =
fluid density in kg/m3 velocity in m/s
fluid dynamic viscosity in Cpo Re is a dimensionless number
-
b. Determine the relative roughness :
See Figure 3 -3 & D
Determine i = friction factor :
See Figure 4 4 f =
c.
d. 5.2.
f *=
P=f x7 LOO ;x
&
=
%t
s
bar1100 rn
TWO PHASE FLUlD
Many correlations e x i s t to calculate the pressure drop for two phases flaw, depending of the vertical or horizontal line, ratio of vapar/liquid and pressure and temperature conditions. That is out of scope of this guide and we mention only some authors :
POETTMANfCARPENTER
FLANIGAN
EATON
BEGGSIBRILL TAITELIDUCKLER
LOCKHARTJMARTINELLE quick methods for an estimation are as follaws :
I5 .7
Revilion: O
T OTA L
unuw
PROCESS
slziwz nrtt: 2fg5
TEPIDPIEXPISL
5.2.1.
Pmg? Ha. :
10.3
"ABAQUE AFTP" for gas could be used with the correction of tht line
diameter. Takin as defined in 1 4 and the liquid viscosity as the fluid viscosity. 2 . 2
Method using MOODY or "regular" fanning friction factors.
I t is the same method as on C 5.1.2.
and V = Vm as defined on 5 9
wlth
f.=P" and the fluld viscosity taken as the liquid
viscosity.
5.2.3.
A more detailed method using the Lockhart Martinelli method i s given i n
section 11.0 PIPELINES. i. NOTES
. .
Tubes dimensions are standard and an example i s given on Table 3.
With "ABAQUE AFTP" the correction for the internal diameter must be done and an estimation of the line thickness could be done with the following formula used mainly for
high pressure.
thickness
rnm
Y =
coefficient having values for tcrritlc steels
P =
Design pressure
bar g
Be
external diameter
inch
S
allowable stress
bar
C =
corrosion allowance
mm
e
s
=
E =
:
longltvdial weld joint factor
5, E and Y are not always available so the following iorrnular could be used for an estimation.
t
r
P =
thickness in mrn design pressure in bar g
= corrosion allowance in mm K = 43 for carbon steel and low temperature
c
carbon steel de =
external diameter in inch
54 for 3.5 % Ni and stainless steel
For small diameters upto about 10" usc the thickness given by the schedule on fable 3. For
P do not 'forget to take into account the change in clevstjon for liquld and two
phase 1low.
TOTAL
Reviaion : 0
PROCESS ENGINEERING DESlGN MANUAL
Pw No:
PRCCESS WD ImXLITY
Dete
LXN~IZ~NG
T EPIDPIE XPISUR
: 2/85
30.5
_ _ _ _ _ _ _ _ _ _ _ I _ _
-
fi
9h!
? P? 0
E
4 0
1 5 9 9 N' N-
a
.-,
n
C.hC.C.CA-CICI
s>
3 EUP
NN
= a
22 E
0 0
m*
I?
_ _ l _ _ _ _ f _ _ _ _ _ _ _ _ _ _ _ - - d - - - 4 - - -
e4 &I
2u
b
rn
EC
5 .-
g;aE
9
3
V
G.2
S.$Z E
=if
5:
a
-.'
z 2: 11
0 0 0 0 0 0 O D "
*-=z
=22
+-
$
k
x:3m -___________-_______--------0
I-
i
E E
G
k
ML L U
vl UJ
d
m
w~n
0
= x:!i u OaaS 2
P
5
td
5 n z u ct
0
n < >
'-+vv V O O h a m n a
A
d
RE
w
2 U~ M
~
5oa: .snV gam, o . , .
g .-" U, .*
c
L
8u 2l .-m r a5
go N :
v,,
/3-5
8 8 NP.4 " A
U
g: yg
. ; Z
*0
58 G
E
k k EE 0 0 11 U
.. ; -5 M
4
2
f
v
P
a
..
D rd
On v
M
:
a
n
V
d,
-
.. 5 < s , > _-_________________---------I
EE
W
b 3-k u a v n dVgfi
....
3 z
0
0
A
P I
Revision : 0
f LPIDPIEXPISUR
Date:
2/85
P ~ g No. l :
10.6
7. REFERENCE5 AND USEFUL LITERATURE
,
LUDWIG
.
Flow of flulds CRANE
,
.
"Gas liquld flow in pipelines I Research regults" by A.E. DUKLER May 1969 Publ by A.G.A., API and Union of HOUSTON "Gas liquid f l o w in pipeline I1
- Design manual" by 0. BAKER, H.W.
BRAINERD, C.O. COLDREN, FLANIGAN and J.K. WELCHEN, October 1970,
published by A.G.A. and API
-
.
"Proposed correlation of data for isothermal t w o phase, two component flow in pipelines" LOCKHART, R.W. and R.C. MARTINELL1 (1949) BEGCS , H.D., and
BRILL, 3.P. Manual lor "Two phase
[Low in pipes" 1975 university of
TULSA
.
.
ABAQUES AFTP:
.
"Pour le calcul des pertes de charges des liquidcs dans lcs
-
conduitcs" "Pour le calcul des pertes d e charges des gaz dans Its condui tes"
PEPITE PKOGRAM "CHEMICAL PROCESS DESIGN ON A PROGRAMMABLE CALCULATOR"
W. WAYNE BLACKWEIL, 8.5. Page 22
.
-
"Two phase pressure drop computedqq Mafik
156
SoLirnan, Hyd. Processing April 84
-
TOTAL
PROCESS E N G l N E E R l N O D E S I G N MANUAL
Revirion :
uTmn LINE SIZING
0
.
No :
PROCESS AND
'IEPIDP/EKPfSUR
Date
10qow
:2(es
Iblnr
1
10 .7
.Flsr
rJ.L*m.
*
hvrllonlll t*e-ph~#a no* (b.& m earn hDm I", i'
as& Ha. 10, lBU, D. IhODO I
s, I,DOD
8. Bx.-
210.7
-
0.5
(gO.I66\
WG
BY =
(
0.33
1
SeC P.11.3
7.102 WC
fl V
O E z
OSHINMYO -CHARLES TWO PHIsE FLOW MAP FOR VERTICAL UPWARD f LOW a
D
- P i p Inside durnmHr, inthn
p 1- Liquid dcfisity. L ~ / F I '
xr 4
~ r ~ ~ / f i 1#53[(0, . .
.
+ o , ~ ~ m ~ u]11.5111 [ p ~1'1~0.25 ~ ~
FIGURE
P
1H.I
I TOTAL ( T EPIDPIEXPlSWR
PROCESS ENGINEERING DESIGNMANUAL PROCESS AND UTILITY
LINE SIZING
Fi y r c 3
I
tlevi~mn:
Date
- Relative
: 2/05
I
r *yn
o.tr
.
1
10 .o
rawghnas of pipe
Pip Dim&r, ia Frd -P
-
P i p Djmlel. in lKhn d
I
t
,
.
'
ror mchrdulr 10 9 < 1 4 - m r * mot used n ~ r n . 1 1 ~ mr rolloli.. a i d t . . . are nor c m m r 0 , Y O . I I 31 fox QI lo- lim dl.+rcrr i r c m a n in 2 " incrrrrml.
11
21
>
.______---~
160
2 "2..
3 I/='# 5"
~ e v ~ s i o: n 0
TOTAL
page NO..
PIPING CLASS Date:
TEPIDNEXPl5UR
2/85
10.11
1. APPLICABILITY
as shown on a PID line whtn the f . i ~ i n gmaterial class document does not exist. This is generally the case for
The purpose of this chapter is t o determine the piping class uscd
feasibility arid pre-project studies.
2. CLASS NUMBERING PRINCIPLES (From DD-5P-TCS-112 "PIPING MATERIALS CLASSES") 2.1.
GENERATION OF NUMBER The class number shall consist of a capital letter representing the ANSI series and 5 two-digit number representing the main material entering into the composition of the material used for the valve bodies, tubes, fittings and flanges of the network in question. Example :
-0
.. ............
Series 150
01
. ....,........Carbon steel +
The tables below give the letters and numbers to be uscd for numbering piping
Claases.
2.2.
LETTERS representing the series of the class Series
1 125 1 150 1 250 1 300 1 400 1 600 1 900 1 1500 2500 1 1 1 1 1 1 1 1 l I
Traring
I
Symbol
2.3.
A
B
C
D
E
F
C
3 1
Y
NUMBERS representing the main material of the class 01 t o 20 21 t o ir5
: Carbon steels (ordinary, galvanized, normalized, etc...)
56 to 70
Stainless steels : Special alloys (Monel, Hastelloy, etc...] : Other materials (Cast-iron, copper, copper alloy, t t c ..I
f l to 85 86 t o 99
:
Alloy steels
:
Glass Plastic, cement-asbestos fiber, ctc...
*
H
/61
----
TOTAL
Revision : 0
PIPlNc CLASS Date : 2/85
T EPtDPIEXPtSUR
(
Pagr No. :
10.12
1
3 P R U I U R E TEMPERATURE RATINGS The following ANNEX G is extracted from ANSI 8 16-5 1977 (AMERICAN NATIONAL STANDARD STEEL
PIPE FLANGES AND FLANGED FITTINGS).
Far pressure temperature ratings higher than series 2500 tho Iollowing is used 5000 PSI,
10000 PSI,
...(used mainly for well tubing and wellhead).
WOttS ( e l p*rm.aible bul r M rwrarnnendad lor prolanomd vr. n h r * {dl "01 tab. uwd ova, 65O.f {.I n m l t* b* uwd o7.r I M ' F (h) nol io b. uswd er.r 1000.1
m'f SI
Conv..s*n
-
Llo {go1 6 . 8 V I
plls
_
."
.
..-I-
TOTAL
Revision : 0
Page No. :
SELECTION OF TYPES OF VALVES
TEP1DPlLI(PlSU R
Date:
2/85
10.13
1. APPLICABtLlTY The purpose of this chapter is to determine the types of valves used f o r designation on the
PID.
.
valves are used tor two mains functions, isolation and control.
The following is only a guide line for selection of types oi valves which must follow the piping material class document when it exists. 2. BLOCK VALVES
The main types are :
. .
, ball plug
2.1.
gate butterfly
BALL VALVE
Ball valves can be full bore or reduced bore. 2.1.1.
Full bore u x s
.
flare system : upstream and downstream of PSV, rupture disc, flare line if
required.
.
downstream pig launcher and upstream pig receiver.
.
vents and drains on hydrocarbon equipments.
,
piping valves on instruments for hydrocarbon.
. 2.1.2.
utility except water for diameter larger than 2".
Reduced bore uses
. 2.2.
far block valves on hydrocarbon lines if the pressure drop is critical.
Block on hydrocarbon service without solid particles.
PLUG VALVE USES Plug\/alves have the same use as reduced bore ball valves when used for high pressure ( 6 0 0 ~Plug valves can be as~irnilatedto reduced ball valves, Generally, plug valves are the smaller and lighter of the two.
163
Revision : O
To
SELECTION OF TYPE5 OF VhLYeS
. TEPIDPtEXPISUR 2.3.
Page No. :
Date : 2/85
10.14
GATE VALVE USES
.
Gate valves can be used as ball valves except for downstream of pig launcher and
upstream of pig receivers. The vertical physical space requlrcd by a gate valve is greater than a ball valve.
.
T i t h t shut off for ball or plug valves is superior to that of a gate.
.
For hydrocarbon service w i t h solid particles presentor as wing valves on well
heads.
2..
+
For quick dosure purposes.
,
On utility lines tor low diameters < 2"
BUTTERFLY VALVE USES
.
On water lines for service, utility or sea water, generally for diameters larger than 2".
3. CONTROL VALVES The main types are
:.
. .
3.1.
globe butterfly special
GLOBE VALVE USED
.
Control valve used in most Q! cases except at very high A P as defined by instrument group, or on water networks, and compressor suctlon lines for throttling purposes.
3.2.
BUTTERFLY VALVE USED
.
. 3.3.
On water networks Throttling a t compressor suction
SPECIAL VALVES USED Special valves are defined by instrument grwp :
.
.
for very high A P the angle valve could be used for cornpressor anti-surge cage valves could be used.
164
Revision : 0 TEPIDPIEXPISUR
Date:
Page No. :
10.15
2/15
I. APPLICABILITY The purpose of this chapter is to calculate precisely the pressure drop in a piping network. This may be required for either study phase for situations where
A P is a critical
A PI wil
however calculation of process lint
consideration. For most proj-ts
not be
required. The pressure drop calculations are based on a summation K method. P THROUGH VALVES
2.
YALYES OPEN
2.1.
1 I
TYPE
I
K
I
I
I
I
I II 1 I I
GATE VALVE
I
0.15
GLOBE
I I I 1
VALVE
I
I
0. I
I
1,
1 I
2.4
1
P in kglcm2 : Iluld density in kg/m3
1 bar V
P 2.2.
NALlNE
CHECK VALVE
:1.02
1
kgicrn2
: fluid velocity in m/s
BALL VALVE
A P through bell valve with reduced bore : This extract of CAMERON BALL
A
P depends on the valve vendor. An
VALVE PRODUCTS is given as an example.
The example below gives aomt values of the pressure drop coefficient K Lor fittings cncounterd in cylindrical conduits. For further information, refer to "MEMENTO DE5 PERTES DE CHARGE by I.E. IDEL'CIK, EYROLLES idition, PARIS".
A P in kglcm2
PV I
fluid density in kE/rn3 : fluid velocity in mls :
A P=K
ELBOWS
K values for elbows.
I
RID
1
90'
-I
@I* 0.1 + 8
I
I I
1.5 0.17
t
2-36 f f
I
3 0.12t4.721 0.08
t
2.36 f
I I
I 1
1
5
I
0.09 + 7.87 f
II
0.06 + 3.94
f = friction factor see chapter PROCESSIUTILITY -LINE SIZING 5 5
I f
1
---
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
AP
THROUGH VALVES AND
FIlTINGS
Date
TEPlDPlEXPlSUA
3.2. taLr-t
aF
A
T-l-#
:?/as
ra--~*~
S. \I.
-C
'44
Revision : 0
1
%\-
.
s,
$9
~ D H
LI-I
Y'&,= r ,
I
:A,
5
K-~'CI
- $1
-K '
Pogo No :
10,~.
-
*
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
A
Revirion :
o
Page No :.
P THROUGB VALVES AND FITTINGS
TEPIDPIEXPISUR
Date
:2/B5
1 0 .I 7
.
v
3.4
trc 5,ts,
3-lr.4
Q15,
zy2 -L
p
Q
Q,
5 4
vaunl
Cr.*)
a
a)Lku.\
3-lc.2 -
5. =
V.,%.
>S.
br-h
sp++b-a
- '-'. 5.
x . ~ + ( ~ * ~ - 2 ( , . ~ ) - , . b , , ~ ( ~ )
z . l - ( r - sa),
1
.
-
TOTAL
Revmian : 0
PROCESS ENGINEERING DESIGN MANUAL
A P mrnUM
VALVES AND
F l g a No :
PI'ITlNGS
f EP/DPf EXPfSUR
: 2/85
Data
10. 10 4,
3.4 3
-
v.
+--?$ 5.
L+ .&\.
),c
J '.
5,
&=***k
O C ~ C C ~a -. l ,(
= kt
[, *($
- 2,
A --I
M.72
f b
-
K
b)
--
*($r]
~ t r . . ~ h +bic*.h
K
.-
R . [O.%
-
.
5 V.
+
2)
+* 4
~ * q * '
j v.
oql, ( I - 4,
16f
-3
2/,
I 4'. 1 C.
4'
:
0 4
h.
5 & 0.0 v. 5 Ye
)or$
TOTAL .
Revision :
PROCESS E N G I N E E R I N G DESIGN MANUAL
0
P 4 t No :
A ? THROUGH VhLVfS AND FITTING5
Dart
TEPlDPlEXPlSUR
;2/85
Resistance Coefficient. K The rtsisrrnte coclicicn ncrlculatrd by thr formub:
K= r
D
L
V a l m of 1ht Irktion fmor, 1, b r valiovr pipe sizes are lined in rablt 1.17. W l u n for LtD and C. k r Wy ~ n t valwr d were taltulared from thearetical s~nldcratiom.Vllvcl of C. for panialty open u a k u were rnripolalrd from in1 rnultJ lor rtprcrenlrtwe sizrr of brll v a k . Chrn 1 * 18 provides graphic reprcsrntation of vahn pahion *nus the percent of full O w n ires.
Table 1-47
FricIlon Factor Ill
Table 1.3 Calculated Values of t/D for Full Opening Cameron Ball Valves In Full Open Position
m ] T l -.-
.-
~
ro
dm
1.1 8,
I . 8.
I
I .
SC rn
7-
I.I I-
-
'I1 .-1 *#
.. ir
am 5-
in I*
.*
1 11
1.1
IY
1r
1 rn
m
1 Is
I Y Im
--
10.19
.
-
- -.- -- -..
TOTAL
A P THROUGH
v~LVESA m FI'ITINCS
a
TEPIDPIEXPISUA
: 2/85
t
Table 1-5 Calculated Values of L/D for Reduced Opening Cameron Ball Valves in Full Open Position
-
---.... _ --.
mw.
un.
--r
1.7
-
4 9
..1
1.1
m..
3Z.m
*I
aI 'I II5 111
I1
a. 1,s
11 1
11 1
111
11 1
ISP 11 1
I,.
nnm
111 LI
11
, I . "
P*
muu - ~ m4-=d -1
. --41111a -- , i t1 *' nb g:
u.n
I.rlI
11 1
11 1 111
ma
w v u .
-
HI+I
a a l p ~ -
m e w .
F 111m
-1011 --.-m
dI
nI
tl
rnl
n.
LI
1%
111
m*
*!I
I.
UI
*I 3.e
Ita
111
a>*
"'
1,.
11 1
it.
aI
*a
#'*
2 2 19
I. I
11 I
k* 1.1
111
74.n
P. IH
1.,
111 13'
111
I, I m.
I1 7
111 1Y 111 11' 111
In* 111
I.1
H I
I-
nn
1.1
Table 1-6
Calculated Values of L/D for
Venturi Openin Cameron Ball Valves in Full pen Position
8
-,-.
,
A
.
n.
91
Pago NO :
~ * v i ~ i o: n
~ D O C E SE~N C I ~ ~ E R ~ DESIGN NO MANUAL
.
10.20
-
I. . . I I
CONTROL VALVE SIZING
10.21
TEPIDPIEXPISUR
1. APPLICABILITY Tht purpose of this chapter is t o give some formulae to estimate the size and the number of control valves installed for one given service, and to estimate the capability o f the control valves i n case of revamping. The final sizing should be done by instrument people.
2. CONTROL VALVES CHARACTERISTICS Them are determined principally by the design of the valve trim. The three fundamental characteristics available are quick opening, linear, and equal percentage. 2.1.
QUICK OPENING
As the name implies, this type provides a large opening as the plug is first lifted from the scat with lesser flow increase as the stem opens further. The most common application i f for simple on-off control with no throttling of flow required. 2.2.
LINEAR Linear trim provides equal increaws i n stern travel. Thus the flow rate is linear with plug position throughout i t s travel.
2.3
EQUAL PERCENTAGE Provides equal percentage increases i n rate of flow for equal increments of stem travd. The characteristics provide a very small opening for plug travel near the Seat and very l a r ~ e increase toward the fully open position. As a result, a wide rangeability of flow rate b achieved.
3. CONTROL VALVE RANGEABILITY For an estimation only it is common practice t o select a valve i n which the valve opening
. .
at maximum flow is smaller than or equal to 9 1 per cent. For normal flow the valve opening should be at least 60 per cent while for minimum flow, il applicable, the opening should be larger than 10 per cent. If the inlnimurn flow is clor
.
the n
'o or smaller than 10 per cent, a smaller valve should be installed i n parallel with n valve.
For a flow rate the valve opening depends on the valve characteristics and i t is given by vendor i n their catalcgue.
4. FORMULAE
The valve area is characterized by the coeificient Cv (except lor FISHER which use Cg for the gas (see hereafter). The Cv coefficient is the number 01 U.S. gallons of water flowing during one minute through a restriction and the pressure drop through this restriction is 1 PSI. The following formulae are slmpllfied and to be used only far an estimation of the Cv. Some corrections may be necessary for the installation of reducers around the control valve. I f so, the Iormulae given by manufacturcrs i n their catalogues w i l l be used for a better Cv calculatlon.
/ 7/
-
TOTAL
2/85
Drte:
4.1.
Page No. :
CONTROL VALVE SIZING
TEPlDPlEXPlSUR
I
0
Rcvir~on:
10.22
LIQUID
A
1 1 I
- Sub critlcal flow
8
- Critical flow
P v < P Z a n d P I - P 2 < ~ f 2A P S I P I - P ~ > C ~ ~ ~ P S
I
v
. ..Q j PI - PZ
= I
=
CI
I 1
c
v
.
JEZ ~ Ps
critical flow coefficient (given by manufacturers and depends on the
type of valve and the action of valve by increase of variable) cf Pv
=
P1 P2
:
fluid vapor pressure in bar g. upstream pressure in bar g.
=
downstream pressure in bar g.
A pi
= PI
I
- (0.96 - 0.28 @ ) Pv PC
or to simplify, i f Pv < 0,s PI,
4.2.
<
-
APS
PI
- Pv
PC
=
Q
=
fluid critical pressure in bar f b w rate in m31h at upstream conditions
sg
=
specific gravity at flowing temp. (water = 1 a t 15.C)
GAS AND STEAM
I I I I
- Sub critical How PI - P2 < 0.3 cf2 PI A
I
8
- Critical flow
PI
- PI ) 0.5 ~
f P2I
1
I
,--=A 295
Cv
=
-1
GAS
-
(PI P2)(PI + PZ)
I 1 =-,
I
I I
47.2 W
1
JIPI-P~)
I I
( P ~ + Prg ~I
Q 257 Cf PI
C V = 54.5 W
ct PI
G
W = mass flowrate in t h
172
-
TOTAL
Revision:
0
Page No. :
CONlROL VALVE SIZING
TEPIPPIEXPISUR
Date:
2185
10.23
SATURATED STEAM
I Cv
I cv=- 83.7
72.4 W J(PI ~ 2 (PL 1 + ~2)'
r
-
I I I
W
Cf P I
SUPER HEATED STEAM C v = 72.4 (I
t
0.00126
I
I Cv = 83.7 (1 + 0.00126 Tos) W I Cf PI I
Tw)W
PI - P2)(P1 + PZ)'
Cg, PI, P2, Q =me definition and unit as 5 4.1.
G
= relative density (air
T
=
Z
= upstream compressibility factor
W
= =
Tos
1.0)
upstream gas temperature OK = 273
+ 'C
s t e a m weight in tlh s t e a m superheat in 'C
43. T W O PHASE FLOW For sizing, maximum
A
P
-
PI
- P2 = 0.5 ~ 1 P2I
- Without liquid vaporization
&=
I 1 B With liquid vaporization
1
-
1 cv
51.8 W
q-)
I
.
36.6 W
Cg, P I , P2 same definition and unit as 5 9.1. W =
t o t a l fluid flow. in t/h
dl =
upstream mixture density in kg/m3 d=
W x 103 WII dl1
-t-
Wlv dlv
Wll = upstream liquid dl1 = upstream liquid 1 = upstream vapor d l v = upstream vapor
172
flow in kg/h density in kg/m3 flow in kglh density in kg/m3
i
~ O T 11 A p m.ouci.
Rkvilion : 0
v,uvis
rrmNcr
d2 = downstream rnjxturr density in kg/m3 d2
=
W x 103 W21 w2v -+d2 1 d2v
W21
r
downstream liquid flow in kglh
d21
t
downstream liquid density in kg/m3
W2v t d2v
4.4.
=
downstream vapor flow in kg/h down~trcamvapor density in kg/m3
FISHER FORMULAE For gar 'FLSHER" use Cg instead of Cv
C1 = valve coefficient (given by catalogue)
-c ]
W
Cg = 0.4583
dplsin
3
dag.
W =
gas flow rate in kglh
d = gas density at upstream tanditions in kg/m3 PI : upstream pressure in bar (a1 P2 = downstream ptessurt in bar (a)
5.0
REFERENCES AND USEFUL LITERATURE
-
-
Vendors documentations
CPSA chapter 2
rPage
No. :
TOTAL
PROCESS ENGlNEERlNC DESIGN MANUAL
tEPlDPlEXPBUR
Revision :
Datw
-
/,-=
: 2/85
Plgr No :
-
-
TOTAL
Page No. :
Revision : 0
PIPELINES
. 7EPlDP/EXPISCIR
Oate:
AP
and A T calculations will may be necessary however to make an
For both feasibility and preprojcct studies, long pipeline normally be performed using PETITE or RESEAU. I t
11.1
2/85
estimate by hand. Details are glvtn below on how l o proceed on this.
I
2. PIPELINE PRESSURE DROP FORMULAE
2.1.
GAS TRANSMISSION
there exist many methods of calculating arc :
hP
for gas transmission lines. Some of these
American Gas Association Formula
Wcymouth
Panhandle 'A' and '8'
Darcy
Colebrook Below is given the Panhandle 'A' for use : r 11.1539
Where
Pi
s
P;i
=
C
=
Ts ps T
= :
L rn
=
q d Z E
r:
=
=
= =
Upstream pressure bar (a1 Downstream pressure bar (a) Specific gravity of gas K (273 K or 298 K) Base temperature Base pressure bara(l.01325 bar) Gas flowing temp K Pipeline length krn Flowrate at Ts, Ps bast m3/d (at Ts, Ps) PIPELINE DIAMETER crn Average gas compressibility Efficiency (0.92 for a clean line)
The formula does not fake into account the pipeline profile which, i f significant, can be added t o the A P calculatcd if required.
I
22.
LlQUlD FLOW IN PIPELINES
Use Darcy equation :
M
= Mass flow
kdh
F
p
=
kg/m3
E
D
= lim id
AP
z
Density
pressure drop
crn barlkrn
= '=
Moody friction factor
Absolute roughness (KC page
= viscosity
em
10.8 and 10.9) CP
.
-
1
TOTAL
Reuis~an:
Page No.:
PlPELlNES
2/83
Date:
TEPIOPlEXP~SUR
Re
0
= 35.368 x M
F = 6@lRe F
x 0
i
-----a*---
1
( 7 i ~ e I . 9+ (0.27 E/D) 0
=
2000
=[(31~d12 + i/(A+B) 3/21 1112
Ln
with : A - 2.457
<
for Re
I
11.2
for
Re > 2000
l6
(37530/~e)16
BE C A R E F U L when using friction factor charts as confusion arises
between MOODY F and FANNING F' : 2.3.
F' = 1/4 F
HORlZONTAL
T W O PHASE
Estimating 2-phase flow
A
P by hand for long pipelines
is not recommended, a8
the flow characreristics and equilibrium wUI alter along its length. However an estimate of
A P can
be hand calculated providing the phase regime is fairly
stable.
Given below is a calculation method based an LOCKHEAKT-MARTINELLI-
BAKER method. This method can be used for both longpipelines (stable regime) or process lines.
METHOD
A P2 PHASE
-
A P HORIZ
+
APVERT
1
Evaluate flow regime and adjust Pipeline @ if required
2..
. a ~ c u ~ a t eA
P ~
3. calculate &pr 4. Calculate ( ~ P ~ / P P ~ I ~ ~ ~ 5. Calculate
AP
2 PHASE
factor....
:P H
6. Calculate ApVert factor (vertical section of pipe)
For convenience pipe ids are in crn viscosity is in cp.
/7f
-
-
-
11.4
1 1 1 1 1 I
(W
Vs=
I 1 I II
+ m) W1
=(&)f
I I 6. CALCULATE LOADlNG FACTOR WS
I I
WS
I I
-
I I
I 1 II x = C.\\S
I
I I I 1 1 I
I
I
1 I
1
I
II
I I I I I I I 1
I 1 I I
1
I
1 1 I
I
I I V3 = average velocity I
VS = !-!. 0 3 ;n/s
I ws=7?123 1
W i x 0.205 A
r
I I
I I
5. CALCULATE X RATIO
x
I I 1
1 1 I
4. AVERAGE VELOCITY
1
7. CALCULATE PH FACTOR FOR HORIZONTAL FLOW L
(
TYPE OF FLOW I
I I
1 I I I
I
I I 1 II [
I I 1
I
I
W..S€D
..I
Rt
[..UP
•
I I
i
BUCBLE
*X
Oltl.
wbl
ANNULAR
FLOW TYPE = b;si'f52rb
b
e
. m
-
.1.*1.*
b.&-&Wd 4 3
Q
LI,.,~"
~4 1
#]I
mu.
1-3I
*'' I
-- -
I
1 I I
D+S5J
Ey+- - I
WAVE
I
fS
I
PLUG
HI.=.&
~h
WG
]A?,
II
-
A
- -
-
rk Fn * 0 . 2 1 1 1
- -
-
hhs
-
-
FLOW f YPE =
7
A PZH =
A ..
=S.t54
rn
I 1
m ~ ~ p w~ h~ ~1. >
8 . -CALL . 'LATE ~n FACTOR FOR VERTICAL SECTION
i1
Fw
-
I x I I
SECTKIN
I
I I I I I I I I I
I
. . X
V i r m h D i n cm
ra.9 "'/a (x) I I R N P . ' ~ ~ XD in D i s p r r d 1l@r
APH,.
a19
t.510
to 1-1 PH r m .
Horizontal
:
Vertical
:
TOTAL
1-r 8 1 \.St0
A PZH =bpGx PHZ
A PZ,, = ~ P xGP
&P = (ApZHx L +APzv x h)/1000 =
=
H =~
1%3 4 0
o.ri>
bar/km
I
I I
bar
1
PROCESS CACCULATlON SHEET
OAT^
TWO PHASE PIPELINES P CALCULATION
ITEM :
Ilao T I T L ~. rzniirr i
JOB NO
I
barlkm I
/SO
TIC~W?T)tC'€lP~SUR
c nx
PH z pH,=
I I I I I I I 1 I I I I I I I
I I I
9. CALCULATE TOTAL TWO PHASEAP
m@/ TOTAL IV
WAVE
3-793
bar/km
YLRTICAL
I
1 I I
I 1
I STRATIFIED I
,
I
I
I I I I
I.Pf8
=
PH
I I
Sheet 2 of 2
NO. :
Itv
TOTAL
Revision :
0
Pmgt No. :
PIPELINES
TEP/DPIEXP/SUR
Dare :
2/85
I I.5
3. TEMPERATURE PROFILE For detailed and accurate AT and hP calculations in 2 phase lines buried, subsea or in air the program PEPITE should be used. The hand calculation method presented on pages Il+6, 11.7 is accurate t o wllhln 10 96 for both gas and liquid lines. The procedure is easily adapted t o a small pragrammablo calculator and increases in reliability the greater the number of segments used. The fold #ingshould be remembered when designing pipelines,
.
For long pipelines assuming isothermal flow can result in overdesign in pipeline sire and
A P.
.
If the plpeline is constant with regard t o material, insulation and burial depth along its route a fixed thermal conductivity (k)can be assumed.
.
For gas pipelines the internal film rcsistivity is negligible - Ignore it.
.
For all steel pipelines the resistivity of the metat 1s also negligible.
. .
Small plpelines 1< 20") have a large heat flow compared to the specific heat of the flowing medium. Consequently the gas w i l l reach ~roundtseatemp in a relatively short length. For large pipelines the converse is true and a long distance is required t o reach ambient. For oil and small gas pipelines the asymptotic temperature Ta is that of the surrounding medium. For large diameter gas tines, Ta d e p n d s largely on the JwlrThompson effect.
The attached calculation sheet can be used for hot lines in cold surroundings or vice verm
For subsea pipelines, epoxy wrapped, concrete coated resting on the bed an overall heat transier caeff of U = 10 I S k c a l / h m 2 * ~is a good estimate for calculation purposes.
-
/r1
+
-
?.
11.6 Coverinn Mcdjurn :
%,?.
b
y
DATA -
AY
0
h PI
P2
AP TI J
)
Tg
Total pipeline length No of segments L e n ~ t hper segment Total elevation change Pipeline diameter Pipeline diameter Burial depth to c e n t r e
rn
= 2aa.o
m
=
ins rn
= 3= 0.16~
m
=
=&
-+ m
losoa
= a 1-a
-
GAS FLOW
I.tl
bar
=
OC
= A?
Valumetrlc flow Molecular mass M Mass flowrate Cp Speciiic heat
10
FLUID JOULE THOMSON COEFFICIENT = (set fig. I , page 11.8)
I I
-
5
I
= tkT/ln[n + (x2
I x I s 1
- l)f)
I
.at flow ratio per unit a
1
1
I
II I
I I
I
( a
c
=rrHti ~ ~ - 1
1 I 1
I I Ta=-hI°C I I I
T2 I
4. Calculate downstream temp
T2 =(Tl
I
I
- ~a)c-aL+ T a
I 1 Repeat steps 3 + b for each segment I See s h e e t 2 for stepwise spreadsheet I
m&u TOTAL m z 3 sun
I T2 =bl.kqC I
I I
kcal/kg*C* 0.6
o.ooao5)
:o-L<'~lbrr
I I I
NOTES
I
1
k
kcalhm~ I
I
1.99 0.022 0.508
I 1 1 I I I
0.30 1.49
1 1 I
I
I I I I I I
I I
f I I L is segment length I j = 426.5 & I kcal I
I I I
I I I 1
1
I
I
I I I I
I I
I I I
1
I
1 t?2 PROCESS CBlCUlATlON SHEET
BURIED PIPELINE AT CALCULATION
1
I Sheet 1 of 2
ITEM Ho.
T€PrmP*oIPEX@
CHK
m3/d (std)s ?d 0-e = tq kg/h = wcabS
:3.33 Soil = 5 keal/hm°C 1 Air I Water I Sand dry I Sand wet
I
I @@ I 1 a = r/MCp (liquid or gas1 I I 1 3. Calculate Asymptotic temperatureTa 1 1 Ta=Tg-(JbP+Aylj~p)/al
x
I I I
VALUE
I
1 1
1 1 2. Calculate .
rc *F/IOOOpsi (
s I I
I I I
07
Volumetric flown3/h = Density (av) k8/m3 = M Mass tlow kg/h Cp Specific heat kcallkg * C =
bara = L o bara = l a
Inlet pressure Exit pressure Total plpeline Initial Temperature
I
Temperature * C = \O Therm. cond. kcal/hmnC = 1 . Lq
LIQUID FLOW
I I STEP t I I 1. Calculate heat transfer Iactor 1 1 x = 2h/D
I 1 I I
k
-+ TI,?.
L
-
C
L
q
OCTE
108 TITLE
tsAdl€
100 Mo
REV
-
.
11.7
AT.
ITERATIVE CALCULATION LOG FOR A BURIED PlPELlNE
I
I
SEGMENT N*
I I
I I LENGTH I I I I
I
I
I I
1
1
I
2
I ,*eo, I
3
I
I
I
I I I I
I
I 1 1 I I
5
I
8
1 I I I
9
I
I
a
,..a
41.0
I I 1
I I
I
7
1 I 1
I
I
I
1 I I
I
I I
I +QT£.
)
b r
wrfc
a
c
t
..In1.1.c\*i
PC I I I ~ ~ C. hIs0 t u v P L t O \ * ~ ~ 3 .*,I uc~.o,. . hu
*td
I 3 ~ 16 3 0
I
I
-
I
I
I
I
I
I
I I I I 1
I I
I I
I I 1 I 1 1
I I I
I
1
1
1 1 I
I
I I I I I I I I I I I I I I ! I 1 I
1 1
I I I I I I 1 1 I 1
1 1 I I
I
I
ou
1
1
1 I
Cp -1
PP L q . 4
I I
I
I I
I I
wnrd
I I
I I I I I I 1 1 I
I I I t 1 I 1
I
I
I I
I I I 1 1 1 I
I
I
I
I I
I
I
I
I
I
1
I I I I I 1 1
I
I
I
I I
I
I I I I 1
1 I
J
.
I I 1 1 I 1
I
1
I I I I I I 1 I
1
IAI.L II -
1 1 I
I I I
I I
I 1
I
I I
I
I I I
I
I
I I I I I
I
PZ
A
I0r r
I I
I
I I I I
I I
I I
I
I
I I I 1 I
10
1 I I I I I I I
I I I 1
1 I I I
~
13s
~3
I
1
b
1
1 I I I
I
I 1 I I I PI I T I I Ta I T2 I I I I 1 I I
1 I bar a l ' C I 'C I ' C I b a r a l I 1 I I 1
-+ m
I I
m
I
4
ELEVATION
J
I
I I I
I t
I I I I
I
I I I I
I I
kl
LWU&JC
4
4
j.L~liv~
l r
&
1
<>
PROCESS CALCULATION SHEET
BURIED PIPELINE AT CALCULATION
CHK
oa~t
ITEM
uo
flP'OOP'D~?'ta~~sun
II
Sheet 2 of 2
I roo
TITLE
t s ~ ~ t * i L
JOBwo
I
ntv
I
d
r
Revirion : 0
TOTAL
Page NO. :
PIPELINES Date :
2/85
11.8
4. LITERATURE AND USEFUL INFORMATIONS
9.1.
LUDWIG YOL I chapter 2
4.2.
CAMPBEL VOL I chapter 12
4.3.
KATZ, HANDBOOK OF GAS ENGINEERING chapter 7
4.4.
CRANE MANUAL
4.5.
"Equations predict buried pipeline temperatures" GiKinp, 043 March 16, 1981
8.6.
"Two phase
Soil
hP computedM
1.19
Wet soil 4 9 Ground -> air 2.98 G r w n d --> water 29.8 Steel 38.7 Epoxy coating
0.67
Caai tar
0.22
Hydrocarbon Processin)! April 1984
R. Soliman
concrete
0.65
sand(dry1
0.30
sand (wet)
1.C9
Air
0.022
Water
0.5 10
-
1.19
'5 1
ri 2
loule-Thornson coefficient' r
m.*--
Specific heatso \
f
*
'*-.Htlwa--
4
I
0 PI
ra
Pr ~.mol*l.rollml.IDP2.OPI
-c
*
DI
-
rn
b)lm.ut411nIJPIm *
I
-
TOTAL
PROCESS EHCINEERlNC DESIGN MANUAL
TCPIDPIEXPISUR
R.risim :
bat*
4
12, PACKAGE
UNITS
: 885
P q r No :
-
-
TOTAL .
Revision : 0
Pagt No
Date : 2/85
12.1
DEHYDRATION
TEPIDPIEXPISUR
I. APPLICABILITY For many studies undertaken there wifl be a requirement i o r 8 gas or liquid dehydration unit i n ardcr to reduce the water content of the export phase to acceptable limits for pipeline transportation. Generally this design will be undrrtaken by a vendor sperialist. However the engineer should be aware 01 some o f the options available for dehydration schemes, some of
the dos and donts of design and also how t o undertake the basis slzlng of the most common unit (TEG). The majority of this section i s concerned with gas dehydration using tri-ethytene glycol contact, this being the most widely used. 2. GENERAL DEHYDRATION NOTES
(English units ate used throughout this section for convenience)
, Gas is normally dehydrated to 6 to LO lb af H20 per MMSCF in order to prevent hydrate formation in gas tranrmlssian lines, and reduce corrosion. Unless the gas is dehydrated liquid water may accumulate a t low polnts and reduce the flow capacity of the line. Methods of dehydration i n usage arc : I. Adsorption 2.
Absorption
(Alumina, silica gel, male sieve) (di- or tri-ethylene glycol)
3. Direct cooling
4. Compression followed by cooling 5. Chemical reaction (for method injection see 4.0) The last three methods have minor usage and are discussed elsewhere in literature.
.
A sumr,
y of the advantages and disadvantages
of various absorption liquids i s given in
Table 1. Tri-ethylene glycol is the preferred (mast widely used) absorption liquid. Example flawsheets of di- and tri-ethylene glycol arc given in Fig. 1 & 2.
.
In order to limit the overhead glycol losses a max practical operating temp of 38
*C(100
'PI is used. A maximum of 50 'C (50 @ F )i s recommended t o prevent problems due t o t h t glycol viscosity.
.
Glycol losses arc usually i n the order to 0.012 gaIfMMCF (0.0016
r n 3 / ~ ~ r n 3due ) to
vaporisation and loss in the overheads. Total lossea due to leakage, vaporisation, mlubility run around 0.025 gallMMCF (0.0033 r n 3 1 ~ ~ r n ~ ) .
.
Concentrations o f TEG upto 99.1 % can be acheived without the use of stripping gas. For higher purities gas w i l l be required.
if?
'
TOTAL
Page No, :
Date: 2/85
12.2
DEHYDRATION
~EPJDPIEXPISUR
.
Revision : 0
Glycol foams in the presence of light hydrocarbons. This can be minimised b y goad
feed
prescrubbing and addition of anti-foam agents.
.
Actual gas e x i t dew points are usually 10-15 ' f (5.5
-8
'C) above the theoretical
equilibrum dew point. Take this into account when setting the specification.
.
The number of trays (or packing height) is usually small I 4 trays) an excess of either is always provided i n the design. Recommended efficiencies are 25 % l o r bubble caps 33 113 % for valve trays. Use 24" tray spacing*
, Regenerator temperatures should not be above 400 'F (204 in order to prevent
#CC)at atmospheric pressure
-
glycol degredatjon. L i m i t heat flux to 5000 7000 BTUlhft2, aim tor
-
6000. Provide a t least ZOO0 BTUlgal pump capacity.
.
To prevent hydrocarbon condensation i n the glycol feed maintain at 10-15
.
'F (5.5
- 8 ' C ) abave the gas exit.
Regenerator s t i l l column should run at
220
the inlet temperature
'f (104 'C)a t top to prevent loss 01 glycol
but maximise water rejection.
.
Glycol clrculation rates should be between 2-4 gall/lb t i 2 0 removed (3 i s a good number).
3.
PRELIMINARY SIZING CALCULATLONS An exact sizing of a TEG unit will normally be performed by the vendor on request. The CFP lnhwse program "GLYCOL" also exists Ior estimating vessel sizes, circulation rates
and utility consumptions. These arc based on data from the B5+0 design guide. The following hand method can be used however t o estimate the required size :
1. Determine water content 01 inlet gas t o contactor a! required temp and pressure Fig. 7 Ibs/MM5CF, k g / ~ ~ r n 3 . 2.
Calculate total water mass in feed gar to contactor
3. Repea: nlcuiation lor exit gas using required exit dew point (add 10 "F contingency). Calcula. dew point depression 'F, 'C.
b. Calculate amount of water to be removed in contactor. 5. Use 3 galls f E G / l b H Z 0 evaluate glycol circulation rate.
6. Use Fig. 3 to determine required TEG concentration. % Use Fig. 0 t o determine required stripping gaa rate 7. Use 2000 BTUlgall TEG circulated to determine rcboiler capacity.
188'
Rewislon : 0
TOTAL
Page No. :
DEHYDRATION pate:
TEPIDPIEXPISUR
2/85
12.3
8. Use Fig. 6 t o determine number of trays required in contactor and Fig. 5 to determine contactor diameter.
9. Evaluate contactor height (set section I vessels) include integral KO pot in base of tower. Hence estimate weight of contactor. A more detailed sizing method can be found in
CAMPBELL VOL 11.
4. METHANOL IN3ECTION (HYDRATE INHIBITION)
In order to prevent hydrate formation in gar transmission lines the product is normally dehydrated in s TEG or mole sieve unit as defined in previous sections. On some occasions however (wellhead to plant) this is not possible due to the location of the source. If the minimum pipeline temperature is below the hydrate point the inhibition of water i s required. This is acheived by infection of inhibitors to depress the hydrate and freezing points.
.
. .
Common inhibitors are methanol, DEG, TEG. R ~ C Q V ofC ~inhibitors ~ a t the receiving plant ir normal, t h e liquid being then recycled. Econamics of methanol recovery are not favourable. Methanol i s adequate for any temperature. DEG not good below Limitations. Above 10 ' C better as lower vaporisation losses.
-
10 *C due to viscosity
Predict injection r a t e for hydrate depression as follows :
W =
W =
d M 100 Ki+dM
TO uw
v e equation
:
weight % inhibitor
= 'C hydrate depression M = Mol w t of Inhibitor
d
Kt =
.
-
1297 for ,Me OH 2220 for DEC, TEG
1. Predict hydrate formation temp at max. press in line TI 2 Estimate rnin flowing temperature in line T2 3. d r T I - T 2
The amount of inhibitor injected must be sufficient to depress the hydrate point as
calculated above and also provide !or vapour and liquid phase losses due to vaporiwrtion + dissolving. Adjust injection rate accordingly. For glycoI use 0.0035 r n 3 / ~ r n 3 (0.23 I ~ ~ M M S C Fvaporisation. ), For methanol use vapour pressure charts (CAMPBELL pp 159).
/ST
w
TOTAL
Rtvision :
0
Pmgs No. :
DEHYDRATION
TEPtDPlEXP/SUR
2/85
Date:
12.4
5 SOLID BED DEHYDRATION Solid bed dehydration is used when lower residual water concentrations arc tcqulrcd than the over achieved by glycol units. This is generally around the
- 40
' C mark or 1 ppm
residual water. Solid bed dehydration can be used l o r less stringent design requirements
TEG.
providing the cost is competitive when cotnpared to NOTE5 :
. .
LNG facilities always used molecular sieve dehydration t o acheive I pprn H20 or less. Available dessicant medium :
k~HZ0/100 kg bed
.
Bauxite
4-6
Alumina
4 -7
Gels
7 -9
Molecular Sieve
9-12
Beds can be severely degredated
cheapest
most expensive
by heavy oils, arnines, glycols corrosion inhibitors,
salts and Ilquids. i t i s essential t o have a good feed filter or scrubber prior t o entering the dessicant bed. ,
Bed life is usually 2-4 years depending on contamination.
-
Gas flow through the bed is generally downwards. Regeneration gas flows upwards.
This
ensures the water is stripped from the media without having to pass a l l the way t h r ~ l g h the bed. Figures 8 and 9 show a typical molecular sieve arrangement. Regeneration temperature is usually 175 " C
-
230 OC. Too high temp destroys the
media, too low results i n poor regeneration. Table I gives a summary
of operating and regeneration practices.
6. USEFUL REFERENCES AND LITERATURE 6.1.
~AMPBELLVOLIICHAPTERS~~AND~S
6.2.
HANDBOOK OF
6.3.
PERRY
6.4.
GAS DEHYDRATION
N A T U R A L GAS ENGINEERING, KATZ, Chapter "Fire tuning existing fleld installations"
D. CRAMER 63.
"Cutting glycol costs I"
- World O i l - Jan 1981
C. SIMMONS 0
+ C3
-
Sept 2 1 1981 Sept 28 19111
"Cutting glycol costs 11" 6.6.
16
"Correlation eases absorber-equilibrum dehy4ratian"W. DEHR 0 + 93NOV 7 1983
1Yo
line
cales
for
TEG
natural
gas
--
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Revirion : 0
/
Fagr N o :
DEHYDIUTION
TEPIDPIEXPISUR
Date vrn
CCYT
n
avca
12,5
: 2/05
WIMT
no. g no- *tar b h i a h y l w m glyml ddtydrerian plant i C o m M omd lwrmrw.
.
s r m u ~ ?a wm*cu IAD D r s w w w m r LtWlD
C.IC1-
MVMffiU
Chlor14.
L L ~ L I P cU.111.
U#i c.pst1ty
1.1
b . = . = . . . I . . I.*.
UI.~
k t b71rmlit14 l l m i l f kr
10-xr p*.c.nr
MU
00-11 ?.rr*.r
WC Umt-r
t-v..
wht I=l.mm.L..
.I
-tw
L o n - i m ~ cI11wL..
1.1
pu~%fi..
I . .1 .
a . ow.lln.
Di.lh,L-.
Clw-1
Lubl. SI
..lIdih
is c o 5 ~ 1 r . c d
wlrcm. IC.bI. L. p.m.-.
d .UIlrrs .I u-1 e+.r*tw ta?-mtw-. ant-
.rl
cq
I.
mwr brr-.r* Can? w n uii I
I
b*. n m l U i I ~ im .m.emcr.s*4 1 1 m t h . Bnmbb Is V.UY* 01 o r i t u . EW1.1c q a t w r u l 0p.r.t1.# i"~.t.*..... I I B h I ? hY11.rm.lc m a i l l r.ll.rmt.4 c- I t y r C"t
.
t.pemair= 1 .lY1 1 ..
Y ~-.rej.l
11.1..
-1".
D.h~dt.t..
bullltl.~I i c b e l l , Cerrmd.m ~1rrrrsl~~lc.ll~ la" I . . pll. I.p.I..II hlr*mn rdlU.'lsru 11.=1piI.Imm
.,...
1.-Y'C
e*. .IS .lalr-*arol~.
Ol?col r4doc.e
TABLE 1
DIYWUI*DU
nu, lyhlvp l ~ l l
3-10 l m r = * m *
- urarrrm rxwwr
UI"th.
C.*q l.t -11 llmh i.r v1.c 1.~~10111
sarrl n . r mlrmel.
Ciur.r
I..
rk..
r l t b rrhthrl...
L 1 d z . d 1.r i r ~ r t i s a puxpom*m l
I.
mnmr l.bllr.mim. r r himh rq.a.*.rlam chp.r*tur~. me.4.1 rmrra.1r 1 . prmblu. D.I pist d.pr.111m 1. 1hLt.l a.1 1.~. t h e lie t=bt h r l w 117~m1.
Calr, e m # w u t r l h l m r i l h t r l m t b l n a t11101. n t . Ia -1 r t r n t s a l n l r r r ir & l o t w o 4 m#.U?.
.,...,
i in I... th.. t s i m * w ~ - s mimm~ namb i m i r v l *em& k. ,.Id
.I,b
li'h l m i 1 h 1 a w l w i b i t m so- r-mi., t-d*=, is ~ t u =a . -1 Itmhr L l l t a c ~ t bIlqrli.. ~ bf ~ m l m m*IWL mu*= -ltll* b1 1 4 d d .
!
!
I
TOTAL
PROCE5S ENGINEERING DESIGN M A N U A l
Rtvision : 0
Plgb No :
DEHYDRATION Date
TEPIDPIEXP/SUR
: 2/85
12.0
a f 10unt 0 I I A Y D O R I*CI(INC RrOUIRIO TOR
I
--
-.-
II~Y~.
.
..
7 ../.
rant
unm err w m . *C ca.rm< or w m.m * r
I q4
s t u r - l -9.
OLlCOt D E H I O M T O R S
1
TOTAL
PROCESS ENGINEERING DESlON MANUAL
DEHYDRATION
I
rm Y
r
12.9
-
maw
rmwr
m m
1.r h e 1 1 1 . 1
1
I,**,warn
mllrnm
n.p
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m~*rlr..
, ~ M M
n.~.rm
!w*n mn
tu r w r * M r Sornmm-W r ~-WIII*LIC.*I. rmrlu(Wmmm
rrmln
n r m r n
!u#lanl,
r.ll"lm~*
{*I
o w
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: U
: 2/85
Date
~ E P ~ D P'{SLIR ~E
I
Pngo t4a
Revision :
d w l h * l * l W y h
Y h""lhl
I* M.
I
11111.11
I.,WY*
n,, .
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I ".*imn mumw-u,,lma. *,whdId
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w
1111 r r m n n - a e q Y l l , r * h C
Y
I
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11 11 I
JI
s
1
.
~ ~1 1
~ U W IL I
".U."
-.13l
h l d r n n m *
- r .lhrtn
n
C.hnl.P11.11 IM
IU & h l evP
hkd.. r l h ~
,
wdlh
hm Drrrhadam L CFIW LV ~l#lt(wlt lhPm*l
/ a-tm >I m l l r m . 11.
'
I*ICL
'WCUID41
11*111
~nl l .ell,." 11111
I
I
8
fnml
,
ct
,
n(dl.m
I0
hlb*
llm*
R
h l m I I C ~~ k k
:
Y I W W W-a ~ Lmwlm ilmln<18
I
n(tlN
I WIHVIII
.nh
!m l l b h t
*- > I 8 ;I*IttLI. 't
1 ELM
ulw ca.nvn*h I. 1tmr8 IJI hwq I* rlrhrtrlhallr 1Irn.IICmlm"L .(
*a i r m , w IW*
I,1lblUI*lMl*
HI1d nnrmm i m l l , I..,."i.lmy
I
I
ft4r)U
3
Basic Charmtteriattc~Of Kolecular Sieve*.
om*
SAI
IECICLEO QbI CObPIlEiSDI
F,Cdkc q
I C Y t Y N K OllO.lY
O? YOLCCULLfi l l l V l fiV10.p11m
/# r
*
.
TOTAL
RevisiMl:
0
PageNo.:
GAS SWEETENINC
TEPtDPtEXPISUR
Date :
2/85
12.10
1. APPLICABILITY Generally natural gas, or associated gas contain acid components, mainly carbon dioxide :en sulfide (COS), carbon disulflde (CS2) and mercaptans.
(C02)hyi
To obtaln a commercial product, gaseous or liquefied, the gas needs to bc treated t o eliminate these sour components for safety or process reasons. An other aspect of gas sweetening is linked with the development of the C02 injection to improve oil recovery. In this case C01 is extracted by a selective process. This section details different methods available for gas sweetening and lists their advantages and disadvantages. Guidelines are glven on which system to select lor specific services. A detailed sizing method is beyond the sccpt of this section, but can be found in the
referenced literature is required.
2. UNIT The specification of treated gas can be given in grains/lOO SCF for H2s or sulfur content
1 gralnllOO SCF r 16 ppm volume 3. GAS S WEETENINC PROCESSES
Various prwrcsscs a r e available :
-
3.1.
chemical absorption
-
solid bed adsorption
phy slcal absorption cryogenic fractionation chemical conversion using catalyst the absorption process b the most utilised
CHEMICAL ABSORPTION In this type of process, the chemical solvent absorbes t h e acid components present in the feed gas by chemical reaction and releases them by heating at low pressure. T.he main chemical solvents a r e :
-
-f h t Alkanolamines
. . . -
.
Aqueous ?6 normally used -
cwt)
MEA (Monoethanolamine)
DEA ~Diethonolomlnc) DCA [R)(Diglycolamine), {FLUOR ECONAMlNE) MDEA (Methyldiethanolamine) DlPA (Diisopropanolamlne), (AD]?)
or alkaline salt solutions as potassium carbonate KzCOj
146
15-20 20-35 up to 65 15-30 30-50 25-40
.
-
TOTAL
nevirion : 0
page Ida. :
GAS SWEETENING
TEPIOPIEKPISUR
act*
!
2/15
12.11
Alkanolamincs cannot be used undiluted because :
.
I
. lo
-c t o solid s t a t e a t ambient conditions
gtability et high temperature (heating is needed to extract the absorbed acid
gases) wlth generation of highly corrosive products by decomposition. Table 1 shows the advantages and disadvantages ol these p r o c t s ~ s .
3.1.1.
MEA PROCESS ( x e figure 1) MEA solution was the first solvent used and is still widely used. Generally a
I5 % weight solutjon is utilized. a) A d v a n t a ~ e s
-
high reactivity
- good chemical stability
-
low solvent cost
-
publicly available (no licendng fees)
b) Disadvantaftcs
- irreversible degradation into corrmlon products by sulfur components such as COS, C52 - trreversible degradation lor t h e salvent by oxygen (Direct contact with -
air must be avoided) ineffectiveness for removing mercaptans
- high utility requirements - high vaporisation losses - need of reclaimcr t o purify the circulating solution - no selectivity far absorption between H z 5 C02 - foaming problem and
C)
Fields of utilization
- general use
: MEA can be utilized for gases conraining from 60 ppm to
I5 % volume acid gases without COS, CS2, mercaptans and with acid gas partial pressure up to 100 PSlA currently maximum capaclty for a MEA unit is around 250 ~ 1 0 SCFD. 6 3.1.2. DEA PROCESS
The second most wldely used gas treating process with a tcndancy t o replace the MEA process and some improved processes. Flow diagram very similar t o MEA process without rcclaimer.
14 -7
TOTAL
Rrvlrion :
0
Page NO, :
GAS SWEETENING
- TIPIDPIEXPISUA
Date : 2/15
12.12
a) Advanta~cs
-
-
no degradation by COS and CS2 (hydrolysed into C02/H25} a significant amount af the light metcaptans present on the feed gas is absorbed a good chcmlcal stability a very low absorption of hydracarbons
publicly availabIe
-
no need for a reclaimer reduced vaporisatian losses
b) Disadranta~es
-
lower reactivity compared to MEA and thus higher circulation rates
lor the conventional system (Not applicable to SNEA-DEA process)
-
-
C)
an irreversible degradation of the salvent by oxygen and HCN hlgher utilities rtquirelnents no selectivity l o r absorption between H2S and C02 foaming problems
Fields of utiiization The DEA process i s used t o treat gases containing H25, COZ and also
COS, CS2, RSH (up to a total acid gas content of 20 % volume)
Hz5 content of the treated gas lower than the normal specification
requirements 14 ppm volume) can be achcived. The CO2 content of the treated gas can be as low as to I00 ppm volume. Performance of the
process depends on the C02/bi~Sratio in the feed gas.
dl Improved DrDceSSeS I. Split flow (see figure 2 ) For sour gases w i t h high acid gas content (above 25 % mole), DEA
flow rate can be reduced. Investment cost increases significantly (more equipment, complex columns, increased regenerator height). 2. SNEA
- DEA process.
SNEA company has developed a pracess using a hlgher concentration of DEA (above 30 % wclght). The process licensor claims to give In one step, for gases containing 0 to 35 % of Hz5 and 0 to 35 % of COz, a treated gas matching the most stringent H ~ spe~iiication s (4 pprn by volume).
1qr
TOTAL
0
Page No. :
2/~5
12.13
Revision :
GAS SWEETENING 0ate :
TEPIDPIEXPISU~
3.1.3.DIGLYCOLAMINE
(DCA) PROCE55 (FLUOR ECONAMINE)
The DGA process has a limited number of units compared w i t h MEA and
DEA.
Although in the public domajne, the process was developed by FLUOR and is refered t o as the FLUOR ECONAMINE process advantages and disadvantages to compare with MEA arc :
a) Advantages
-
low solutlon circulation rate due to the concentration (same absorption
capacity as MEA)
-
low utilities consumption
- very low pour point (-b0.F)
- Plants in cold climate areas
b) Disadvantages
- needs cooling of the solution during the absorption phase -
-
high solubility hydrocarbons and aromatics are dissolved high solvent cost.
c) Criteria of selection
Like MEA, DCA reacts both w i t h C02 and CS2 and a reclaimer is required. The process i s applicable to gases with acid gas content from 1.5 to 30 % volume and CO~/HZSratios between 300/1 and O.lf1 a t operating pressures above 15 PSIC. 3.1.4. DIPA
PROCESS
This process has been developed by SHELL under the ADIP trademark name. It is characterized by the selective absorption of H2 S in presence of
Cot-
3.1.5. MDEA PROCESS As with DIPA, MDEA is characterized by its selectivity for H2S i n presence
of C 0 2 . MDEA processes arc proposed by process liccnaors :
-
-
SNEA (Dl UNlON CARBlDE : UCARSOL
lr Y
Reviston : 0
TOTAL
Paga No. :
GAS SWEETENING
TEPIDPIEXPISUII
-
Date:
2/81
12.1b
3.l.b.HOT POTASSIUM C A R B O N A T E PROCESS (see figure 31 A n activator specific t o each process licensor is added t o increase the reactivity o f the ~ l l u t i o n
- BENFIELD (amin@m d other activators) -
-
CATACARB (aminc and other activators) GIAMMARCO-VETROCOKE (arsenic and others activators)
The main characteristic of the process is that the absorber and the regenerator operate a t the same temperature (1 101115'C)
a) Advantages
-
no degradation by COS and Cs2 which are hydrolysed
- no need for a reclaimer
goodthemical stability
-
no reaction with alr
low hydrocrarbon absorption
-
low heat requirements (isothermal)
selective C 0 2 absorption (GIAMMARCO)
bJDisadvantages
-
-
licensing fees required
high water content of treated gas
- no mcrcaptan absorption
low reactivity with M2S
c) Fields of utilization Applicable mainly on gas with high C02 content. Low H2S absorption makes it difficult t o achieve specification of 4 ppm voiume.
Generally a two stage process w l l l be used
-
K2C03 for C02 removal
This dual system (amine
-
/ K2CO3)
arnine l o r H2S removal
can
be
in
some instances more
attractive cost wise than an amine process 3.1.7.
CONSTRUCTION MATERlALS
Carbon steel generally utilized in the chernical absorption units. Regenerator can have a strainloss steel cladding and trays. Rtboller tubes can be stainless, but s t i l l subject t o corrosion. Monel is an alternative by costly, copper alloys shall bc avoided. h
2 00
TOTAL
Revis8on : 0
Page No,,
GAS SWEETENING
TEPIDPIEXPISUR
Date :
2/85
12.15
Generally solutions treating gas with high C02iH25 ratio will be rnorc corrosive. When the C02/H2S ratio is high, 3tainless steel w i l l be preferred far the following
equipment : amlnelamine exchanger
tubes,
expansion
value
internals, regenerator trays and rtbailer tubes. 3.2.
PHYSICAL ABSORPTION In
i
type of process, the solvent extracts the acid components by simple physical
cofltc t and releases them by simple expansion at low pressure.
High pressure and low temperature favour the physical absorption. Table 2 l i s t s the advantages and disadvantages of physlcal solvents. These processes are applicable especially in the case of high acid gas partial pressure (above 5 bars also). Not suitable l o r sweetening at low or medium pressure (10 bars abs) gases containing large amount of heavy hydrocarbons. Can be considered for a selective absorption. The main processes a r t : 3.2.1.
WATER WASH Can be used as primary treatment. For absorbers water wash can be achieved by addition of trays
in the top section.
Because of Its low efficiency, water wash should be used mainly on gases with
a large amount of H2S. Corrosion problems for this process should be considered carefully. 3.2.2.
SELEXOL PROCESS (see figure 4)
-
developed by
NORTON CHEMICAL PROCESS can
be applied to gases
with large acid gas content.
-
has been applied for sweetening of gases containing up t o 65 % of C02 and 9 % of H2S a t pressure ranging from 25 t o 100 bars abs. treated gas specification can reach 0,02 % C02 and 1 ppm W2S. When used to absorb selectively H2S or C02 it can also dehydrate.
-
other sulfur compounds (COS, mercaptans) are also eliminated.
do 1
TOTAL
R r v i s i ~ n: 0
Prge NO. :
Date : 2/83
12.16
GAS SWEETENING
TEPIDPAXPISUII
3 . 2 3 FLUOR SOLVENT
- developed by FLUOR, propylene carbonate is used as t h e solvent
-
primarly intended for t h e removal of C 0 2 from gas containing up t o $0 % volume residual CO2 content arwnd 1 % volumc in treated gas.
-
C02 solubility is higher than t h a t obtained with MEA o r potassium
carbonate.
- c a n bc used
to treat gas containing Hz5 and C02. H2S content would
require a iinlshing t r e a t m e n t douwstrcam t o obtain 6 pprn of H25. COS and rnercaptans a l s o absorbed.
3.2.4
requires an extensive use €rotating equipment.
PURISOL PROCESS
- proposed by LURGI uses n-methyl-2-pyr-rolidone as solvent - ss t h e scrlubility of Hz5 is higher COZ can be c~nsidertda s a rclective than
precess t o r e m o v e H2S even in case of low H2SICQ2 ratio. 3.2.5.
RECTISOL PROCESS
- developed by LURttl, uses a refrigerated solution of methanol as solvent. High s e l c c t i v i t ~lor C 0 2 , primarly used on synthesis gas o r on p r e c w l t d gas (cooling by an external refrigerant c y c l e for example).
- major disadvantage of t h e process, when not integrated in a plant already equipped with refrigeration cycles, needs refrigeration a n d methanol injection.
3.2.6.
ESTASOLVAN
Developed by F. UHDE GMBH uses trl-n-butylphosphate as solvent. Selective process for H2S extraction. li C02 specifications on the t r e a t e d gas ate stringent, additional unit downstream will be required.
3.3.
PHYSIC0 3.3.1.
- CHEMICAL PROCESSES
SULFINOL this process has been developed by SHELL
- involver a physical solvent (rulfolant) and a chemically reactive agent [DIPA alkanolarnine) in aqueoLls solution.
Revision :
*
PrgeHo. :
GAS SWEETENING TEP/DPiEXPISUR .+&
------
Date :
------r*-rrrrr.....-.--
2/85
-..,.- -.
A
12.17 -.--.--
Sulfolane permits deep absorption of C 0 2 and H Z ~Arnir~e . facilitates the
-
extraction of the acld gascs from solvent during repcncration performances for selective and non selective kt25 absorption depends on operating conditions process also permits extraction of mercaptans and other sulfur cornpounds (C05). As tor physlcal absorption, absorption of heavy hydrocarbons
occurs (mainly aromatics). Does not d9hydratc the treated ias. Compared t o smine processes, SULFINOL shows a low foaming tendency
3.4.
SULFINOL solution freezes at about -2.C.
SOLID BED PROCESS
3.4
h4OLECULAR SIEVES
-
not widely used for gas sweetening can be used as a finishing treatment to remove rnercaptans absorption in molecular sieves is particularly well adapted for LPG as finishing treatment to obtain the sulfui content specifications of propane and butane
-
3.3.2.
good absorption capacity for Hz5 low for C 0 2 . They retrlove water preferentially sieve l i f e is reduced for gases with high
C02 and Hz5 content
IRON SPONGE PROCESS
-
-
-
could be also classified as absorption process or as a conversion process (Hz5 is converted to sulfur)
mainly applied t o gas with low H2S content discontinuous process, iron oxide has to be regenerated or replaced. Spontaneous combustion of the fouled product occurs w i t h air.
4
CRITERIA FOR SELECTION OF ABSORPTION PROCESSES
-
there is no multipurpose process for gas sweetening, each case
is specific and shall be
studied accordingly
-
final selection is done on the basis of ccor~ornicalcriteria from short l i s t of prwesses which seem appropriate to satisfy the treated gas specifications
d
--
c.2
-
-
-
TOTAL
Revision :
0
Psge NO. :
GAS SWEETENING
TEPIDPIEXPISUR
Date:
2/89
lLll
k
-
chemical processes are characttrizcd by their ability to absorb acid gases w i t h a Low
-
influence of the gas pressure. They require a large heat quantity for regeneralion physical processes performances are more dependent on gas pressure. A t high pressure with high acid gas partial pressure, the absorption is better than l o r
-
chemical processes
selection criteria listed herebelow can be used for preselection of sweetening processes but shall not be considered as definitive.
4.1.
C02 ABSORPTION (NO HtS 1N THE GAS) (we figure 5)
4.2.
SIMULTANEOUS ABSORPTlON OF CO2 AND H2S (see flgure 6)
Q.3.
H2S ABSORPTION (NOC02 I N THE GAS) (see figure 7)
This is not e frequent situation with natural gases. 4.b.
Hi
ELECTIVE ABSORPTION (H25AND C02 IN THE GAS) (see figure 8 )
Physical solvents are particularly welt adapted in this case. Among the chemical proccsscs, only MDEA and OlPA seem t o be adapted for this
service.
5
REFERENCES AND USEFUL LITERATURE (1)
Natural gas production transrnlssion and processing
F.W. COLE, D.L. KATZ, L.S. REID, C.H. HlNTON (2)
Gas
conditioning
and processing [volume 5)
gas
and
liquid sweetening
by
R ~ B E R TN. MADDOX edited by JOHN M. CAMPBELL.
40'1
i
i
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Revision : 0
GAS SWEETENING
Data
TEPIDPIEXPISUR
FIGURE 1 YE). P R O C E I I
?Lor
DILGRIY
.. 2/85
Page NO 12.10
TOTAL
PROCESS ENGINEER~NG DESIGN MANUAL GAS SWEETENING
ntvllloll :
Oat
T EPIDP16XPISVR
: 2/85
Pnye No :
12.20
h
TABLE
4
AOYANThGCS CNn W l A P V h H f A G t 5 OF AnwPP7KYI PUC€€S5Ef . . I CHEMICAL J O L Y L H ~
xIt#nl i . c m n e ~ tel i h r q w . r L n y p r t s r w e
~ r r n r v It ~ Lpnw!lw
i
l o a m 6 9 when ihr $alutom t i ~ ~ l l ~ l ~ d l h ~ o r f f ~ r b o n l . . ~ s w " d e d 5011d11
RiL
m rh*
v t r y slicnt ~ b g o r p t i o n01 h r w y hldroc~rbonb~a,8blv w r ~ c n 80l !he feed a l l
C o r r ~ m n mproblems r e s v l t i n ~1r.m ~elulbono.~allmbn l c m 1 1 ~ 1w l l h ,if) a irom mlvrlon ~lp*rhc.ain~hlrmng rtFtnrr*loen.
r l a r r -1 i h r I*W~%ICJ availnbb ir the mhblic o o m l m Irm trrcnMn# I t r r )
Pure
..I+,tequmrrd to dilvlr !he mlv-nl
.lcmd # a r l t o l ~ = n rt ~ u i l i b r i 4 ~.1n . IltlC~aIw.
Hilh
*.re,
.~.ll.blr
in the
H~.tin@ r m u r t d lor wlrefil 1101aEe.
i l ~ 4 ~ 0 ~cog1 b l 01 t mlrmls
TABLE 2 PHYSICAL D V '
.
SDLVLNT~
tGEI
L o w e r u r l y tequtrrment? !or
@~SADVANTAGLI
.
te#emwariam
I
. Ler
I
.
r m r r r r m l e n t of thv
!remt*d
8,s
V o healin# required lor w l r e n t ,Iarqr
c m l m l 01 l h r ~ r e a l t d 11s
n l l h i m l t b i l i l y .s a d d 81s ~ r t i a l prr~~url
.
4bim~1ia.sI h r a w hlrdrcc.~lrbom lram the 1e.d
8Ij
. Highcssr 01 lhe %ol-*nn
--
-
TOTAL
Page No
Revision : 0
PROCESS ENGINEERING DESIGN MANUAL GAS SWEETENING
12.21
: 2/85
Datr
TEPIDPIEXPlSUR
I
.el0 *.I
mamum ue"YYL.IoI
1011
8 . ~ ~ OCI 1
.,u
nut" IOI
*
.11*..1n
IlllL".!
~ 1 0N1I U V ~
IWI C I S
I
11EA"
M O T C A l l B O N L T € PROCESS
FIGURE 3
-
n2$ 6
RESIDUE G A S
AIR
COMPRESSOR 4 HEATER 4
FUEL STRIPPER
aBS0RBER
-
'ICET G A S
COMPRESSOR
SOLYEWT VENT M
O
L PROCESS FLOW FOR HlGW GOl AND MIOM HIE
FIGURE 4
PIR
-
.
.-
TOTAL TEPIDPIEXPISLIR
PROCESS ENGINEEllNG DESIGN MANUAL
Revision : W
W\S SWEETENING
Dale
: 2/85
TOTAL TEPIDPIEXPISUR P
PROCESS ENGlNEERfNG DESIGN MANUAL
Revi*ion :
o
Psgc No
GAS SWEETENING
Dale
: 2/85
12.23
:
Revision : 0
TOTAL
Page No. :
REFRIGERATION Date:
TEPiDPlEXPISUR
2/85
12.24
I . APPLICABILITY For both fea5ibility and pre-project studies, the engineer will be required to select a process scheme k c . : choice between coid frac and refrigeration system) t o estimate the power, utilities, weight af this package,
2.
DESCRIPTION
The description is based on simple cycle. A refrigeration cycle is based on the exchange between a hot source and
s cold source. The
cold source is a refrigerant, the air or rhe
water, the hot source is the gas to be refrigerated. (see figs 1, LA) Figure 1 shows such a cycle where : tl
:
Is refrigerating stream temperature
t2 P~ P2
: :
is condensed refrigerating srream temperature is vapor pressure of the refrigerating stream a t t l
r
is vapw pressure of the refrigerating stream at t2
Pd
:
compressor discharge pressure
td
:
Tl/T2
:
Compressor discharge temperature initial and final temperature of the hot source initial and final temperature of the coid source
TRlITR2 :
On the figure I A , i t is easy to explain the cycle on a pressure enthalpy diagram
A 91
:
is the duty of the process to be refrigerated
A Q2
:
is the duty of the condenser
A Q2 3- MODIFICATIONS
Q1
:
HP HP i s the power oi the compressor +
- ECONOMISER
During the. discharge of the cryogenrc refrigerant, a mixed phase is generated (vapor and liquid). Only the liquid phase participates i n the coding duty. The vapor phase being compressed from low pressure t o the high pressure without participation a t the refrigerated duty. I t is possible to remove a part of this vapor phase by addition of an intermediate pressure stage removing the vapor from the low pressure stage compressor which i s called
economiser (see figures 2 and 2A). An economiser is widely used in the industry.
a ia
-.
Revision : 0
TOTAL
REFRICERAT [ON
TEPIDPIEXPISUR
Date:
.
4.
Page No. :
2/85
12.2s
SELECTION OF THE REFRIGERANT Depends on the required final temperature of the hat source and the disponlbility of the
country where the units are installed. Tables 1 shows the performances of different refrigerants in various conditions. it
is recommcndtd that the compressor suction pressure be maintained abovt atmospheric
pressure. 5. CHOICE OF DIFFERENT PARAMETERS
5.1.
REFRIGERATlNC STREAM TEMPERATIJRE t l AND COMPRESSOR SUCTION PRESSURE P2
tl
to be
3 t o 6*C lower than the final temperature of the hot source 12.
With the selected refrigerant and t l read on the MOLLIER diagram of the selected
refrigerant the vapor pressure.
1.2.
CONDENSED REFRIGERATING STREAM TEMPERATURE t 2 AND COMPRESSOR
DISCHARGE PRESSURE Pd In first, estimation take t2 t 2 to be checked later If it
:
TRl
(initial temperature af cold swrce) + I 5 or 2 0 ' ~ .
Is compatible with the cold source flowratc
and the pinch
of the condenser [pinch are shell and tube g 3 note 2) which should be 3'c minimum. With t2 determine PZ which is the vapor pressure of the refrigerant a t t2 (read MOLLIER diagram). Cornpressar discharge pressure = Pd
: P2
+
P through the
condenser.
5.3.
PRESSURE I N THE ECONOMISER
P,
This pressure w i l l be finalized with the compressor manufacture but for an estimation take
p,
.
!
=
Pi
dI/
TOTAL TEPIDPIEXP~SUR
1
6.
7-----r Revision : 0
REFRICERATION
,
Oate :
Page No. :
-
12.26
2/g5
CALCULATION N T H ECONOMBER (a figure 2A) Step 1 Deterrnlne refrigerant circulation through the evaporator = rn2
W vapor at evaporator inlet
% liquid a t evaporator inlet
=
=
/
.
Hz
-
H3
'42
-
'45
HZ
x 100
- '43
Step 2 Determine vapor refrigerant circulation rate through the economiser = mj % vapor a t econo~niserinlet =
% liquid a t econorniser inlet =
m1=
H4
-
H4
-
HI
H4
-
H5
"I
H5
% vapor at econorniser inlet
m2
x 100
H5
% liquid a t econorniser inlet
=
m2
Step 3 Dctermine refrigerant circutation through the condenser rn=
Step 4
ml
>
HQ
=
-
-
H5 HI
m
rn2
Duty of condenser
A Q ~= Step
+
HI
x
rn
(Hd
-
HI)
Calculate the compressor discharge temperature and power (see compressor chapter).
Step 6 Check the pinch in the condenser and the cold source flowrate (if not acceptable select a new 12 and Pd and repeat the ca1culation). Step 7 Size drums evaporator and condenser (see vessels and shell and tube exchanger chapter 5).
TOTAL
Revision :
Page No. :
0
REFRIGERATION
t€PlDPlEXP/SUR
Date:
2/81
-
12.27
7. SELECTION OF MATERIAL The material selection t o be made carefully. We recommend t o take the temperature corresponding a t the vapor pressure at the atmosphere pressure (1.e. : for propane it 1s recommended to select the law temperature killed carbon steel).
.
MULTISTAGE CYCLE
If we look at the enthalpic curves of the exchanger (precess refrigerant) with or withwt economiser, it i s obvlous t o see that the area between the process stream and the refrigerant stream is proportional t o the compressor work (in a first approximation). It is possible to reduce this a r t a by addition of several pressure levels between the discharge
and the
5'
regulation)
'ion of the compressor. However, there is more equlp~nent(drums, exchangers,
d the compressor
is more complicated.
The number of pressure levels is an economical problem but the maximum i s 3 or 4 selections of these pressures: the pressure ratio between each pressure
Is for a
first
estimation.
7
=ne
n PI P2
= number of cornpresser
suction
= first compressor suction pressure condenser pressure
9. REFERENCES AND USEFUL LITERATURE 9.1.
Gas conditionning and processing volume 2 by Dr. John M. CAMPBELL
9.2.
Applied process design l o r chemical and pctrxhemical plants volume 3 by Ernest
LUDWIG
9.3.
Chemical Engineers Handbook by Robert
21% L
H. PERRYICECIL M. CHILTON
E.
-__-..-.
,
TOTAL,
PROCESS ENGINEERING DESIGN MANUAL
Revision : 0
REFSICATION
Date
TEPlDPIEXPISUR REFRIGERATION CYCLE WITH
ECONOMISER FIGURE 2
EVAPORATOR
ACCUMULATOR FIGURE 2A
: 2/85
b g e No
12.29
-
m
I*
oC
Frean12
Amnia
rcfrSgcntlon
Brrke hovscpol*r pr ton of rtfrlgerbtlm
I
~ i l w a t ~r t ton of r e f rtgcrrtta
s
Pmpylme 1.21 Propane . 1.30
W n i a h p y l a n e 5.59 5-57 to pure Frcon12 6 .
Propylac 7.49 Propane 7.47 F r e m l 2 8.09
2.91
Jamnia
0 D.YOI 0.614 0.363
5.986 1.11 0.868 0.491 -
0.716 1.13 1.2 0.641 -
0.958 1.79 1.41 0.827
1.26 2.21 1.1 1 1.63 2.69 2.16 ,
cOHPARISON OF COmON REFRICEWTS
2.095 3.31 2.63 1.64 2-02
3.M
2-65 4.00
3.27 3.72
3.33
3.22 2.95 2.89 3.23
3.87 4.33
4 3.96
0.206 0.889 0.925 2.2
2.79 2.62 2.56 2.83 1-80
1.75 1.73 1.4
1.60
1.51
1.54
1.55
2.32 2.47
2-67 2 6 2.01 1.99 2.L3
2.15
2.69
2.09
2.08 2.06 2.03 2.14
2.41
2.80
3.23 3.10 3.03 3.31
3.74 3.61 3;43 3.19 2.41 2.3L 2.26 2.47
0.197 0.798 0.807 1.96
0.200 0.199 0.830 0.812 0.853 0.830 2.05 2.00
0.202 0.848 0.875 2.11
0.204
O.871 0.898 2.16
1.33 1.30 1.31 1.37
1.78 7 4 1.75 1.83
0,767
0.780 0.789 1.91
1.12 1.09 1.11 1.16
5
1.46 1.49
1.50
0.776 1.87
0.195
0.196
5.30
5.01 4.92
6.72 6.60 1.11
1.17 1.21 2.8
3-70 3.97 3.86 7
4.24 1.45 4.S 4.66
3.27 3.50 3 . 3.57
4.60 4.78
5.85 5.46
4.38 4.71
2.54
1.11
1.07
0.219
6.25
4.96
0.221 1.10 1.15 2.63
5.32 5.18
5.68 5.96
2.7
0.223 1.13 1.19
3.13 3.66 3.59 3.61 2.48 2.73 2.68 2.74
2.84 3.09 3.03 3.12
2.U
0,215 1.41 1-04
1.81 4.11 4.06 4.18
0.217 1.03 1.07 2.47
0.835 0.830 0.800 0.W8
2.18 2.41 2.37 2.39
3.20
3-18
2.08 2.1D 2.07
1.89
2.78
3.23
1.63 1.80 1.81 1.80
1.42 1.51 1.54 1.54
2.03 2.07 0
1.90
2.54
2.79 2.81
2.92
2.19 2.41 2.43 2.41
0.211 0.210 0.203 0.957 0.234 0.912 0.980 0.953 0.925 2.15 2.27 2.21
0.940 0.895 0.925 0.970
0.464 0.498
0.591 0.633 0.753 0.791
1.32
1.22 1.33 1.32
1-77
1.12 1.11
1.03 1.16
1.38 1.55 1.50 1.49
1.63 1.78 1.77
2.10
0,206 0.875 O.BB0 2.05 0.207 0.894 0.903
0.110
-1.02
0.952 L,10 1.03
0.835 1.96
0.BU
0.204
0.366
0.342
0.362
0.360
0.925
0.761
0.977 0.821 0.933 0.788
0.865
1.24
1.25
1.16 1.31
2.01
0.205 0.857 0.857
0.483
0.483
0.W 0.485 0.49 0.490
0.699 0.694 1.10 0.647 0.622 0.668 0.623 0.619 0.716
1.41
9.03 7.58 4.99
0.648
0.112 0.7OB 1.73
0.768
0.726
1.03 1.00 1.01 1.05
1.26 1.20 1.24 1.24
7.79 6.485 4.23
6.15
0.191 0.191 0.190
3.56
5.51
5.03 6.62
0.721 6
2.97
5.68 4.64
4.11
0.193 0.192 0.153 0.139 0.756 0.739 1.81 1.79
3.31 4-82 3.86 2.46
0.213 0.980 1.01 2.33
Cmdcnaed Liquid T e m ~ r r t u r c52'~; Condenser Pressure *n U r s : L R o n i g 20.8B; R o p y l m a 21.64; Propane 17.92: F r m 12 12.68
tgm refrigerant per alnute prr tan of
3.73 3.72 4.25
h w n e Freos12
Propylmt
LRmnl*
5.10
refrigeration
Xlloultr pcr tom of
4-98
1.98
Propane
Freon12
0.913 0.958 2.28 4.47 4.3'1
Ammia Prapy3ent 5.M)
Brake hwsrpo*s* p t i tcn of refrigcrbtfon
0.655 0.513 0.271
1
W c n r c d l i q u i d T a O c r r t u r t 35%; Condmser Proswe In B*rs i9mPnir 35.58; R o p y l w 14.61; Propme 12.20; Frwn 12 8.48
0.38t5 0.198
0.4%
krsnlr R . o p y l e ~ 0.939 RDWIIC 0.990 FreolLZ 2.35
h n l a Pmpyl*lc Proplna Freon12
kqn refrigerant p t t minute p a r tan of r efrlgcratian
-
I n hrs
P~CISUN
Evamratw
Tap.
Table
0
.
..
3
..
4
0
z!
R Z
'"
m
m
9 '2
Z
z
n2
m
C)
0
v
n
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Revision : O
REFRIGERATION
Dart
TEPIDPIEXPlSUR
Refriv*ranl Wvlblr
(kR1 mlprutionl
Vapor C 1.013 lrrr
P ~ p eM a :
-1'~
I
-22
r-113
F-111
:2/85
12.31
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Revision :
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TEPIDPIEXPISUR
13.
Omre
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: 2/85
UTILITIES
21 q
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. Revision : O
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Papt No. :
UTILITIES
Date : 2/85
TEP/DP/EXPl5UR
13.1
-
1. APPLlCABlLITY For both feasibility and pre-praject studies the engineer will be required to make an estimate of utility requirements both in consumptions and equiptnent required. This section details e few gutdelints and notes on the following utilities :
WATER TREATMENT UTlLlTY AND INSTRUMENT AIR INERT GAS GENERATOR5 WATER SYSTEMS FUELS 2. WATER TREATMENT
T h e following details the common used effluent water treatment equipment given in order of
effluent quality :
API gravity settler
.
Usually the first line of d e a n up. Simply a settling tank with a top skimmer to remove any floating oil or debris and a bottom skimmer to remove sludge.
,
. .
Effluent quality around 150 microns globules and 150 ppm oil. Large bulky items, cannot be used offshore, Either circular or rectangular in design.
Simple, cheap very common in onshore use.
Tilted Plate Separator (TPS), Corrugated Plate Interceptor (CPJ)
. . .
. .
Widely used both offshore and onshore. Uses plate packs, usually at 45* mounted in a tank and relies on gravity settling between ail + water within the spaces between the plates. €[flu
quality dawn to 60 micron oil globules and >0-200 ppm.
Can have problems with high solids content
it upstream settling tank i s not installed.
TPS units are usually used as the first treatment stage offshore.
Flotation units
.
Uses induced or dissolved air flotation t o remove any residual solids/oil in the cjlluent. Works in reverse to a gravity settler (small air bubbles trap debris and float to top of tank).
22 >
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UTILITIES
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Effluent quality better than 40 ppm. Vendors usually guarantee
13.2
< 30 pprn.
Can be used both offshore and onshore. Usually instalIcd downs~reamof a T PS unit or API separator.
Filtration (Use for Water injection systems only)
.
~ i l t r a t i o nunits either uses media beds [sand, anthracite, garnet, walnut shells) to achieve water quality or filters (fibre sccks, mesh, stainless steel cage).
.
IJrwlly not required for effluent water treatment unless very ldw residual solids content eniorced by lacal effluent standards.
.
More commonly used for water re-injection where high quality, low solids level is required. Can achieve 1-2 ppm in certaln beds, 10-15 ppm is more common. Units arc generally cornpacl but heavy due to media bed weight.
.
Good pre-filtration is required to prevent fouling up of main bed units.
Effluent standards
Listed below are maximum residual oil content in effluent water for dumping t o sea :
NORTH SEA
40 PPm
INDONESIA t MIDDLE EAST CHINA
30 pprn 20 PPm
5 pprn (European standard)
LOCAL ESTUARY (river)
Process drains, produced water, deck (site) drains [see figure 1)
.
Produced watcr may need degassing before treatment. If the amount of dissolved gas is small it may be possible to handle it i n the TPS unit.
Deck
or
site drains normally iluw to a separate sump tank before Qe-oiling. If the deck
drainage i s small or produced watcr itow is small, both streams can be combined through one TPS unit.
.
Process d r a l n ~are normally manually initiated and pass directly to the return oil slop tank. These drains are generally watcr free. Always try
3
use gravity iced between units. Pumping can cause e m u l s i o ~and make
oil-water stparatian harder. Similarly avoid fast flowing lines and turbulent pipe arrangements.
22
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2h5
13.3
3- UTILITY AND INSTRUMENT AIR (see ligutc 2) C O m p r e ~ f e dair is used on plants lor instrument control, turbine a n d engine strtt-up sod utility services t g : pneumatic tools, cleaning, etc.
:
For turbinelcngine start-up 17 -25 bar supply will be required.
. .
For general instrument and utility air, compressor discharge around 9 bar is adequate. Consumption :use 0.6 scfrn 0.017 rn3lrni1-1)for each air pilot (- valve) 0.8 s c f m (0.022 m3/min) lor valve pasitioner (instrument air) generally 1 m31h per valve unit will do as first estimate. Add 25% to comprcswr capacity for design.
.
Utility a i r : consumption is intermittent and difficult t o estimate a t early project stages. Add 75-100 t c f m (130-170 m3/hJ t o compressor capacity for initial estimate.
.
. .
All plants should have 100% instrument air standby capacity. Utility and instrument air c a n be supplied from same compreswr or separate ones depending on capacity requirement. Instrument air must be dried befare use. Dew point of air b dependant on minimum air t e m p e r a t u r e in location of unit. Generally dcssicant bed driers arc used giving dew points
as low as -60°C.
.
Size air r t c c i v e r s t o give 10-15 minutes of instrument air assuming t h e compressor goes down. Pressure in the instrument air receiver should not f a l l below SO psig (I.>bar g) during this period.
.
For long air transmission headers in cold climates intermediate KO p u t s may be required.
.
An e s t i m a t e of compressor and dryer weights and power a r e given in figure 3.
4. lNERT GAS GENERATORS (N2,CO2) Inert gas i s required in all plants for purging and incrting of equipment. For small requirements Nz bottles c a n be used in racks. This hawever is not feasible for large units and so gas generators must be supplied. The main types a1 generator in use are :
- cryngeni,~distillalion of air - oxygen absorbtian on sieve
-
.
gas combustion
For nlrrging purposes estimate capacity based on 3 times the volume of the largest vcsscl to
bt
lrgtd in one hour.
-
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UTltlTlES
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Cryogenic
13.4
"stillation is used only for large volume requjrtments, $pecifically LNG
plants. Not
.
Page NO. :
ed offshore.
Gas combustion produces a N2, C 0 2 mixture for inerting and purging purposes. Not used
much these days except for onshore large volumes.
.
Pressure swing absorbtion is the must common used method for
N2 generation. Skid
mounted units are sometimes supplied with dedicated air compressor, or can use existing plant air compressor for supply. Air consumption is 4-5 times inert gas production rate, residual 0 2 i n gas is 1-2%-3%.
.
Details and weights of common units are given i n figures 4 and 5.
5. WATER SYSTEMS
Seawater
.
Used for coaling purposes both onshore and offshore.
Can also be used as wash water,
sanitation water and feed to potable water units.
.
Seawater is also used for fire water systems but is usually a separate system. The seawater cooling circuit is normally connected to the fire water ring lor emergency supply only.
.
Always coarse filter the seawater before circulating to the plant. This removes any
debris or rnatine life.
.
Treat with chlorine at I - 2 ppm concentration
- maintain a residual CL- level i n the
water exit a t 0.3-0.5 ppm.
.
S e a w t e r exit temperatures t o outfall canals or drain caissons shouId not be above 40'C
to prevent corrosion.
.
Once thrwgh water systems are preferred for small, cooling duties with only 3-4 exchangers. For large duties and number of units where the cost of corrosion proofing i s prohibitive conslder using a closed loop cooling medium system. Cornmon used i s
- 25% TEG
.
in water.
For cooling medium/~awater exchangers consider using titanium or similar plate exchangers. These are especially ideal offshore due l o reduced weight and space requirements.
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13.5
Potable water
.
Depending on location of plant potable water can be made i n sttu or supplied by tanker lor storage, or taken ditccily from a mains supply.
-
For onshore plants most common method of water supply is evaporative distillation. Problem with these units is size and weight are high and residual
T D5
(Total Oissolved
Solids) is 5-10 pprn. This results 1s a bland distilled water which is not pleasant t o drink. ,
Increasingly popular now arc Reverse Osmosis units (R01 which art lighter and need less maintenance than cvaporativt units. Water quality is 400->OD TD5 (World Health Organization TDS for drinking water i s 500-1000) operating costs of RO unit5 i s 1.5 times that of evaporative distillation.
.
Power consumptions : for a 100 gph (0.38 m3ihl unit. Evaporative Distillation unit Reverse Osmosis Vapor Compression unit
.
IEO) 3.5 kW (XO) I kW (VC)t5
kW
Most common unit ofishorc a t present is the VC unit which i s very reliable and easy t o
operate. Unit operates a t 100.C and is more susceptible t o corrosion.
. .
RO units are relatively new, operate at ambient temperature and has lew mechanical parts lor servicing. Average membrane life is 3 years. Consumption : estimate on 50-60 gallons per day per man (0.2 m 3 ) Storage
: allow 10-15 days for oiishorc units
I0 days for onshore remote artas
.
Potable water can be dosed with hypochlorite a t 0.4-0.5
ppm to inhibit bacterial growth.
U1astt water and sewage
.
Before discharging to rivet, sea, or underground sewage + waste water must be treated t o meet local health regulations prevalent in the area.
.
Limlts are imposed on BOD (Biological Oxygen Demand), COD (Chemical Oxygen Dcrnl-d), coliiorm bacteria count and 75s. Examp
Limits are r
<
bacteria
T DS
200 per 100 ml 150ppm
BOD
CL' residual
22 3
< >
100 mgll 0.5 mg/l
<
1O , mg/l
-
d
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TOTAL TEPlDPlLXP/SlJII
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UTILITIES
,
D a t t : 2/85
13.6
Sewage is treated by physical attrition, airation and chlorine dosing to 30-41 ppm raw sewage.
.
Provide 15-20 hr retention time for enzymic action to reduce 3 0 0 .
.
Allow 30-50 gall/day per person (0.15 m3) for sev;age, shower, laundry and kitchen wastes. Use upper limit for hot unsociable climates.
6. FUELS
Diesel . Used
for emergency generators, pump motors and air compressors, cranes, and alternative fuel lor turbines,
.
For emergency equipment pravide individual day tanks sized on providing fuel for 2@hr operation.
.
Main diesel tank [for fecd to day tanks) should hold 10-12 days supply. This is dependant
an location of plant and normal supply periods.
.
Diesel should be filtered t o
* 5 Microns.
Can be centrifuged to remove residual water
and smaller particles. This is especially recommended offshore where longer storage times, supply boat debris, seawater contact and poor supply quality can lead t o operation problems.
.
For storage use atmospheric venting tanks with vacuum-PSV pedestrals, platform legs or inter-deck space for of lshort storage.
vent. Use crane
Gas -
.
.
Fuel gas is supplied as normal fuel to generators, turbines and any gas driven motors.
Always pass FG through a scrubber before use. Filter gas supply to turbines 10 10 microns (generally turbine manulacturcr will s t a t e quality required and may InClude his own filters)
+
- do not rely on this and provide separate treatment anyway.
Maintain FG temperature at least 15'C above dew point. Minimum temperature of gas to be 5'C.
.
Common supply pressures a r t 15-20 bar fsome jet engines need 35 bar).
Size fuel g a suppiy on maximum design duty of all users operating. Allow + 10% margin.
-
FC used for flare purge and pilots, ctc., does not need t o be filtered to 10 microns
- use
gas strai, ' off scrubber overheads.
&k if
-
Ldyoul plan
I a i mn*rrsur PAhcdr 3 num,r
4 Adwbrr 5 Pmduo buLv wsul 6
sblrrrt
-
-
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14.1
COMPUTER PROGRAMS Date :
TEPIDPRXPISUR
. AMINES : Sizing of gas sweetening unit. FUNCTION This program provides capability for the calculstion of gas sweetening p r c c e s r s using s single aminc (MEA at DEA). It also determines the main equipment characteristics of the unit for preliminary studies.
OUTPUTS Contactor bottom temperature Amine Howrate Exchanger amine/amine area Contactor diameter (3.5. CONNORS formula) and number of trays Stripper reflux drum : height and diameter Reflux ~ w f f p:power Amine pump :power
RANGE OF APPLlCATlON The temperature of the rich arnine entering into the stripper is 190 f.
The bottom temperature of the stripper is 240 F. The default pressure of the reflux drum is 20 psia. Steam saturated temperature i s supposed t o be 250 F. 2. BRILL 1 and I1 : Pressure drop profile in gas and liquid pipes FUNCTION
BRILL 1
The program predicts pressure gradients and liquid holdup occuring during the simultanews
flow of gas and liquid i n pipes; BRILL I1
This program is specially assigned t o calculate the transpdrt capacity in the case of a mixture of t w o gases.
RANGE OF APPLICATION These programs were written for the
FRIGG pipetine.
However, the)' can be used for other
lines, sptciaHy far gas w i t h condensate.
REMARKS The line can be level or not.
The r i s e r s are calculated. BRILL 1 takes into account the line temperature profile.
i
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Revision : 0
COMPUTER PROCRAMS Date : 2/85
TEPIDPIEXPISUR
1
Page No. :
14.2
3. FLASH : Equilibrium ~ a l ~ u l a t i a r . PROCESSING The program is based around the
Peng Robinson equation
of state and the API (modified
Lee-Kessler) corr+sponding states method for thermal properties.
REMARK This program is not as robust as large commercially available batch simulators such as PROCESS, but it is very quick, cheap and easy to use.
L%nswersare instantaneous.
The program is self documented.
1-
C O M W L Y : Multi-stage compression unit
FUNCTION This program simulates a multi-stage polytropic compression unit.
PROCESSING CPSA method.
RANGE OR APPLICATION The transformation i s assumed to be polytropic,
The number of stages is fired Qr calculated (for a compression rate). It is possible t o input non-standard components. The KATZ table glving Z (Pr, Tr) is included in the program.
I
5
GLYCOL :Sizing of gar dehydrating unit
FUNCTlON This program simulates a gas dehydrating unit using tri-ethylene glycol. PROCESSING
The gas is countercurrent dehydrated in the absorber using a triethylene glycol solution which is then regenerated by stripping in a packed column. RANGE OF APPLICATION Gas input pressure into the absorber must be between 200 and 2000 PSIA.
Gas input temperature into the absorber must be between 40 and 160 F. Gas dewpoint temperature must be >
- OD F.
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COMPUTER PROGRAMS
TEP!DPIEXP/SUR
Date : 2/85
14.9
6. GULF : Sizing of petroleum ptatlorms
FClNCTlON Estimates and simulates pttroleum platforms. For preliminary studies, it calculates :
.
. .
size and weight of equipment5 [ p r ~ e s utilities, s drilling quarters)
size and weight of structure and substructure cost of the construction
PROCESSlNG
The equation of state used is a modified version of SOAVE REDLICH KWOWG. REMARK Oil flowrate can vary trom 3000 to 300 000 BOPD. The program i s specially adapted for compact platforms [drilling, quarters, production) but can also be used for production platform only. The accu
y
-
of the weight and cost estimations is respectively about + 15 % and + 20 %.
7. HANLEY : Density, thermal conductivity and viscosity calculations
FUNCTION This program uses the HANLEY equation t o calculate density, thermal conductivity and viscosity of hydrocarbons and hydracarbon mixtures.
INPUTS
The program w i l l handle a 20 component mixture. Library data is available for C1 thru' Cl7' Nitrogen, Carbon Dioxide, Hydrogen Sulphide and Water. Pseudo components can be dcflned
-
in the input file r if they are used, thermal conductivity will not be calculated. A datafile i s required. For each pseudo component, the following properties are needed.
. . .
critical pressure, atm critical volurnt, ~ r n 3 / ~ - r n o l e critical temperature, Kelvin
. .
.
Acentric factor Molecular weight Normal Boiling Point, Kelvin.
This empirical equation is believed t o be the best correlation currently available for
estimating liquid and vapour densities a t pressures above LOO aim. Vapour densities calculated using this method a r t believed to accurate up t o 680 atm. The viscosity correlation is very accurate !or the vapwr phase, but not as reliable for
liquids. The best available method is probably the Chung-Lee-Starting equation, with an average deviation 01 24 %.
The thermal conductivity correlation is included for completeness, but i t s accuracy has not been assessed.
2 p s
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COMPUTER PROGRAMS
Tf PlOPlEXPlSUR
8 . L l B P R 0 0 :Fluid
Page NO. :
0ate :
14.4
2/85
physical properties calculations
GENERAL
The LIBPROD iibrary encloses
FORTRAN subroutines for calculating various properties.
FUNCTION Subrwtine ASTM
:
stock tank oil viscosity at a certain temperature by the ASTM
correlation. Subroutine CALBO :
Oil Formation Volume Factor by the STANDING correlation.
Subroutine CALFRI :
Friction Factor by the MOODY diagram
Subroutine CALSIG : Subroutine CHEW :
Gas-oil surface tension by the BAKER and SWERDLOFF correlation 01 viscosity by the CHEW and CONNALY correlation
Subroutine LEE :
Gas viscosity by the
Subrwtine RSOUPB:
Solution Gas Oil ratio by the STANDINC A N D LASATER correlation Gas compressibility factor by the STANDING and KATZ correlation
Subroutine ZED :
LEE-ET-AL correlation
9. MASBAL :Creation of mass a n energy balances resulting from PROCESS program. FUNCTION The "MASBAL" program generates mass and energy balance tables, in conjunction with the
SSI program, according t o the user's specifications. The program uses %heoutput of SSI program and generates mass and energy balance tables which can readily go into a report.
PROCESSING The tables can be generated either in Metric or in English dimensional units system as i t
.
may be the case in the 551 program. The clasaificatlon of components defined in the 551 program can be reduced for mass and energy balance tables (components up to C20 for SSI program can be classified up to C[o+ in mass balanccl. Printout of cnthalpy is optional.
The stream composition can be expressed in the four different ways : rnolal flow rate, molal percentage, mass flow rate, mass percentage. Each table contains 8 streams maximum.
P 3d >
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Revision : 0 COMPUTER PROGRAMS Dale:
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I
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14.5
LO. MONOAGA : Pressure drop profile in dry gas pipes
I
FUNCTION Calculation of pressure lossscs for steady flow in dry gas pipes. PROCESSING MONOAGA uses the A G A method which is based on the general equation for compressible
fluid in pipes, whatever their profile may be.
OUTPUTS Any af the lollowing five variables can be calculattd :
.
flowrate
.
length inlet pressure
.
.
.
outlet pressure inside diameter
RANGE OF APPLICATION This program can also be used to predict the behaviour of gas with very low condensate contents (less than 50 crn3/~rn)). The profile of the ground can be f l a t or otherwise.
The tern--raturt profile can be fixed.
I
1l.F'EPITE : Pressure drop and temperature profiles in gas and liquid pipes
FUNCTION This program calculates the profile of pressure, temperature and hold-up liquid along pipes carrying single or two-phase fluids. PROCESSING
This program user the most efficient correlations which exist at the present time for single or two-phase flow, whether the ground be flat or otherwise.
Pressure losses for two-phase flow are based on the research work carried out in BOUSSENS. The calculations methods used are commented in the note "Two-phase flow in pipelines" written by Mr LAGIERE, and included in the 1982 Surface Seminar.
OUTPUTS The program can determine, at any point of a pipeline, the pressure, the temperature, the flow pattern, the liquid content and the other hydrodynamic characteristics.
..
T
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Revision:
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COMPUTER PROGRAMS Date : 2/85
TEPIDPIEXPISUII
14.6
R A N G E OF APPLICATION The many tests run under various conditions show that PEPITE is definitely better than
other models. The good results arc obtained by PEPlTE 80 t o 90 % of the time, whereas traditional models only provide acccptablc results 50 % of the time.
The least effective results obtained by PEPITE are those for steep uphill slopes. This drawback is on the point oi being solved. On a whole, the accuracy of the calculations i s in lint with that of the accuracy of the measurements themselves. REMARKS In addition to pressure and temperature calculations the PEPITE program will define the flow pattern. The user can do ten dif ierent calculations with a single run. The results can be either summarized or detailed, on request. Either starting on finishing conditions can be given as inputs lor the PEPlTE program.
12. PETREL :Pressure drop profile in gas and liquid pipes FUNCTION Calculation of the pressure losses and liquid content of the pipes, for condensate gar, oil and gas, oil gas and water flows in horizontal, slight slope pipes.
INPUTS Temperature profile o r average temperature. Physical properties af the fluid. Line profile. Some physical opertles can be predicted with correlations included in the program. PROCES51NG
The PETREL program offers several caiculations methods corresponding to different fields of application. Methods available in PETREL include : DUKLER, HUGHhlARK, EATON, BONNECAZE and FLANIGAN.
OUTPUTS Anyone of the following parameters can be calculated : inlet pressure line length outlet pressure
. .
.
RANGE OF APPLlCATION This program does not calculate risers. The calculation of liquid contents is doubtful in the case of condensates gases.
.
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-
14.7
I
13. RESEAU : Combination of PROCESS and PEPITE programs
I
GENERAL
This program i s the combination of the PEPITE and PROCESS programs.
FUNCTION This program calculates pressure drop and temperature profiles using the results of the proctss program. PROCESSING Fluid physical properties needed in the PEPITE program are interpolated into tables generated by
PROCESS program.
INPUTS
Input data is composed with : Process input data Unit called "US 14" (name, inlet and outlet stream numbers)
1
Options of the calculation Pipeline ~haracteristics RANGE OF APPLICATION Pressure must be included between 1 and 7 250 PSIA Temperature must be included between - 200 and + 200 'C Only tv-nty "US 14" r a n be calculated per run.
The PRC
'SS options r OUTDIMENSION, SCALE and SEQUENCE cannot be used.
The PROCcSS option "CALCULATION TRANSPORT
= 2" is compulsory.
lib. THERM :Pressure drop in liquid piper
FUNCf ION The TERM program computes heat and pressure loss calculations in liquid pipelines f o r Newtonian or non-Newtonian flow. It can
alsa predict the restarting pressure after a shut d ~ w n .
I t also allows pump calibration.
Revision:
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COMPUTER PROGRAMS
TEPIDP!€XPISUR
Date:
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14.8
INPUTS
Physical properties of liquid :
, viscosity versus temperature (for Newtonian flow)
. . . . .
viscosity versus temperature a t dltferent shear rates (for non-Newtonian flow) ylcld strength versus temperature density versus temperature
specific heat versus temperature thermal conductivity versus temperature. Some of the above properties can be predicted, but it is preferable to obtain viscosity and yield strength of liquid from laboratory measurements. OUTPUTS
Three artput formats may be selected by the user "finite clement length" "percent length increment"
. . .
:
"preselected finite element length"
In the third case, the program also computes the restart pressure as a function a1 time after shut down.
15. UPFLARE :Flare calculations
FUNCTION Radiation level calculations for an oriented pipeflare or
a Coanda flare tip.
INPUTS Boom and tip characteristics.
Gas characteristics (flowrate, gross heating value) Climatic conditions (wind, sun) Calcvlatim
ions
PROCESSING The calculatjon methods a r e API RP 521 or KALDAIR.
OUTPUTS Flame profile
Radiation levels a t given points or isopleihs {lines ol constant flux).
REMARKS The method used [API RP 521) has been extended to three dimensions and any flare tip orientation.
a ro C
-.
.-
-
l
-
TQTAL
PROCESS ENGINEERING QESIGN MANUAL
TEPIDP/EXP/SUR
Rarision :
Dmtr
"..
Z YI
: 2/83
Pbg?
Ma :
-
Revision :
TOTAL
0
Page No. :
DATA SECTION
T EP!DPlfXPlsi!R
Date:
2/85
15.1
-
PAGE
2 3-9
General data Converslon tables
I0
PSEUDO CRITICAL5 AND OIL PROPERTIES
11-14 15 16
Figs. 1-3 9
5 17 18
6
7 8
19
20 Z1
10 11
22 23
12
24
13
25 26 27 28 29
30 31 32 33
18
19 20 21 22
23 24 36 37 38
25
39
26 27
40 4I 42
28 29
k3
30 31
32 44 45 16
47
48
DENSITY -density of petrolturn fractions VS T Relative density of petroleum fractions VS MABP
VlSCOSITY Viscosities of hydrocarbon gases V i s c ~ i t i e sof hydrocarbon liquids ASTM viscosity chart
VAPOUR PRESSURES 14 15 16 17
3Cr 35
Phy slcal properties of hydrocarbons Camprtssibility factors of natural gas Pseudo critical pressure VS. MW Critical constants for gases and fluids Critical temperature VS. normal boiling point Characterised boiling points d petroleum Fractions Molecular mass, BP, and.denslties of fractions
33
31 35 36
Low temperature vapour pressures High temperature vapour pressures True vapour pressures of petroleum products and oil Hydrate formation pressures SPECIFIC HEATS Specific heats of hydrbcarbon vapours at 1 AT M Heat capacity correction factors Specific heat capacity ratios a t IA T M Specific heat capacity of hydrocarbon liquids THERMAL CONDUCTlVlTY Thermal conductivtty of natural gases Thermal conductivity ratio for gases Thermal conductivity of hydrxarbon liquids LATENT HEATS OF VAPORISATION Latent heats af various liquids Latent heats o f hydrocarbons Heat of combusion of liquld petroleum fractions
SURFACE TENSIONS - MlSCELLANEOU5 Surface tensions of hydrocarbons Dew points of natural gases Solubility of natural gas in water and brine Sobbility of methane in water Solubility of natural gas in water Solubility of water in hydrocarbons Temperature drops for expanding gas Temperature drops for expanding gas Physical properties of gas treating chemicals Physical properties of water Physical properties of air
2 93 7
I
-
4
TOTAL .
, J.; ~o~.~~~'*."'*~rdr-
~ ~ l ~ it,. . , *,Ck~**,,,~~.n.~o.C.J
-**(
-"
T.~,..~.,. r,.~.. a
J r* d n*
.-
L . 0
I L
C.. b.1.m'
L1.r
T
1 .L*. -
1 -I .D . I
bn*
bur
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b-d
b
K
M1
L
i d
I
own m- M e i?rn
I
h
Y,
,
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h' hJ
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.I
ems l a 5 6.
~.~6...11. lo8 .."pl..
,d.cb,
lo
brwr Bmuml or A.P.1. Th. rrl.bmn Gmtiry erprrrd by the 1 0 i b d n r formuln: F~~ (i+d. lighter than w o w ~ ) r ~ Bmumb ~ t m =
h*.m LW.h
.a
I,.,
.
-
Specific I
-g - 130
-
m w wuVL..
IYM
+ D e v c ~ SA.P.I.
-
G
145
-
-
5/9
~egress Bwmb
51 prrfi.rr id Mvl~lptiallaf1ct.n: Pr.(br
he weight
HH
I@
i~
1cJ
nrP ti10
ot m i x l u r ~ dl d*n'!ty = velum. p r ~ p o n of ~ ~oil n dion o i l of dz d e n ~ l t r s Volume pmPq & = #+ficGr.vlt~ or d t " + ~ of ?" &, specific Gravity or drnnsty of n
,
h
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0-1
milli mW
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pia
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ta * drd
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D e Denlily or SpICL.ncCr.vity
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e
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321
= *F+ 468.61 - 1.8 K
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-
I
145
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{ermt grrvitin:
PF
., .
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.t th. w e i l h l 01 given
0.c.ndi.m
11.111 11.b)L
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-F L 915 (me)+ 32
145
,,,,lmi,,.t~.r~lg
y(
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15.I.C
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41
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1
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11.a37
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m o ma 057 m
Y-lrm*
.m
I
d.
~srm
GENERAL DATA
TEPIDPIEXP/SUR
&,,*
Ravision :
~ R O C ENGINEERING E ~ DESIGN MANUAL
IOU rn44eJ-d
.
*.&I mt*= )I.I? frls2
=
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% , +*.
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TOTAL
PROCESS ENG~NEERINGDESIGN MANUAL DATA SECTION
TEPIDPIEXPISUR
2
1
cenrimitn
I . ~ ~ D D ~ rE ~ Z
Data
2
Page NO : 5
15
-4
AREA
I
LENGTH
I
1 , M Y ) o O O L ~ Z 1 . O m W E W 1.6d0000EtiO
mitre
Revisien : o
3.937wO€+01
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VELOCITY
TEPlDPlEXPlSUR
DATA SECTION
DENSITY
5.)8? 037 t -04
TOTAL
PROCESS ENGINEERING OESlGN MANUAL DATA SECTION
TEPIDPIEXPISUR
.
Pan* No
I5
: 2/65
Date
VISCOSITY (Kinematic)
n i t r m ad Wr
u d *
mnu'nokwr
I r t
pw wand
,quan feet @r bru*
1
I
1
munr.
Revision : 0
-7
-
1
I
~.WOWO~+OF
1.076 3ni E+OI
3.835 091) E fbr
\ w o O Q l E Q
I
1.016 391 1-05
3.11 75 008.5 -02
9.290 304 E-02
e . m lor r +ol
I
a.6m ~ o Eo*a3
?.6806*0 €4
2.W1180 €+Of
3.117)78E-M
,
I
TOTAL
PROCESS ENGlNEERlNG DESIGN MANUAL DATA SECTION
TEPIDPIEXPISUR
Revision : 0 Dale
: 2/85
5PEClFIC HEAT CAPACITY
THERMAL CONDUCTIVlTY Cr*IDUCIIY,Il
I*€sY'Om
rwr-.'c
WIC.~
m , m, ,-4
muw
N-'
ern.*
ha.**,. 4-4t.kir
,"
1
1101rn 1-01
I H I 1I1I41
% . i t 1l?lIiQO
I
4 . 7 1 s 1 U € -01
~ . ~ e r n t r s
1 . . 1 ~ 1 ~ 1 * 0 0
hr+dIm
..
Mi!hulArrk. I,.-w
F h W h
waw*.h:#
HEAT TRANSFER COEFFICIENT
FORCE
Paw No : 15
-8
--
7
TOTAL T EPlOPJEXPlSUR
I
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
Revision : o
Date
; 2/85
Pagr ffo :
15
HEAT CAPACIT Y/ENTROPY €NICI#IEt
carrcilt
~UERMIW%
JIK
1
LWIK
I
POWERlHEAT FLOW RATE
ktd'~
9
TOTAL .
Revision :
,
TwtnP/Ewnutt
0
Page No. :
1/15
15.10
DATA SECTION
'
:
PSEUDO-CRITICAL5 AND OfL PROPERTIES
.
Deflnitionr :
True vapour pressure
-
I
actual vapwr pressure of a crude oil a t the actual
temperature of the fluld.
Reid vapour p r c w e temperature of I00
r
- reference vapour
*F (used as a basis for
Mom average bo-
pint :
-
pressure of an oil at a controlled
product specification).
equal to t h t Sum of the mole fractlcm of tach
component x i t s atmospheric boiling point
Volume average b o U i ~point r VABP :
OR.
- average temperature at whlch the ASTM
10 %,30 %,50 % , T O 96 and 90 % volumes boil. VABP. T I 0 % + 730 % + TJO % + T7O % + T90 %
5 M e a n averrEe bailing polnt :MABP I
- the slope of the AST M distillation curve i s used
to c a r r u t the VABP t o give MABP. See
Fig. 7
-
Cubic average boULng point z CABP : another corrected form of VABP. llOP K or WATSON CHARACTERISATION FACTOR
KS~!!!!
i g at 60/60 CABP in ' R
Sg
Thfs lssued as a characterisation factor when defining crude oUs. I t is required for variws other data evaluations.
dS3
-
TOTAL TEPIDPIEXPISUA b
1
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
Pagm N o .
Dare
: 2/05
15
-11
7
TOTAL TEPIDPIEXPISUR
I
PROCESS ENGINEERING DESIGN MANUAL
Revision : 0
I
DAth SECTION I
Dam
PHYSICAL CONSTANTS OF HYOROCARBONS(27)
: 2/85
PW No : 15
- 12
.
-
7
TOTAL
PROCESS ENGINEERING DESIGN MANUAL DATA
TEP/DP/EXP/SUR I
5a NUII NO
-
-.-
Revision : 0
SECTION
Date
Pagr
: 2/85
15
10.
1
12.
I l ~
H U I ~ WIW. 15 *c'
i
13
;
Flarnnyb~la~v
ASTM
tumuls. "01 % ~nb+r rniw!u<~
hrmw
DCI~W
I
1
cmwum
-
-
37.691 33938 I wrnmr 68.032 51.58bh 1s 4 5 b 1 Elham 60.395 86,453 93972 Y 1 . W 25 39Ib 3 Prmw 4 n.Eulwt 112.391 121.>19 49.158" 247ll)L l12'.0Jl 121.4X 49.DUb 27621. ' 5 lr~qrl1n . ' I=,= 149664 . 8 . ~ 7 PIw a nPtnlarr 7 lwpntm# 13,0114 149.31S 48.570 90333 137 465 I 4 L 7 S . 8 4 2 f h 281L064 I Nmantrnr 1Sr.402 l 7 t . W ' 4.W 32091 9 n.Mbrw 10 2 ~ l l l v l ~ n l w lbr076 171.22P 46313 9 1 7 4 2 11 3Umhrlmnlbm 1 w . 1 ~1 7 1 . ~ 1 #.m 3 31 512 1 7 6 1 1 I 2 keoh*=m 161 0% 171.170 40.1W B 1st 13 2.3.Dm~thvibutalu 14 n4ilotrn 1m.m ~ 0 6 4 3 1 48.101 m a s 190,099 205.132 4E.m) l 2 l O O 15 Z*Hlthwlhm.M IW,243 m . 2 7 6 u . 0 ~ 2 3 3 2 4 ~ 16 3.M.lhvihr.*~ 35m6 17 1Eihvlmn1mr 1555327 205.3S -.rot 1896XI KY.m 479b4 I@~ ~ ~ l m l h u l p . n t b n I n 2,44vnr1n*lpn1an IBP.W3 20..d% 1B.W 32501 4 1 33. I 20 3.30imlhrlo.nnn I I W W 71Y.722 47Sa2 33319 f l Triolm 318174 2132M 47PtB 33166 22 nOtlmm 215,191 2 3 1 7 m 47la32 33 312 23 Diirobrl~b 315.732 232.644 A7.843 PlZPD 4 Ismclan 342.389 =;.I= 47.7B3 M 4 5 25 *-NDIW 2 8 9 ~47.8'10 ~ ~ %PBS 21 n-D.onn 131.114 tW.KP 41955 35225 z7 Cvf~oafiram ?I W t n v l h ~ l ~ m n ~ r r *1S6.757 IM.033 46.8Z3 JJ 270 S497 46.1580% 167.29 C~rcbhesaw 1E1,%7 1 9 4 . I M 46.5n J5Wt 3 wm,lc,ck,n.bm 50.10Q 55.042 31 C l h r r lflhvbml 07.11G 11.402 n P ~ o D . ~ i.rr-l..wl l 0 7 . 4 n 114.991 .80814 Zn9leh 33 18ul.N I~UWIHI 107.191 114.701 47.027h P ~ S L 34 ri1.2.0urw 1 W M 7 114.473 4 7 M a " 19 lMh 35 t~.ru.1.€lucmr 106.755 114.211 4 7 . 7 W =feen 3 ltarrrr ~ 133465 lumo 47.71~) m 37 I*UIUUM 101.118 1a.755 4Y .W* 31 21011 JI l I . & r w m r * 29242h 101,017 1 0 7 5 8 41.P I . Z h w i ~ 1273m iIY.141 aL4m 31 62d 40 IVCPYP70 53cw 41 Aolvllr* rY,OSS 139691 4t.843 3642 Bvru*rr 159531 107.MO a2450 DOOO 43 Tolunr lE%,s% lV4.DS 43.014 37478 44 Ethvlhnr.rr 165.002 194.407 42WO 37 935 15 a.Xvl*rr 1%5,0;10 194.415 42.M1 37 245 40 m.xrl47 #.XvIer* lll5,OSO 191.445 4 2 W l 37 131 1@0,?PO 1 8 7 . W 42.213 3 8 4 8 4s Slyrru 443.410 375Q1 211.324 1 ) 2 r # imp.opv~brny*ru 3 Z W . 2 2 . a I 8 067 . 28 ? Za CIu.1hVl.lcYW2 W.WS OQ.107 23513 51 Elh*l .*&I 11.9% ll.SS 52 Clrmmmwmm& 0 0 53 Clrbon d i o d e 21.912 23.791 Y n v ~ , w wit* 55 Sullur dm141 1 p . m ~ 10.1ai 54 4vmonib I 7 Air 12.a1 10.230 5d Mvdl-n ;
-
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59 Omvw 60 M t r m
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81 Chlarbn
0
6 2 W11.r
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1.879
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- - - - -
0
0
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m1.U ~31511
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285.89 27154 2
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6 1214 0 4 ~ 1,219135~ 1.33?0*.
-
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1.31342 1.391 W 1 W @ I 1.S4BB 193P2 1.407 73 I 1 1.r11027 1.412 UI I.42llS2 1.42566
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PHYSICAL CONSTANTS OF HYDROCARBONS(~$)
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No
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a
A
A
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DESIGN MANUAt
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)I
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-<
-
T EPlDPlEXPISUR
DATA
Ps.ud.
SecrIm critical ptrrnurr
Dale FIB. 4
: 2/85
15
- 16
TOTAL TEP/DP/EXP/SUR
PROCESS ENGINEERING DESIGN MANUAL DATh
SECTION
Ctirical Irrnpmralur*S N o m d boitinp point. *C
Revision : 0
brtr
: 2/05
P b y NO:
15
- 13
-
TOTAL
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
TEPIDPIEXPISUR
as-u
o Y smna IP t-
Revision : 0 Oat,
: 2/05
PIOI No :
IS
- 18
.C.hlara mr-M
cular mass, botllng d relative densltles
100
200
4 00
300
Mean awlaye boililly fminl. O
C
26 I
-
TOTAL
0
Revision :
page NO. :
DATA SECTION
TEPIOPIEXPISUII
Data :
2/85
15.15 M
DENSITY
VAPOUR DENSITY
Yapour densities or molar volumes can be caiculated from the equation :
Specific gravity of a gas
a
MWalr = 28.967
r
LIQUID DENSITY
The density of a multi component mixture can be calculated utng the summation af the component densities :
Wl= mass component = density component
P'
liquid densities for hydrocarbon mixtures can be estimated using. Figures 10, 1 1 in this section.
-
262
.
--
-
-
TOTAL
-PROCESS ENGlNeCRlNG DESIGN MANUAL DATA
TEPIDPIEXPISUR
SECllON
Pw Na :
Revision : 0
Date
; 2/85
15
F16. 18 kppeomimate t c t t i v n density of pelrslrum frotiionr
I.mp.l.l"l*
-.---
.~
----
26 3
.L
-20
TOTAL
Reuision :
0
Page NO. :
DATA SECTION Date :
TEPlDPlLXPlSUU
2/85
1S.U
VISCOSITY
UNm : Dynamic vlscoslty
r
I centipooc
=
0.01 dyne.rlcrn2 e
=
0.01 ern2/s
Kinematic viscosity : 1 centistake
Other quoted units for kinematic viscosity arc
Saybolt universal Saybolt fur01
r
0.000672 1bfft.s
Dynar&icv:yit
y
i
Redwood
Engler
conversion charts are sited in literature
VAPOUR VISCOSITY
. Use .
figure 12 in this section or
Calcolatt using :
i) r m =
Zp- 1:
fl
~~6
mlxturt viscosity
P= y; = component viscosity nw: = component mol.wt
ii)
3:
rn = A exp l0f)
Az
0-
(q.4 * *.Ql w) -r!.r (CW 4 14 n.ru,,-r) \a4
-
9tc +
3 .
0.01
MU
= component mo1.frac accuracy 2 5 %
T in
L o L T L kCo
@F
7-
C = ?.A )7J.
P'sRT
PL !oo.o
0.1 b
I A . ~L
P
R = L65.P
a+'
pr:%
LIQUID VUCOSlTY
. .
.
Use Figurt 13 in this stetion or :-
Calculate using :
1)
/-'a
[-
(y
The viscosity of crude oils with an API
> 30
hf
X; =
component m o l . f r ~ c
(sg = 0.88) can be estimated using :
-
logy- a (0.035HAPI) .C I a
centipoise
I
where
3%
54 71 88 104
.
1 1 1 1 ]
2.05
1.113 1.55 1.30 1.08
Corrcldtiolrs for tiquid vi~cosltypusscsa u general rclidbillty or
- 15 t
%
[ TOTAL 1 TEPIDPICXPISUR
I
I
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
Revision : D Date
: 2/85
VISCOSITY OF NATURAL GASES
Papa No :
15
- 23
.?LC
I
TEPIDPIEXPISUR
DATA SECTION I
Date
: 2/85
TOTAL TEPIPPIEXP/SUR
PROCESS ENGINEEAINO DESIGN MANUAL DATh S E C T I N
rcmpcrature 'F
QSTR VISCOSfTV CHWlT
96'6
Rsrisbn ; 0
Datr
: 2/65
P.01 No :
15
35
( TOTAL 1 TEP/DP/EXP/SUR I
PROCESS ENGINEERING DESIGN MANUAL DATA
SECTION
I
Revision : Date
O
: 2/85
FIG. 14
I1 15-26 I
TOTAL
P R O C E U E N G I N E E R I N G D E S I G N MANUAL DATA
TEPIDPIEXPISUR
SECTION
Ptrml~rlblmmzprnrlbn of 4 0.7 rtlrtivr density
Revision : 0
Date
: 2/85
Plpr
I5
NO :
- 29
~ P e r m l ~ ~ li~panrlon blr O l I 0.8 rrlatlvb dmnrlly
Prrmlrrlblr mapanrlon of r 0.6 rmlrtlrt density
a
I
10
II
T n n w r a i u r 'C
n
w
FIG.
17
rn
2 D M 3W04000 6W3 I D 0 Flnbl vrmssurn. hPb (ab.1
MmO
HYDRATE FORMATION
2TJ
-
TOTAL
0
Revision :
Pap.
:
DATA SECTION
TLPtDPlEXPlSUR
Date :
2/85
SPEClFlC HEATS
(HEAT CAPACITY)
1 BTUllb .F
BTU/lb O F kJ/kg *C
UNITS :
I BTU1lb.F
=
4.19 k3lkg -C
= 1callg.C
VAPOUR MiXTURES
.
Use figs 18, 19 in this section
.
Cp* Is a fuctlan of ternper*tlue and can be calculated ualng r Cp*
s
A + BT + C T ~
where A, 0, C are constants dependant on system composition
and T h In * R [K) Values of A, 0, C are cited In Kern, or Perry.
.
Cp* can be corrected for preswre if Pr and Tr are known uslng Figure
.
K = ratio of specific heats
8
this should also be ~ M r K t e d for pressure If required.
LIQUID MIXTURES
, Use Figure 21
in this section or :
, Calculate using Cpl Cpl
NO.
= =
- 1.34 G + T (0.00620 - 0.002349) 0.68 - 0.31 G + T (0.00082 - 0.0003 191 2.96
G
=
liquid specific gravity
(accuracy t 5 %)
1 rt3
k3)kG * C (T in 'C)
BTUllb
O F
(Tin *F)
CAMPBELL
15.30
TOTAL
PROCESS ENGlNEERlND DESIGN MANUAL
T EPIPPIEXP/SUR
DATA SECTION
Revision : o
Dae
Pagm No :
: 2/85
FIG. 18 SPECIFIC HEAT OF HYDROCARBON YAPOURS AT 1 ATM (NOTE UNITS ARE BTU/LB/*F)
TOTAL TEPlDPIEXPlSUR
PROCESS ENGINEERING DESIGN MANUAL
phra SECTSON
Rnision : 0
Dale
: 2/05
PW ND:
15
-32
8
Ut4~~D 4 0l l % b V . ~
a01
02
FIB.
0 6 01 ID
01 a4
P # # * c *~r e > w * , 4
=
8
19 HEAT CAPACITY CORRECTION FACTORS (NOTE UNITS ARE BTU/LB
M O L E / * F ) (8t attnospheric prtswre)
2 ?S
--
Revisiorr :
0
pagt N@r:
2/85
I>.%
DATA SECTION Date :
TEPIDPIEXPtSUR
THERMAL CONDUCT1VITy
BTU/lb *F
UNITS :
VAPOUR MIXTURES
.
Use figs 22,23 in this section
.
Low pressure thermal conductivities of pure gases and vapours can be estimated
ushg
:
k=
r(=r
I-Af
accuracy 2 8 %
k
-
y Cp -
B1Wh.ft.F
lblh-ft BTUIJb 'F
llp~as
. .
Usc fig 24 In this section or : Liquid hydrocarbon mixtures can b t estimated uslng :
a = WE' [ I =g
-
accuracy + 12 %
- on003 (r- 32)] k
rg
- BTU/h.ftaF
- specific
gravity
7 -OF
< > -93 32 < > 392 .78
mLl!3S
.
See Perry of Kern for details of metals, earths and building materials.
277 --!
1
mTnk TEP/DPIEXP/SUR
F I O C E S ENGINEERING DESIGN MANUAL DATA SECTIQN
vision : 0
Orte
: 2/85
Pagr No :
15 -35
lhcrrnol ronductiwity r o r i o lor goran
t.1m.d
f HERMAL CONDUCTiVlTIES OF HYDROCARBON L I Q U ~ D S Ft6. 24
r*..nr..?a
Revision :
0
Page NO. :
DATA SEtTtON
-
TEPIDPIEXPrSUR
Oatr :
2/85
15.36
LATENT HEAT OF VAPORISATION
UNITS s
BTUflb
1 BTUllb = 0.5556 kcallkg
kcallkg
. .
Use figures r 25, 26
Estimate using Trwtons rule :
A-2 l - ~ hcallgma~c accuracy 2 20 %
.
Tb s boiling point *K
For relief valve calculations use 50 BtU/lb If actual Lt.ht i s not known.
, Detailed estimation methods in Perry :pp 238
2 74
TOTAL TEPIOPIEXPISUR
,
PROCESS ENGINEERIN5 OESIGN MANUAL DATA SECTION
Revison : 0
a
: 2/85
Page NO:
15
-33
E3 PRECISION : 10%
L
LATENT HEATS OF V A P O R I Z A T I O H O F VAAlOUS LlbUlDS
FIG.
a 2 &-0
-
>
TOTAL
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
TEPIDPIEXPISUR
CPl
W2
QO4 Q05 03
0.2
0.4 C5 PRESSURE
!
Revision : - 0 :, Oatr
1
: 2/85
P w No :
15 -38
2
- ATM
LATENT HEAT OF VAPOURlSAflON OF
HYDROCARBONS
F I ~ .26
-
.2g
TOTAL TEPIDPIEXPISUR
PROCESS ENGIIIEEIING DESIGN MWWLL
DATA ACTTON
Date
: 2/85
Pago No :
(5
-39
5 K)/WmF . '
1.10
Rmwuan : 0
.no
7
TOTAL
Revision :
0
DATA SECTION
TEP!DPIEXPISUR
Date :
2/85
SURFACE TENSIONS
.I dyntlcrn = 10-3 ~ l m
Dymfcrn
UMTS :
N/m
. .
For surface tenslons of paraffins use fig. 28 To estimate surface tensions for hydrocarkn Iiquida/gas
a-.
'[nu . "-PI
use
4
(2.A
w r c e r baker
accuracy :2
=
1U %
18.07 + 2.996 M W for paraffins with M W < 100 = 278 + 2-55 (MW 100) for paraffins wiik MV > 100
P
c
Parachor
PI
r
liquid density iblft3
-
pv = . vapour density lb/ft3
.
papa NO. :
For oilagar mixtures can also use 0 . .
-..a*?
T
=
temperature in O F
P
=
pressure in psia
7
-
0.
zc1
A?L)
-
Lrp
source B e g s ' + Brill
2
r3
(- 6 . 0 . 0 ) 7)
U.40
.
PROCESS ENGlNEERlNG DESIGN MANUAL
.
TEPIDPIEXPISUR
DATA SECTION
Revision : 0
ma
:Z/ES
Pw No : IS
-41
TOTAL TEPIDPIEXPISUR
7
PROCESS ENGlNEERlNG DESIGN MANUAL
RarNon :. o
DATA SECfTQN
-
Ontc
: 2/85
Paw No :
15
- 44
FI6. 55 solubllny of watar In hydroearbonr
Z? 7 --
"
U
g a
I.
0
o
-.
0
-
.-C . .-> d
2 3
z
2 z CI
0
3 .
.
.
I
a v
-
\n'
* 2 .. 0
.-
8
z
-.
0
4
s- E3 . - 2
Y1 LU
.z 0
2
W
8 W
0
0
K
Q
. a
.
.
;S
E
Il ~Utt'l
.
r 1.9
3.m id1IWI XOOLeL.'o 3.051 +.'I LWI rclj
.%oc %OOI~SLS
1COl
.
3.0~~ C O L .
>.I'1F
2-02 0 co WC.IOI
WL'I rpc I 616 ~5
I'd
1st
LII-
ut-
X S L P B'S
J'S2
J.E I L W L
3 . c ~ IWIO '
3.s~
3 . CC
, -CU011 WZ
*
r ,*.mq,.r(y.wg 3 .I-.*-
.
3.M 1+'I
eUI'O
CLZ'O 13.01-*$1 Dl?'& LIIL'O WI
OIL
OS~C
1.um3 . Lral
mlna
rW IOEG H O ~ H ~
.-~-wrs
'
-
'Ulrrr LC1 LOLI'I
3.001 1LI'O 3.a * F L L O as'? >.st- Q 8'01
--
rm
~
aW ~ D
**I C.IO&
>.(rl COI'I
W'l L'TMI
--
C~P-
ZH ~
WZ4I c
--4r,lrtUYl
. ~~
LH r&r I
...&?LC
>WIUOI WICIOI
1Ll.t
0.r t P*ZL Cl? rbez
.-
-
U C r I
CC I
90
a WI
.~.
PPI bCEr' I
LC1 US?'&
LUl-
a . 7 ~ 1r w ml-
.
Lumlvwm
. . Crl
u?~'L
.~ . .
911
Pltrl
).0Ci4.0Z
r s W~E.IOI*QM
5sll.l
1.~511
""4.""
....
..fDdy...
-4!-wA
-
.*+V*U
qqq4
#.W4 :#,OH
%WPUW
""
bD . r,n
........ .................
'"'
a,(3..~q)R~'Ir!aod*r
*lmWdmrP
I*
qulq*
w d
I rn-4
.4,!W*
IIUWIO
.
' I V ! ~"!ZBU~
'e*rwdwrl 'mci#*q lonvr~
'Mu.? 3.Ot
.ryml.r
i . 4 ~
IW-SL
rayW e W
I-
..................................3 .................................. s~n w w ow113 w ww a1fll .....3-02 lwh..r~'llr '&u!3.r~~ q!ds "".."".."""
lq('9nlndl
).QLIS.Ol ...................... 1UIQ ........................ x ...................... 1 q m ) o& -nu........................... 3. .............
g.--4
".."."........................
lu(md
3. CIOL1 ......................... ....norn,rp,**W
"
~
puy~
P l~
......................,..*Y
''N
................................. & . Z %>'# ......................*.+-.-. 3.M "
'"...'...'.h-8. r q I- Btrrr
'Irpodw rv*v em05 -&!'.P mAwpu
..............lrDvr
@r
'wed
WWma
'mm8orrdur*l
EWIQ~
'3.04 a h u - a ................................. 3. ............................... 119e) *ry '-a44 .................................... P W J 3. Oqzbud ...................... 3. '119.1 9'101 **!@a ........................
m-'-'"m-"'-
LWO l*t)r.pa~~r ".. .........3.a. h 9 . q b li.n4J/rq IC'C .. ..m.-..o.,wuh......... 3.0~t3.w ...............................
ru~r~
1wtv
KI.HtMn
ELldl
ELC
c111
WQL
.
roi VOdl
W.I9
'W,,,4)CW
.IV+ Odyq l* 'mrpu! v*pwr)*a
>.'303 ...................3.w 'w
"... ."" ".." ",. ........................-" ........................
Cb
LSV'L
3.ua
W m --All ILI 9111'1
. nuauw 3.a IWC
Luo!wr
.
1111 101 LSPI ISrL
zl.voL
HrlO,H'J~H
'
su
l-40 *-I1wm tll
.I.-
CCSl'l
r
~.OL*CIOI CWIIad-
3 . 0 8 19tE'C
-1 C ' I O I @VEm '.'(@90) %34e
.I3 U'd &W9 MC'O
#to1
SEE
-I
LIS'Z bOCfOE)4&4Vt
OSC
6PC ? I'SOI
PEL'O lWL
SUll
Y I E'LOL d O I E W I C . t O l
w o
WC':
~ ~ ~ e 4 .3.08 o I L'SP WFLOI **I? ~ir~ot+o ~ 9 r 1 . LIC'O >.PS' I .)6tL'Q W.2 ~C~I'I
cr II or CMC
EvKlLLC Lac L C ~ ~ I 11'osl H ~ I O W ~ ,,qD.H'3)O" ~
>.St& >-PC 3.w
-
mdl(PlraI
-
'
WOwh-4~ W o -WIW
.
Z??
a??z
OCf l'l *111 CiE
SMS
zue
r'zz
,",,,,.n(Xrn)
---
'
CLLC
out
21-.
b1'911
. w tv
,,qmrj0
p s ~ 121 1i'SOt
(nm.odwoa.O)
4IZ
4++,r( , , , 6 ~)n
CI'CCI ,,,,t(tncm) I
..*-
.IPY.(UYIw I
O
..IYUIwII
3mQC1U I ' C ' IdC.2 3.0ClSP 1WQ 2150'1 3mOC.4bb ?.Ptl&IEOI MI . to1
V
qmlul*yr k l l r n a r ~l o 6 (m rmlr*dord 10-
i
!
.
.
DATA StmlON
PHYSlCAL PROPERTIES QF WATER
,
Il-mkn..
m.4
r+ T l l C
tim
4 wmr a d Skim.
.ruan.J('W
,
,
,
PROCESS ENGINEERING DESIGN MANUAL
'
~ e v i s i o h: 0
----
I
btntm a1 a b n r m & r l . ~u rn Iunetimo Fw tk d 1h ~IM, U.''In~#rm.LiomJ Cljef.J .T&-," vd. 8. M;' b Tim 011 snd 2-34.
I..
' h p k d h r E ~ b ,sc td,h n $1 ~m. hm W' lo 1Yn.L. 1 h. IW b.n. h V-mn. L.r,~cL&r. ad bbwd 5bmpkr*t*l m n n d rm id ira c a m . - WF. W. and ?.E-SSf tnr TI a m . 1C1. rru -n -I-. Irwl- d PF.IM
IWC,
nt K l '
I t .
.
n a XI Im
1
. P q b No :
PHYSICAL PROPERTIES OF AIR
P
Revision : 0
Page No. :
PROCESS CALCULATION SHEETS TEPlOPfEXPfSUR
Date :
EQUIPMENT CALCULATION SHEETS
AIR COOLER
SHELL AND TUBE EXCHANGER
PUMP CENTRIFUGAL OR AXIAL COMPRESSOR RECIPROCATING COMPRESSOR
TRAYED COLUMN VERTICAL LIQUID GAS SEPARATOR
HORIZONTAL TWO PHASE SEPARATOR ' HORIZONT A 1 3-PHASE SEPARATOR
PIPELINE TWO
PLPELlNE
PHASEAP CALCULATlON
AT CALCULATION
2/85
16.0
OPERATING CONDlTlONS AND NATURE OF FLUID I Duty
.IQ= I
Fluid inlet temperatwe Fjuid outlet temperature Fluid inlet pressure Air arnbiant temperature Overall heat transfer coeff. l ~ e Table e 2 and/or a t t a e a
IT1 ITZ=
1
kcrl/h I aC 1
-
'C
-
*C
*C I FLUID AT^ = T l T 2 IF= bar abs 1 Itl= I 'C I INLET ATL TI t l = I'U = i kcal/h m2 *C I
I I
-
work sheet)
I
(Based on bare tube area)
1
NOT@
STEP 1.Optimum number of tube rows for U selected 2. R = At air/ t m 3. T1 TZ/TI tl 4.Y =At air/Tl t l . 5. Atair s Y x (TI tl) 6. Exit air temp t2 =&air + tl 7. Average differential temp. At, = dtalr
-
-
-
!N=
I
I
(N~VC
N* 4)
lR=
1 I
I
(curve
N* b)
1
*c I I *C I
IY= I
-
I I t2 m I I 1 km* 1 T . 1 . I 8. Bare tube surface A r LA= 1 Ux tm I I 9. Bare tube areatrow Fa=AIN I Fa = 1 LO. Tube length IL- I 1 1 . Tubeslrow TR = FdLlt0.08 ! TR 1 12. Cooler width W=TRxO.O635 1 W 1 13. Total fan power =Fa*0.795 1 Fp I 19. Number of tam I NF I IS. Fan diameter I FD I 16. Powcrfian Fp/NF I PF I 17. Estimated weight 1-M I 4.88 (36.4X9.35 NIxWxL 1 1 IAtair
-92
*C
I 1
'C
1 I I
rn2
(curve Na 5)
I m2 I m
5
1 3, 4 , 5 , 6 , 7.5 or 9 m are common I (I" OD tubing)
rn 1
kW I
t
max. fan dlam = 4.6 m
kW
1 1.
kg
I
m
(including rnotars)
I
Notes : Curves numbers refer to Process Dedgn Manual Chap. 4.
246
EZU 4223
PROCESS ~ ~ L C U U ~ SHEET O N
TOTAL
ITEM:
AIR COOLER
T€*mO?QIC E X P I U I
sv
1
r nr
- DATE
I
101
~mt
b.! 1406 he..
I
urvl/
. 1,
LIQUID COOLING LIQUID VISCOSLTY AT
s
T2
+
2
GLOBAL HEAT TRANSFER COEFFICIENT :U = (Read curve n* 1)
2. GAS COOLlNG
MOLECULAR MASS :Mw'=
GLOBAL HEAT TRANSFER COEFFICLENT (Read curve n4 2)
:U =
3. TOTAL CONDENSATION
Tl-T2
=
*C kcallh rn2 ' C
GLOBAL HEAT TRANSFER COEFFICIENT :U = (Read curve n* 3) Ir.
PARTIAL CONDENSATION WITHOUT LIQUID AT INLET
4.1.
WGl
-
outkt gas flowrate WG2
-
inlet gas f lowrate
outlet liq flowrate
Tl
s
VL2
- T2
C
GAS MOLECULAR WEIGHT AT
y,
HEAT TRANSFER COEFF. Uc
=
kcauk rn2 *C
(Read curve n* 3) kcal/h m2 'C
:
HEAT TRANSFER COEFF. Ug (Read curve no 2)
GLO~AL HEAT TRANSFER COEFF. kcallh rn2 *C
SELECTED GLOBhL HEAT TRANSFER COEFP. t
=
u
Curves refer to PDM Chptr. 4.
a4 7
L
m
TOTAL
-r
TEI1WP:DV:E X W U *
I*
cnu
1
PROCESS CALCULATION ,SHEET
AIR COLERS
HEAT TRANSFER COEfflClENT OATS I ( 101ilnt
ITIW :
w.. 101No
I
ntv
1 ;
2
WITH LlQUlD AT INLET'
inlet liquid flow rate
WLl
-
kglh
outlet liquid flow rate
Wtt
-
kgfh
LlQUlD MOLECULAR WEIGHT AT T1
+
f2 =
7
LIQUID SPECIFIC HEAT AT
QL
-
t
v
T1 + r2 CP1= --?-
) x CPI x [Tl
- T2)
=
outlet gas flow rate WGZ
-
GAS MOLECULAR MIGHT AT-
=
'
inlet gas flow rate WG1
GAS SPECIFIC HEAT AT
kcal/h
kglh R%h
T 2 CPg =
kcallkg ' C
2
= f W C l +2WC2) x CP& x (TI - TZ)
QG
kcallkg f C
=
kcallh
CONDENSATION HEAT Pc=Q-QL-% LIQUID VlSCOSlTY
kcal/h cpg
AT 71 T2 +
2
LIQUlD HEAT TRANSFER COEFF. (Read curve n92)
Ur =
kcalfh rn2 *C
GAS HEAT TRANSFER COEFF.
U8
kcalfh m2 *C
Uc =
kcal/h rn2 *C
. (Read curve n* 2)
CONDENSATION HEAT TRANSFER COEFF. (Read curve n. 3) GLOBAL HEAT TRANSFER COEFF.
U=
A
$+F+$
SELECTED GLOBAL HEAT fRANSFER COEFF. r -
&y TE?~OCV~PIZ~?ISU(I
6
*
I
CHI
OATE
.
U =
kcallh m2 'C
=
kcal/h m2 *C
U pq Y
PROCESS CALCULATION SHEET
AIR CoOLeRS HEAT TRANSFER COEFFICIENT
4
1 lO# T111f
nzM: ~o
.
100 ho
I
I
l t ~
-
1 I
! ITEM: I
I I I
I
Q
DUTY
II
I I I I I I I I
I T2-tl
I
Inlet remperature TI Outlet temperature T2
COLD FLUID 1n:et temperature tl I Outlet temperature t 2
I I LMTD from formula(l) I
I I I I I I I I I I
.
I
I I I
I I
t2-tl
-
I I 1
TI tl TI-T2
1 1 1 1 I 1
p=t2-tl
rl-tl R=Tl-T2
m
I I
keal/h
NUMSER OF SHELLS F = LMTD correction I factor (3)
I I I I
NOTES : II I I I I Indicate temperature I I I
1
I 1
'C 1 ' C . 1
I
'C 'C
-c
1 1 I I1
1 1 I II
'C
I
I I I
I 'C
I
'C
I
*C
1
I I
I I I I I I I I
I I
-
rn2
1
I
Shell
I
-
I I
I
I I I
I
1
I
I 1
I I
I 1 1
2
I I
1
II
I I I I
I I I I
I I I
I I 3
f I
I 1 I
4
I
I I
I
I
Including fouIing
1 I I I
I
I
I 1
1 U.LMTD ORR I I ESTIMATED TUBE LENGTH FTlrn) 1 ESTIMATED SHELL DlAM I inr(mm)'l I I I I I ESTIMATED WElGHTBundlc 1 - tonnes I
1
I I
I
I
I I I I I I
.c
1 Fig. 2 I ' L 1 I CORRECTED LMTD CORR. I I I I HEAT TRANSFER COEFF. U I kcallh 1 TABLE 3 P a ~ e4-10 I m2'C
I I HEAT TRANSFER AREA I 1 A'.+.
+! I
VALUE
I
I
I HOT FLUID
I I I I I
I
I I
factor
'
I I I I I
I
I
I I I I
1 tonnc~ 1 1 tonne* 1 1 I
1
t 1 1
I 1 I
1 I I
247
i!i&
PROCESS CALCULATION SHEET ITEM:
StPIDD?'D~P~ X P ~ S U U
av {
t
cnx
I
SHELL AND TUBE HEAT EXCHANGER
oat€
JOB nnr
N,
ror NO
.
I
REV
I
-
lndicstc pressure, elevations and system sketch
PUMP TYPE r Speed t
FLUID PUMPED r Liquid : Pumping temperature T r Vapor pressure at T I Density at P, T I Specific gravity at P, T r
'
I
.
SUCTION PRESSURE
Min. Origin Pressures + Static head at LLL = (m x sg x 0.0981) A P suction line
-
-
baral m bar t bar1
2
1 Othu I '
l
+ vapwr pressure correction . m 1
I
TOTAL AVAILABLE NPSH
m
MAXIMUM.SUCTION PRESSURE Vessel
I II
Statlc head at HLL
%
I
. 1
bara bar
bar
bar br bar bar
1
DlFFERENTlAL PRESSURE
1I
1 I
1 I I 1
I
1
r ---
I
..*---
*I
300 PROCESS CALCULATION SHEET
I
CHI
.
1
I I I
I 1 (2)
1
I
,
I
'
I 1 (31 I 1 1 141 I !((I
I 1 I I
-
.
-
ITEM :
PUMP
TECWoPXWP'tI(P I V
I
P ~ W L RREQUIREMENTS
I * .
TOTAL
11 1
I
I Estimated weight
Em7 sun
I
I I bara I bara I I bar I m I
I 4Fig3for 1,)
-1
I I I
1
Design operating load i411qmkWI
I
net bar.
I
I
I I Brake Horse- ower = (l)x(2) kW I MAXIMUM DISCHARGE PRESSURE !I+ 7si. . I P1 1 bard I Estimated mator size kW 1 Max. suction pressure Normal pump AP x 120 % bar1 I I I
I I 1 1
bar I
PRESS bara
1
net bara
II
*
TOT MSWARCE
Suction pressure
~ b d ]
m3/h
I
1 Discharge pressure I I pump 'A P 'I
bar 1
cP
I I
bara I
PSV setting
m3/h
Delivery pressure
m 1 m
Design margin : Design llow at P,T (1) :
I Static head f d P control valve(s) I A P txchan cds) I A P orific 51 1 AP 1 OP lint 105s
I
Line loss
(reL
I I DISCHARGE PRESSURE I
1 I
I I PUMP SUCTION PRESSURE 1 I NET POSlTlVE SUCTION HEAD 1 Static head at LLL
..
Viscosity at P, T Specif ic.gravity Normal flow Q at P,T :
*C
bara kglm3
OAT€
10.
rant
He.
I 0 0 lro
1
rtv
I
r 1
OpER4TING CONDITIONS SUCTION PRESSURE PI = DISCHARGE PRESSURE P2 =
bar a bar a
TI =
SUCTION TEMP*
'C
i
SUCTION f LOW ACTUAI. VOL FLOW
PRESSURE RAT10 P2/Pl
W + V =
*K
MW
kgir m lh
GAS DENSITY AT
a
SUCTION =
kg/rn3
NOTES
STEP
PC
1. GAS PROPERTIES 2. POLYTROPlC EFFICIENCY
3. AVERAGE 8 = MCplMCp-1.99
=
9~
=
SEE FIG. 2
8
=
ESTIMATE T2
3
4. DISCHARGE TEMP ~2 = ~ l ( a )
5. DETERMINE Z AYC
~2
SUCT
2 1
DlSCH AVG
bar a
Tc
'K
K
t
C
=
REPEAT STEP 3-4 IF ~2 IS DIFFERENT FROM ONE USED IN STEP 3
=
Z2
=
Z
r
6. CALCULATE GAS HORSEPOWER G H P = Z X R X W ~ ~ X ( T ~ - T~ If )j p
k
R = 8.314 kJlkgMOLE .*C
kW
tHP<800 kW 8 0 0 < < 10 MW > I D MW
M W x 3600x(X- 1). 7. CALC SHAFT HORSEPOWER PS = GHP x (1 +
FIlOO) x I /. ,q
PS
8 r ESTIMATE DRIVER POWER
ELECTRJC MOTOR PS x K PO PO GAS TURBINE PS x (1.14 + K)
=
- --
kW kW
k
=
F
'Im
5.0
0.96
3.)
0.97
.
0.98
1.0
K = 1.15 K s 0.02 TO 0.04 WITH GEARBOX
9. ESTIMATED PACKAGE WEIGHT
COMPRESSOR-DRIVER-LUBE
NOTES I
M
=
--
kg
(SEE FIG 4 )
- . 301
&2.Lb
TOTAL
ED3
1IPIPW~lhlXI~IUR -(.CUK
j
PROCESS C&LCUCATION SHEf T
CENTRIFUGAL OR AXIAL COMPRESSOR DATE
f JODrrne
lllY :
wo. : 10s mu
1
UIV
1
-
t OPERATING CONDITIONS
SUCTION PRESSURE P1 = DlSCHARGE PRESSURE P2 =
TI
SUCTION TEMP.
V
PRESSURE RATIO P21PI =
bar a C
o
MW
K
=
W
SUCTION FLOW ACTUAL VOL FLOW
bar r
,
z
kgjh m /h
c
GAS DENSITY AT SUCTION =
STEP
NOTES TC =
1. GAS PROPERTIES
PC =
-
2. AVERAGE 8 = MCplMCp 1.99
*K
bar r
II =
.
3. CALCULATE DISCHARGE TEMP Tlx
l-2.
(E)Y
T2
= m
5. DETERMINE t AVG
kdm3
SUCT
Z2
AVG
Z
Repeat 2
- 3 if T2 differs
from that used In STEP 2 ".
*
Zl
DlSCH
'K *C
=
= 7
6. DETERMINE OVERALL EFFICIEN&
'le
s n FQ 3
'lg =
7. CALCULATE GAS HORSEPOWER CHP =
Z x R x W * 11 x ( T 2 - T I ) M W x 3600 x i 1 1)
-
8. CALCULATE SHAFT HORSEPOWER
GHP=
kW
PS =
kV
R = 8.314 kJ/kgmoldC
PS+ GHPlf x v g
f = 0.96 t o 0.97
9. CALCULATE DRIVER POWER Electrical Motor
Po = 1.15 x PS.
Po =
kW
30 2
PROCESS aLcumnoN SWEEI
lmm
TOTAL
ITEM :
EEu
RECLPROCATING COMPRESSOR
TICmwmMXCnVn
mv
cut
O~TI
JOBnnr :
:. IOWUO.
:
IIV
1
TRAY CALCULAnON SHEET
Name :
Columm item :
Number a! passes r
Tray number : to =
.*c
PQ =
bar .a
1. VAWUR.AND LIQUID T O TRAY
I HYDROCARBON :I I .LIQUID I I VAPOUR 1
I TOTAL
-I
I
I
1
I
1
1
I I
I
I
I -1 I
I ! I
I
1
I
I
7 -
-
'I
I
I
I I
' 1
I ---
I
Compressibility factor Z
Kcduccd Pressure Pr
Reduced temperature Tr
From charts Figure 1,2 or 3 page 15-15
?pour actual rate
I ~'
--
Cv=k&= Dv h.
.$W
I 'IEP'DWrDlP'tlCSUR my
OLTt
CUE ,
.
&
m3h
309. PROCESS ULCULATION SHEET
Sheet 1 of 4
ITEM:
TRAY COLUMNS
!
1 Ion tlm,.
WO. :
.
.
10s no
r
REV
I
2. LlQUlD FROM TRAY to =
D15
.C
'
Use figure 10 page 15-20
kg/m3
Liquid flowrats =
DL a t to r
kg/m3
k&
3. DOWNCOMER DESIGN YELOClTY YD bg
TS : = DL-O":
m m T R A Y SPACING" kdm3
m3/h/rnZ From figure 2 Page 3.10 v D dsgo = from table 1 Page 3.9 System factor Kl rn31hlrn2 . VD dsg = VD dsgo x Kl = 4.
V A P ~ U CAPACITY R F A f f O R CAF
.
TS:
mrn CAF 0 = from (Fig.3) on page 3.10 from (Table 1) page 3.9 .System factor KZ = .. C A F = CAF , x K 2 , = 5.
VhPOUR E F F E m V E LOAD V Load
6. APPROXIMATE COLUMN DIAMETER DT =
D m ,
30Y PROCESS CALCULATION SHEET
TOTAL
Em3
TtP'DDCPC.TXP~SUR
rn f r m Vlg.4) page 3.1 1
Sheet Z of 4
REM:
TRAY COLUMNS
*o. ;
1
riv,:,
COLUMN HEIGHT ESTIMATION
I
I
_
1 "a
I
a. HI : See design details on vertical vapour-liquid separators. Minimum distance for H1 will be one tray spacing. Minimum distance between
inlet nozzle and top tray 300 mm.
HZ :trayspacing x (number of actual trays - 1) No actual trays = theorctjcal traysltrray efficiency
= 50%
for tray efficiency see section 22. page 3.3. Assume
Actwl trays a
Note.: ifthe column diameter changes over the length, the transition piece will be h*
~
= @0l
- (2)
long and t i 2 r i l l increase by this amount Selected H2
I
*-
..
TO~AL
,
PRQCE%$ CALCULAnON SHEET . , .. IttM.
TI~AYCOLUMP~S T CP.~bP#Pl@*txt~SUt B
cur
1
'
.
DATE
I
...
!I O B T I ~ L ~,
5
mm
Sheet 3 of 4
no..
1 ror no
I
ttu
I
..
c.
..
H3 r H3 s h l + h2 hl = tray spacingx 2 =
.
mm
h2 = h6 + h7 + h8 (see vertical separator sizing) h6 = hold up time
..
.
For
production flowing to I
.
anothci column
. . . .
. t
r
2
storage
10 5
a furnace
another unSt . reboller/heat exchanger
h6 =
15 rnh
rnm
h7 =
5
rnm
+h2='
Hf = h l + h2 r
mm
h8 :
rnm
.
mm
. TOTAL COLUMN HEIGHT
. rnrn
Selected H3 =
e
HI + H2 + H3 =
mm
~.
p
6.
PRDCESS CALCULATION SHEET ~ h & t4 of
TOTAL
1EPrDDP:DIPJELHSUI
I
C ~ Y
.
~ E M :
Bf.1 81
4
PATI
/
TRAY COLUMNS
ma:
IoRTITLt :
lOrnN0..
.
]
REV
i
:
CALCULATlON SHEET FOR VERTICAL TWO PHASE SEPARATOR
EOUIPMENT N* Operating data :
,
'
Pressure (operating]
bara
r
Temperature (operating) Gas MW Gas flow rate Gas density (f,P) Actual volume flow Qg
'C
=
Mesh pad
Yes No
: :
--
.
Liquid flow rate Liquid density (T,P) Actual volume flow Particle size
kg/h a kdm3 = m3/s
. .
.
Liquid description :
=
=
kg/h kg/m3
=
m3Irnln r microns =
Estimate Vs using Fisure 1 and 100 micron curve If P < 50 bar and )J < 0.01 use Fig. 1 and f 50 microki f > 0.01 use calculation for Vs ~f ~ > ' 1 0 b a r o r
1. Vapour-liquid settling velocity :from Fig l/calculated
Vs a
c =
'
vs =
m/r
m/s
Delete as applicable maximum velocity
2. Derating % = 85
-
Vm
=
m/s
= Calculated drum fi =
Drum flow area
3. Actual volumetric gas flow
m3/1
m2
mm
mm
SELECTED DIAMETER = 4. Required liquid hold-up timer
h5 : HLA
- HLL
h7 : LLL
-
5. Mesh pad:
LLA Yes/no
r
min
=
m3
=
mifi
=
rn3
thickness -s .
mm
. m
mm
rnm ,
Em2
&jetY;[
PROCESS aLCULATION SHEET
I
E ~ C A vAwuR-Wu1o L SEPARATOR
I .-.CII.
30? .
ItTM. YO
Sheet 1 of 2
6. Hci~h:calculation
=
mm
1
U
h4
-
mm mm
h3 :
=
mm mm
h5
-
-
.-
=
mm mm
-
mm
rnm
300 mm for side LC
=
rnm
h6 + h7 + h8
F
mm
TOTAL VESSEL HT TAN#AN
=
-
For "drymvessel
-
A.
'
s
.WLL
LtL
=
mm
h8 :
.I:
-
5
h7t
N
h6
50 % of @ or 600 mm
From step 4 or 350 mrn FromstepIorlSOmrn 150 mm for bottom LC
h6 r
% I
4:
bl
=
With mesh :hl + h2 + h3 No mesh 2 hl + h2 + h3 8 60 % d or 800 h9 : 400 mm + dl2 r d = inlet not2 P hS : From step 4 or 200 mm
I+
L
t 5 % of 0 or 400 mm [Use mad h2 : mesh pad
hl :
TL
ua
I d
mm
t
7. Wall thickness
. .
P= c=
DESIGN PRESSURE CORROSION ALLOWANCE
mm
Max stress : 5 = 1220 bar CS
LO00 bar CS Joint efficiency (.a51
mm
Diameter D =
hrg
t
S=
= Z X SPXx ED- I ~ Z +P C
E=
-
tmin = Df800 + C
mrn
8. Veswl weinht (Flg. 6) t=
mm
L=
m
Dr
m
shell \eight = Head weight = (t x 201
b
ks
dx
TOTAL WEIGHT =
h 30 S T
1OTAL
m.
VER'llCAL YAPOUR-LlQUID SEPARATOR
IEC'DDC'D(PIEXMUR I
I
1
I
----
-
"., . -
.
Sheet 2 of 2
PROCESS CALCUUnON SHEET ntw :
-
. .-.. "
I
..
I4
~ of
CALCULATION SHEET FOR HOMZONTAL 2 PHASE SEPARATOR TANnAN fL' )
t
.
:; .@ 0
HLL
0=
LLL
ht
. h2;
3
EQUIPMENT N * : DESCRIPTION r
Head type cllipticallhcmispherlcal Indicate on sketch if 2emlstcr mesh required +
* Delete as applicable Operating data r Operating pressure bara Opcrating temperature ' C = Gas molecular weight
x
Gas mass flow rate k d h
=
Q g actual val f b w
m3/5
= =
Gas vlseodity
CP
=
Gasdensity
T, P
kg/m3
Liquid nature : Liquid flowrate Liquid density T,P Q1 actual vol flow partide size
I. Vapour-liquid settling velocity : from Fig. I/calculated C
kg/h kg/m3
Vs =
*
=
m3/min = microns = mls
=
* Delete as appliabIe
-
2. Max. vabour'velofity
Vm=VsxfxL
LID 3 3. Actual vapwr volumetrlc flow Qg =
m3/s
mlr
Vmr
b
*" = %=
m2
30 7 PROCESSCALCULATION SHEET
Em3
-
&?P)
CALCULATION FOR HORlZONTAt
2 PHASE SEPARATOR
IEPIOOP UIPIE~PLSUR
BY
C ~ K
DATE
IOD TlTLl
.
Sheet 1 of 3
ITEM : WO.
:
JO@ no
RlV
4. Nozzle sizlng Ivelocity limits (rnfs) = Inlet r 7-13, Gas outlet :15-30, liquid outlet 1-3 i
lnlcr flow =
;
Actual vel =
n
Nozzle ID =
m3/s
mlr
(+ 10 96)
!J2 : Gas outlet = Li@d outlet =
m3/s Nozzle ID = m3fs Nozzle ID = w
n
Actual vcl
mls
a
Actual vel =
mla
5. Drum sizing For trid I t,,
= 4 min
voL
required r b x Ql =,
I TRHL Selected h/D Vapwr area Av % Total area (Fig. 3) Total area At Liquid arcs Al
a
Calculated drum # Selected drum 0
m2
m2 m2
mm 0
-
mm
LID (3 4) Flowpath length
L
rnrn
Tan/Tan length
L1
mm
HLL hclght Volume at HLL
mrn m3
LLL height
mm
Volume a t LLL Surge volume (HLL
- LLL)
Calculated treS
m3 d min
I
I
I 1 1 1 1 I I i 1 1
I
I I I 1 I I I I I I
I I I I I I I
.
I I I I
I I I
I I I I
1
1 1 1 . 1 1 1 I 1 I 1
I I I I
I I ,1
1 , I I I I I 1 1 , I I
1
II -
t
I
I L
I
I
I I
I
I 1
I I
1
I
mm
r
m m tanltm
d
T m / t a n l e n g t h L 1 = L + If x l l + 14 g2 (ignore this correction if D < 1.2 m and use L for volume calcs. For trial 1- use &d ignore heads).
b)
If VOL HLL is less than rquired surge i n c r e a ~D, L or h/D or reduce inspection).
I
1
1 I SELECTED DRUM t DUMeTER
I
'
I I I
I
I
1
.
I
I I I I I I I
I
I I I
I I 1 I I
I
1 I I
I 3
I I I
I
1
1
NOTES r
m3
L
trcs (by
3 l0
FvZa
&qJJ
PROCE5S LnLCULLITlON SHEET
CALCULATION FOR H O R I Z m M
2 PHASE SEPARATOR
TE~QOP*RV XP'~IUI
BY
cnr
D L ~ E
101 TITLE.
sheet 2 of 3
nt~: 116.: IOI YO
.
I
REV
'1
I
L
6
Wall thickness
. +
DESIGN PRESSURE CORROSION ALLOWANCE
P=
barg Max stress
C=
mm
CS = 1220 bar
SS = 1000 bar
5=
Joint efficiency E =
=
p-
PxD
+C
mm
5
8. Vessel Vfei~htFig. 6)
L=
rnm m
Shell weight = Head weight =
D=
rn
It x $r 20)
t=
kg kg
k*'
TOTAL WEIGHT =
.3 PROCESS CALCULATION SHEET
L q T J -'
TOTAL
CALCULATION FOR HORIZONTAL
E a 3
TIPIDDPOIP IXPISUR
BY
CWK
A
T
I
2 PHASE SEPARATOR
] 101TIT11
Sheet 1 of 3
"EM :
Ha' 101No
1
mtv
-
-
II;
f ANITAN LENGTH L' FLOW PATH LENOTH L
-
1
Or
t
TO
.
Amend rkateh if boot requited instead of bfflr .indicate on sketch
HLL
if mesh r.quir+d
.Heads :2 :1 slliptical /hemisphsricaf
EaUlPEMENT No : DESCRIPTION :
1 0. Operating data i Operating pressure a = Opcratlng temperature 'C =
-flowrate
PC Ql I."
GAS MW
= kgfm3 =
Mass
kglh F Density T,P kg/rn3 Vol flow T,P m3/rnin =
CONDENSATE Flowratc
=
Viscosity
cp
Flowrate Density T,P VoI flow T,P Viscosity
kglh
kg/h
Dtnslty T,P Qg Vol flow
m3/h
P
Particle size
WATER CUT
--
PW Qw
microns=
P "'
r
I. Vapour-liquid settling vclwitr: from Fig. Ilcelculatcd C
*
Vs =
-
kg/m3 =
m3/rnin = ep =
ds
,
5
Delete as applicable 2. Maximum vapour velocity
YmrVsxOd5xL
b
LID = 3
3. Liquid-liquid settling
Ut = 0 . 5 1 ~ 8 [ ~ ~ - f ~rndrnin ]
Oil in water
U+il=
mmlmin
Utwater =
mmlmin
)c. I J =~ 0.1 101[-.]
Water in oil
rnrnlrnh
re
31s PROCESS C&LCUCATION SHEET
TOTAL
m
CALCULATION FOR HoRIZONT&
T~F,DOF.~)I~~~P'SUR
-
67
I CHK 1
OAT€
I
3 PHASE SEPARATOR 101 TITLE
-
Sheet 1 0 i 4
1 7 ~ : NO.: to6 lto
.
ltlv
rr. Nozzle sizing r velocity limits (mi$)= Inlet ! 7-13, Gas outlet 11-30, Liquid outlet 1.3
m3/s :.
nozzle 10
actual vel m/s
1. Inlet flow I (+ 10 %I 2. GM outlet I 3. HC outlet r 4. Water outlet r 5. V e s x l sizIng For t r i d 1 use
tresoil
[HLL-LLL) = 4 min
OIL SECTION
I TRIAL Selected h/D Calculated (Qg/Vm) Av as % AT (Fig. 3) Total area Liquid area
Av
At A!
-
Calculated @ Selected I
m2
Flowpath length
L
TanlT an length
L'
HLL height Volume at HLL LLL height Volume at LLL Surge volume {HLL
h1
LID U 5)
h2
- Ltt]
Calculated t,,
m2 m2 mm
I 1
mm mm
mm m3 mm
m3
m3
I I
I I 1 I
tan-tan length Lo=
I I I I I I 1 I 1 I I
I I I I I 1 1 I
I I
1 I I I I
3
1
1 I I I I
I L + Ij x
1
I 1
1
I I I
I I .I 1 I I I
-
+ 02) mrn Ignore if
.
I
1 I I
1 I I I I
I I
I I
I I I
I 1 I I
I
I I I
I
I I I I I I
I
I I I
I I 1
I -1
I a)
I * I 1 1 1 I I I
1
min
Notes or comments r
1
I mm
D
I
I
I
I I I
I
I I t I
I
I
1
I
I
I
D < 1.2 rn
-
- $3
ky>m
Ff OTAL Jrn
T~PDDHQ~FTXPSUR
.i.w
I
I
ewe
I
PROCESS ULCULATION SHEET
CALCULATION FOR HORIZONTAL 3 PHASE SEPARATOR 1 inn rlrm
'TtM:
Sheet 2 of 4 .--
no : IMw e
I
UIV
1
WATER SECTION
Trial 1
= 213 x L r
8
rnrn [rwndcd)
11 Rl AL 4 1 I m3lmin I I I I I
Total liquid vol f lowrate Qw
+
QI
I
8
Baffle distance Liquid area at HLL Horizontal vcl at HLL Ut water b t e p 3) Vertical fall from HLL =BxUt/Vi HLL vertical fall
A1
m2
V1
rnrnlmin mrnlmin
-
i
i
I
i
I
I I
mrn
mm
vz
rnmfrnin
mrnlmin .
mm
hS selected LIL level
mm
h6 selected outlet height
mm
ql water vol at H E (upto baffle)
m3
LlL (upto baffle)
m3
q3 water voi at NIL (upto baffle)
VOI
i
mrn
Horizontal vel at LLL Ut oil (step 3) Vertical rise within dist B * 0 X UtfV2, = mex. outlet height
q surge =
I
rnZ rnrnlmin mmlmin
A1 VZ
Check oil rise r
94 water voI at outlet (
I
mm
Selected baffle height . h3 Selected HIL level . h4 (adjust h3 and B if necessary)
q2 water vol at
I
mrn
Liquid area at LLL Horizontal v t l at LLL Ut water (step 3) Vertical fail from LLL = B x UtlV2
'
I
rnm
I'
-
(ql q21
. ,
i
3
I
rn3
'i
m3
i
I
I I I
min min
swge time q surge/Qw
residence time q3qb/Qw
calculated oU residence time (upto baffle) Vol (NLL NIL)/Ql min
-
I I J
I
I
I
I I
1 1
I
I
I
1 I
I
1
I
'
I I I I 1
34-
Em3 TOTAL
PROCESS CACCUUTlON SHEET
nEm '
CALCULAf ON FOR HORIZONTAL 3 PHASE SEPARATOR
TE?.WC OR,I X M U I m
a
I
I 4""
?ST, r
Sheet 3 of 4
..
ne.: +
I
~
L
Y
~
I
nru 1
6. Wall thickness
. .
DESIGN PRESSURE CORROSlON ALLOWANCE
P=
k g
C=
mr(r
Max stress
CS = 1220 bar 55 = 1000 bar
s= Joint efficiency t
=
PxD
+C
73izlm,
=
E=
mm,
8. Vessel weight (Fig. 61 t
=
Shell weight = Head weight (t x D\ 20)
mm
L*
m
I3 =
m
kg
k!!
1OTAL MIGHT =
tfg
..
-31 5 <
i f
PROCESSaLcuanoH SHEET CALCULATION FOR HOWOmhL "'M-
3 PHASE SEPARATOR
tf P DDPRIP'EXPISUI UT
cnr
01Tf
101t a t .
Sheet 4 of 4
wa: 10s Nn
MV
-
OPERATING DATh
-
GAS FLOWRATE DENSITY
Wg
VISCOSITY
Yg
kglh = kg/m3 = .. cp
Dg
*C
=
PIPELINEDIAMETER D cm LNTERNAL AREA A m2
=
f
k&
DENSITY
VISCOSITY
W1 01 Vl
SURF TEN
st dynestcrn
FLOWRATE
-
FLOWING TEMP
LiQUiD kg/m3 =
cp
m = m =
PIPELI~SE
LENGTH L Vertical change Ah
s
STEP
Wg
Bx + 210.3
I
I I BY r 1
I
I
dmxvel
r
~1213
11
.
2. CALCULATE Apgas
I
I Re = I I
35.368 x W E Vg x D
I Friction factor ( ~ o o d y ) I I ~ P =G 6.254 x f x,wg2 I
D
I
gxD
3. CALCULATE ApLlQ
1 Re = 31.368 x W1 Vlx D I I
I
I A P L 36.254 x f x ~ 1 I Dl x D> I
'
I I
I I I Rex' ! I
I I I I I 1 1 I I
I
I F
I
ldPG I
.-
a
bsrlkrn
r - r n
%LF~DPd'TilP.T XP.%UR CCtK
1-JL
Ohti
1
()osntir ~ * * f i r c ~
40.7
I
I
scr
rf
10-9
I t
I
I
1 I I
I
I I I I
I
1
I I
bar/km
1 II I II I 1
I I I
J I -1 I
pAOCESS a L C U t 4 T I O N SHEET
TWO PHASE PlPELwE P CALCULAnON
CC
1 I
I I I Re= I l f = I I A P= ~ 1
rcr
I
I
z z v --
f TOTAL
i
1
1 I
3 16
-
?
I
I I
=
I
11
I
I
I '-I1
REGIME FROM BAKER CHART
1
I
1
ma*
I
1
=
st I
7.087 x W
I
I
I
1. DETERMINE FLOW REGIME
I I
-
NOTES I -
-
1
= =
Sheet
' ' of
nim. Ma:
I
108 NO..
..
*EV
I ;
. I 1
I 1
4. AVERAGE VELOClTY
I
. \
Y,.
I I I
1 1
3.537
(
1 I v,=
3)
+
I I
x
I I 1
I I
* (w)
I X =
I 1
1
mw-
1
.mnu
1
L I
I
'
m a
I I I 1 I
--'TAVE
.
E.u .
* I . mu7~ #
.I,IN
rn b
I
1
I I
I
I I t I
s
*
r.n-ou3
-
PH
1
LII*
I
d
aY>.&*d
I
l u d t U m U
II I I I I I I
VS
iZ&~
vs
I
- L"_ 1 q # 3
t
I
_. -nt -
-
r h
-
=o;llrr
c
~
H
- -X
FLOW TYPE + WAVE
c - -
FH
.c2
P~D'
I
h-3
WGflC
I
PZH3,
~ulaer
1
I
berlkm
'
8. CALCULATE VER-
I
iI rn
Y -
I X , .
I
I I 1
1
I I I
M
prlh . c . t ~
1 I 1
(
I
!J,q&2
, ,
1
I
1 I 1 I I
1 I 1. 1
I mmIE0 1 d q - L
1 I1
I
I
FLOW TYPE z
I I-4 I
~wt-
I I
WS=
1
-K
mwnb.!
I I I
)
I
I I 1 I
7. CALCULATE PH FACTOR FOR HORlZONTAL FLOW
,
I
.
I W I x 0.205
WS=
1
I VS + average veloclty I I I I I 1 1 1
mlr
I
= APL
1 6. CALCULATE LOADING FACTOR WS 1 I I - I 1 i I
I I
I
5. CALCULATE X RATIO
I
1
1 Iw
I I I I I 1 I 1
PH FACTOR FOR VERTICAL 5EC710N
.
18.2
rlm
vm+Din
a 1n5
PHv =
aJYW@W X .
x,,~nDirpcrrQm~wt.wPn-
1
I I I
'
9. CALCULATE TOTAL TWO PHASE F
HorIzmtaI
:
PH =
Vertical
:
pHV=
I P~H=.PCXPH~= ~2~ = PG x PH$ =
PC=
1 I 1
bar
P = ( P ~ xHL + PZv x h)/lD00 =
TOTAL
barlkm 1 barkm I
'
21 7 P w m
J7 J --r?ofAL
-
PROCESS C A L C U ~ A ~ OWEET N
TWO pime PLPELWES P CALCULATlON
1tPfDOPIMPI~XP~SUI m
BY.
cur
DATE
JO~T~TLE
.
Sheet 2 ~f 2
ITEM: NO.:
108 no,
. atv
J
/
Covering Medium r
rP
b
I
4 1,
~g Ttmpcrature .C = k Thcrm. cond. kcal/hm*C r
L
p'
* 7'!?L
DATA -
LlQU?D FLOW
Total pipeline length rn = No of stgrncnts Length per segment m = Total tltvation change ; rn =
Volumetric flow m3/h Density (av) ke/rn3 M Mass flow kg/h Cp Specific heat kcal/kgmC
-
L Ih Y D
Pipetire diameter
Pipslim diameter Burial depth to centre m
PJ
Inlet pressure
~2
~ x i pressure t
Total pipeline lnitjal Temperature
T1
>
bar
=
'C
'=
kg/h = Cp Specific heat kcal/kgmC =
Molecular mass M Mass flowrate
Covering
1 1 % = I s = 1 1
x t 2h/D s = 2k / h [ x + (x2- ~ ) f ]
kca1fhrn.C
lennth
1.
a
t
I I
3. Calculate Asymptotic tempsrature Ta Ta =Tg (JAP + A y/jCp)/aL
-
1
I
Ta =
-
L is segment length
'C
1 1 = 4263
1
1
I 1
I I
PROCESS CalCULATlON SHEET Sheet
(
CHK
-
'
--
d t CALCULATlON
-
W9.:
TIPmDP'DIP't XPfOUP 81
kk?
I
21 8
BURIED PIPELIhiE
1
12 : C
1 Repeat stcps 3 + Q for each segment I See sheet 2 for stepwise spreadsheet I
FEZ7
I
T2
T2 s(T1 ~a)e-aL* Ta
i'-m TOTAL
I 1
I
I
m-1
I 9. Calculrte downstream temp
1.09
0.022 0.508 0.30 1.09
::
1
I
kca1Thrn~I
-
2. Calculate heat flow ratio wr unit a = dMcp (liquid or gas)
k
I
I 1 SOU 1 Air 1 Water
I
I
*C/bar
NOTES -
s
I *
-
aF/I,OOOpsi ( x 0.00805) =
VALUE
I
I
mj/d (std)
Volumetric flow
1. Calculate heat transfer factor
I I 1
=
bara = bara =
STEP -
I
5
GAS FLOW
r
FLUID YOUtE THOhiSON COEFFICIENT = [see fig. 1, page 11.81
3
=
ins = m =
h
AP
t
DATE
1
101TITLE
100 co
REV
-
7.
%
lTERA71VE CALCULATIQN LOG FOR A BURIED PIPELINEAT.
LENGTH
I
II
I
I
m
1 I
SEGMENT Na
I
I I I I 1 I I I . I 1
I I I I I
I
1
I
I I
2
1 I I I I
3 4 5
I I I I
b 7
1 1
I
L
9
I I
I I
10
I I
I
I I
1 I I I
I I
I
.
~~~ JBL
ltP~VDP.VLP'EXPrSUR #V
(
1CH~
-
I I I I t i
I I I I I
I
I
1 1
1
I
I
I I I 1 1 I
I
I I I I
I
I
I I I I
I
I
I. I
1
I I I
I
1
II
1
1
I I
I 1 1 I I I 1
I I
I I I
I I I I I 1
I
I I
I
31 9
.
&-
1
I
1 1
g
I
I 1 I 1 7 i 1 I ELEVATION 1 PI 1 TI 1 Ta T2 I PZ l 1 1 1 I I 1 I 1 I +m 1 b a r a l ' C 1 'C I *C I baral I 1 I I I I 1 I 1 I I I I I I I I I I I I I I 1 I I I I I I I I 1 I I I ! - II I I 1 I I I I I I 1 I I I I I I I I I I I 1 I I I I 1 I 1 1 I I 1 I I I I I I 1 I I I L I I I I I 1 I I 1 I I 1 I I I I I I I I I I 1 I I I I I I I I 1 I I I I I I I I I I I I I I I 1 1 I ! 1 I I 1 I t I I I 1 I I I I I I I I I I 1 I I I I I I I 1 I
PROCESS CALCULATION SHEET
BURIED PlPElINE DATE
[
101TITLE :
Af
Sheet 2 of 2
nru: CALCULATlON 10V NU
UtV
-
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Dno
TEPIDPIEN'ISUR
32
.
Rovisien :
a
. 2/85
?-
No :
. ,
iP&3T'k.
Revision:
Date:
PROCESS DATA SWEETS :
AIR COOLER EXCHANGER
PUMP COMPRESSOR TRAYED COLUMN PACKED COLUMN
FURNACE
FILTER VESSEL
SllMMAtUES OF EQUIPMENT CHARACTERISTICS
COLUMNS
PUMPS
HEAT EXCHANGERS COMPRESSORS - TURBO-EXPANDERS AIR COOLERS FURNACES
P~~INO.:
PROCESS DATA SHEETS
TEPIDPIEXPISUR
DRUMS
0 2/85
17.0
.I
@En
1
PROCESS D A T A SHEET
E?iL. 1
TLPlDDP! VvLI 8et~lc.:
2
:
AIR-COOLER
cCP
.
PIE
Jab : ~ r r v i e e:
: llem :
Unli
I
ma
1
ha
11
1.111
d r r t l o p ~lu11ue :
1
d
mam
CHARACTERISTICS
2
n
CONSTRUCTION Tbrl p i r r ~ v n
21
0,Blgn lmnprnlun
14 4
TUB6 MATERIAL
.
b.r? bar g
-
C
.
EpE73
TGTAL
5D.3 -
.
I
Job :
krvicr :
1
8111 SUII. per urn#
1
a
35
a 37
38
a# 10
43
Unit : lltm :
.
ttP* Cnerh p r l unlt
I
1
PERFORMANCE
C.lllng Surlmce p r ek.11
DATA
CONSTRUCTION
SI
y
...
EXCHANGER
C F P
TEPIDDPI.
Pagr :
PROCESS D A T A SHEET
T u b r b r e l r -Sl.taonrrl B ~ f t l ecma.
Bwwlw lorq ' t u b ~UWMB Ganitts CO(Ln*cllol@ shall In : charmel In : Carrorlon a t + a r n r . ahall crdt ~ W U I - ~ ~ ~ S Wwlghl 40Ch *hall
fl ~ l l n q - :
: TIPI
:
llw .
tpbclng : Spaclnp :
I
nm
I h l c h ~ r t r:
SvbcIm~:
I
m
T b I ~ t n l l 8: Oul :
5mrltr : Scrlm~: SI*
I
Thlfklnmmm : T h l s k n t ~ l:
IVA
mn
I nn kr1.n : @run : mm
I
t e m ~clan* :
. -4
Full 01 ~ 1 1 1 1
kg
L
BfJZ rnAL
Pmlr :
PROCESS D A T A SHEET
GAY3
PUMP
CFP
I
Job : Smrvitr :
TEP/DOP/
1
Unit : llrm : L
FLUlD HANDLED
1 Flu14 clrrvlrlrd
2 1
Puaplnt trmper*lut?
4 I
Vlrcorltp 11 P.T.
I I
Spuilie q r r r l l r 1 6 / 4 fi*tllic ymvily r l P.T.
*C rg
Vlpor pralrutr *I .T.
.
k r l
J
J
OPERATIHQ CONDITIONS
I C~prelly O i ~ r h r r l epratrun L d i a n bn*nurr ~n ~ t i * * s n t ~nr m l sfuf*
I 10
..
49
4s
math
I
I
brr s bar a bar r
-
I I
I
1
1
PUMP 1
n
.
.. ,
.>
DRIVER
,
I
ir
Tn.
25
nfllns
kw
k
Wwa
I/ ma
27
OprrrI%n( lord Canarcltd lewd
n,
, ,.
-
kwh
kW
-
.
L
D"13
TOTAL
HiwD
COMPRESSOR
C F P
1EP.'DOP/
b
Pn9r
PROCESS D A T A SHEET
$0:
Srrvrce
.
-
Unit :
I llrm :
f LutD
1
7
-
HANDLED
t
OPERATING CONDITIONS Capacily OqC. 1 AT*
. - ,
tlrn3fh
Capacill (sucllan P.7.)
m31 h
Sve11on prcssur~
bm
Discharge prrlsut* C ~ n l p r r ~ ~ if O r l ino
bin g
f
C
COMPRESSOR -3
1 TP*
84
Nurnbc~
P5
~ S I Q OCPP,CI~V
26 87
Ellicimcy L1.1. brake h ~ r s e p o w c r
.1 28
~pcra
NmW b
k hW I/M
Uabri~ls
'
DRIVER T ypr Rating Conneclrd load
kwh kW
Swrd
tImn
Opbraling load
.
LW
. ..-a -
-
-.
--
,
.
KRVICE
*
UTEIIIIL
-
CQKihSUoY AUWAWCE
rn
NOTI!# ;
.. RLVIIIOH
8-?.95'
Vm&L
is^^ C F P
BOUIPUEWT CHARACTERlSTlCS SUMhthRY
~ ~ C I D D 'P ~
AIR
on u*
DRAWING
-
COOLERS
nr
SHEET
w
UYITS
CK~PAC~ERIITICS
--
--
1T€Y M' NUYWR
SERVICE
I# 0 i A e T E M
mm
L C Y S J ~SETWEENTL
null
t
W I Z O M T A L :M L ? V
COSITLOw
MIST L L I W I U T O R
mmu. .OOT
nu
matm
Rrn
6CTWEEY L.t.
wzluil~a
~LFPURE
~rmnrruit~
comlf mu
.
MUM
C
hrg
~
.C
HEmtmE TEWPZ l M T V ~M
fl 'C
.UTCRAL
-
Wltn T H l C X R I
m
COI#DOTm CLLOrAuaE
m
t WTr N O W r
S
rmTIl:
I
*
.
I
w mnaL IIEWSW
I
I
&ZrT
EOUIPMENT CH&AACTERIST~CJSULIIIARV
CFP
DRUMS
TEPIODPI DATE
J0a nm
. 22q
DRAWIWO W
SnEtT
w
-
-
UNITS
CMRhCtER3tTICS
r
-
f t t Y II*
2
HWlLll I
!
SCRVlCE
f LUiO
M L L HOE
-CllCULATLD
TUBL ClDC
.
wr
.
HEAT EXCWGED
kdlb
c
LY1.0. tYPt
ti
3z -
W I L OF ~ SCELU
xw *
:-
CC
LYIQ C O ~ V ~ L C T ~
OWERILL M L l l ? W E 1 1 UTE
ESTIM&TED A OPERI~~WO
-
-
d
m
------
COUDlT!WS
#ii
Csrrrr
MIEWE
bu
PRElWRE
CWITIQNS
"
*C
Tf%P€UTURE
DESION
I
)r
l
'C
TEYP€MTVRS TYPE
YAtEAIAL
ChRQBIQW
nu
ALLOIUICE PRLOSURE
DPEwLtlNC
LI
E I
-
c~olllons
I
1
PRESURE
ComDlTlOns
3
I I
TNPEUTVIIE
--
DESIGN
cl A
ht
I
m
T E M PR ~ A T ~ ~ € *c
1
II
I
TVPE
YATERHL
CORRP61011
I
mm
ALLQ*AHCE
1
I
I
MOTES :
.
I
I nEWS10M
E3:m
rnAL
-
-
flksz
ObPf - --7 E P l-RC v --. -* +
,OA r i
-
-- - --
.--*
*---_C
EOU~PMENTC H A ~ A C T E U I S T I C SSUMMARY
MEAT
-
-, 4 0 0 H'
~
~ -
A -
A
Y
I
-- -3 3 a -
W* H
~lxcn~nti~s O : M E E T n* .-.
--
...
- -. IC-
7
- -.
.-
c n ~ n ~ C t E R l ICS St
---
---1
UNITS
.- -
--
17EU ND
- . I .
.
- -- * . ----- --,
1
-
A -
--A,-,
NWBCR
pnVlCE
. !
o
m
3L
-
WJuR€
YOLECVLAR 1ElCnl - - kfif k
MG ....
fi VILUE CP/CV
4
: =
CCr3nfSslBlLltl
z
FACTOR
D
S
WECtFIC W V I T I
x
PnES'*
i
h f .
T E W EM T W E
O P E M T ~ K FLO. ~ A T L DLUGll
$LO* U T E
DILOIAME COYPIIENIW
w
P(I E W n E
*C
rslh
.V
d / C b r r
arno
YL'l ERlAL
TYPE C m P R C m m R A t t Y G LOlD
W
TYPE DRIVER
COUWECTEO LOAD
n
1
YOtES :
L I I
*
,
RLWCtON
fi3 2 2 7mAL L%3z'
EOUIPMEMf CHARACT R I f T r c r StJMMARv
C F P TE P/DDP/
COMPRESSORS JOB N*
-
TURBO-EXPANDERS
1 DR111RG M*
h
3 s
CHARAC I E R I S T I C S
UNIT5
I
.
t f E U W' NUYBER
SERVICE
.
-. IN. DIAM. BDTTDYI MlDDLCl TOP
m
TOTAL LENGTH T l l T L
1111
TVPE
m-'
E-
NUUSER BQTTQIIUlObLE/ TOP
-
. m
T ~ A YSPACING BQTIClYNLDDLEnOP
PREWRE
OPERAT~WG
..
eg~ay~ml
-we
TEMP. D O T T W / TOP
*C
DLSlGM
PhEWhE
&a
COWDITIWS
TELIPEIIATVRE
'
*C
,
*.
M A T E R I A L B H E L U TRAYS
SMELL CLLC. THfCIII*Y
~~LLCORAO~OHALLOIAYCE
M
mm
w
4
E S T l V r T t D lElGHT ( f Y p T V I
.
T
HOTES : IWrrch)
. REYlIlOll
.
fT&TD
---
RIYAL-
am C F P
tE P / ODP DATE
EOUIPUEHT CHARACTERISTICS SUMMAPY
JOB k'
tQLL'ltrUS
DIIAMWG n-
3 3 9
SHEETU~'
CHARAC.TERISTICS
UNITS
.
1
# T E Y )1'
1
<
..
wuuaEK
! lERVlCE
. .
I? .
J
u
FLUID ClRCVL*TED
i3
.
...
3#C
JEUFZRATURL
t.
I
kg/ n)
FLOW RATE
8 '
-P
t
SPECIFIC OP.&VITY A T SO. F
I
*C
PRESSURE
h a
8PEC lFlC GRAVITY
b#l d
r
8 .
.VIXCIIt*
cP.
WPSH AVAILABLE
m
OESIEW FLOW RATE
nslhr
-DISCWARDL PRES5uRE
brr
.DlFFLREMT1Ab PRESSURE
&r
YATERIAL .TIP€'
%
EFFlClLUCl
.PUMP
OPERATING LOAO ,
-
I8
.TVPE
&RIVER
.
CWWEC'ICD LOAD
'h
kOlLl:
llEVlSlON
EOUIPYENT CHARACT ERlSTlCS SUMMARY I E P I D P I PCOCZ
PUMPS 101 W 9
ORAWIHO N*
S H E E f W*
.
b
~
i
~
WTAL
3
PROCESS D A T A SHEET
~m
'
PACKED COLUMN
C f P
TEP/ POP/
.
Scrvica* :
3 4
Packkg IyW
8
Item : ~-
COLUMN CHARACTERlStlCS Erlnlng l a w n :y. l n ~ l d od l l d n l ~ r Pneklng dlam*ul
~
or no
1
I
,
.
.
"
mm
a
m T
%
1 Unit : .
Jab
1
*
1 plpc
Numbr ml h a s
PACKINQ CHARACTERtStlCS
Ea3
P R O C E S S D A T A SHEET
m A L
DL33 cFP TE P /
Job:
DDP/
FURNACE 1 ~ n r :l j
s*rvlc- :
ltrm :
1 Pro8 :
1
1
I 3
*
id Kcallh
Ahorb4 bml
Mar. ~ I l ~ w w b tbma l l
IIUZ
i#KC~IIII
j
OPERATING CONDITIONS
1
s L I
a 10
n I2 13 14 1I l*
t?
*a 1I 20
COHSTRUCTION
n m a l y , ~ m u u n
.
13
&llorrbla p r * a a u n drcg
t4
tubrmlarlml
25 %
X
Fual
mdlm~lmmalnr ~ D ~ V . C I I D I It o n u
art g k r
-
I
Dm3 M 3
.
I
Job : Setvice
I
Murnbmr
1
3 1
Nstur* of H u l d
S 6
S p r e l w a u i l y d 15/4 S p c l l k grrvily r T
7
Virroaity m 'I P
1
Fr+ealng poinl Mature 08 I n ~ p u r l l i ~ r
Flttrmtion lrnlrntyrr
P
.
LC
cp
OPERATING CONDITIONS
10
.
I
Prtrrure
Flow
12 13 I - . -
bar* nr3/ h
u p ~ ~ l r l l n l / i o n
P
-
bar
Y r i . prrsrur? drop
DESIGN
15
16 17
I
Drsign I*mpetatun b e l g n prtasvrm
CONDITIONS
ec brp.
I
1
.r
MATERIAL
18
40 41
REVISION
42
dale
4 44
~ n f :i 1t.m :
FILTEREO FLUID
2
14
I
:
TYPO
11
'
FILTER
CCP
T E P I DQP/
P.@.
P R O C E S S DATA SHEET
TOTAL
,
7
0
by Checked
l
3Yd
1
2
3
4
U m l
TOTAL
1111
I
TOTAL -
Revisiot~: 0
Page Nu. :
FOREWORD TO REVISION 0
TEPIDPIEXPtSUR
Date:
2/85 I
The purpose of this manual is t o present in a practical way the process design methods to be used by TEP personnel lor quick calculations as well as detailed ones. They have been careluliy selected by the most experienced engineers of the Process and Operations Department
ITEPlDDPtDiPlEXPlSUR). The physical presentation i s different from that of the other TEP/DDP/DIP manuals i n order to get an easily transportable docurncnt as well as one whlch 1s convenient for photocopies.
I
I
Most methods are illustrated by seleeted examples.
Chapter 15 gives a selection of basic data which
is
sufficient for most calculations.
Chapters 16 and 17 consist of blank calculation sheets and Process data sheets that can easily
I
be photocopied.
I
Blank pa& :are scattered along the chapters for personal notes.
In addition, blank pages are placed a t the end of the manual.
They arc to be used !or comments
regarding the content as well as the typing and prcsentation and should be sent back to TEP/DDP/DIP/EXP/SUR in Paris to be incorporeted in the next rcvislon. Use them plea= : they
will be part of our feedback. The following persons have cooperated to the revlsion 0 of t h t manual : MM. J.L. BAGGIO,
P. BERLIN,
Ph.BOURGEOIS,
J.C.
FORESTIER,
B.K.
MARSHALL,
A.
MINKKINEN,
J.P. LUCIANI, M. LE METAIS, R. ODELLO, B. PERISSE, U. WEBER, Mmc K. COTTIN,
fl. LEGRAND
I
TOTAL ..
urnvision '
Page No. :
I N D E X Date :
TEPIDPEXPISUR
I. DESIGN CONDITIONS 2. VESSELS (vapwr-liquid separators)
.. HorizontaI Vertical
3. COLUMNS
.. Tray Packed 4. HEAT EXCHANGERS
+ tube .. Shell Air cmlers
. Plate exchangers
. Furnaces
5 PUMPS
.. Centrifugal Reciprocating 6. DRIVERS
. Gas turbines
.
, Steam turblnes
Electric drivers
7. COMPRESSORS 8. EXPANDERS
9. FLARE SYSTEMS 10.
PIPES VALVES + FITTINGS
. Line sizing
.
Piplng classes
.. AControl P through valves and fittings valves - sizing and sdection
11. PIPELINES
,
Pressure and temperature drops
12. PACKAGE UNITS
., Dehydration Refrigeration 13. UTILITIES
..
Watw Nitrogen
. Gas sweetening .
Air , Drainage
10.COMPUTER PROGRAMS 15. DATA 16. PROCESS CALCULATION SHEETS
L7. PROCESS DATA SHEETS 2 u
-
r u BML
r - r t u c t h h r l u b I I u t l r l t l N l r UtSltiN
MANUAL
TEPIDPIEXPISUR
R ~ Y ~ S ;~ O I I
Date
1. D E S I G N
CONDITIONS
: 2/85
Pave No :
TOTAL
Revls~on: 0
Page No
Date : 2fg5
1.1
DEIGN CONDITIONS
TEPIDPl€XPISUR
I. APPLICABILITY The f~llowingdesign criteria are applicable far both feasibility studies and pre-project studie:.
2. PRESSURES The design pressure of a vessel shall be taken as of the following ;
-
Operating pressure bar13 0 - 10 10 50
MOP t 10 %
50
MOP + 5 barg
)
.
-
Desinn pressure bark MOP + 1 bar
I00
LO0
MOP z Maximum Process Operating
Pressure
MOP+5%
Vesscls subject to
vacuum during operation shall be designed for
the maxlmurn external
operating pressure plus a margin of 0.15 bar. 11 the internal pressure Is 0.35 bara or less the vessel will be designed lor full vacuum.
.
Deslgn pressure for pump discharges shall be calculated by taking 120 % ofithe nvrmal pump AP)when operating at design conditions.
3-0 DESIGN TEMPERATURES
.
Design vessel temperatures shall be as lollows :
I5 *C
Maximum design temperature =
max. operating Ternp
Minimum design temperature =
min. operating Temp - 5 "C
t
or minimum ambient temperature.
.
Consideratian for t l ~rninlrnurn dcsign temperature must take
d s @ f s s a u r m 4f Lhe v t s s ~ lthat m a y (Set sectlon on flaring). 4.0 MATERIAL OF
.
GCWE
durLng e m - e r w 9r&t
lnro a a u n t W do~n.&~alhS.
CONSTRUCTION
Details of the required material of c o n s t r ~ t i o nfor various tcrnperatures are given in Table I.
.
Details on corrosion allowances and wall thirkness a r t given i n the vessel design section.
5
TOTAL TEPlDPlE>
t R e E a ENGINEERIND DPIGN MANUAL
:UR
Data
2,
1
Revision :
VESSELS
7
: 2f85
Pws No ;
TOTAL.
VAPOUR
- LIQUID SEPARATORS
TEPIDPIEXPISUR
neuisioh :0
Page NO. :
Date: 2f85
2.1
1. APPLICABILITY Virtually sll procers zchernes use phase scpararlan. The deslgn and sizing of a separator with
acceptable accuracy b required for both the feasibility and pre-projet phases.
Consideration is given in this section l o the spccifkatian of vertical and harlzontal separators for vapow-liquid and vapour-llquid-liquid separation. Details are also given concerning vessel internals,
Separation of solida from gas or Bquids is not cavcred in this design guide. Gencraliy a vendor will be cmsultcd for details af a proprlctory designed vessel. 2. SEPARATOR APPLICATIONS AND COPWOERATEONS
2.1.
2 PHASE SEPARATORS (uwaly
.
unless stated)
Compres~lra d Fwl G u KO drums
Efficient sepretbn of liquid from vapour rtqulred. Always consider a mlae elimina-. Provide sufficbmtirurge t1me)ll to 2 minutes) between ttte HLL and t r l p p i q the compressor.
. -
-
R d l d Syrm KO drum See =tian
9 4 F1are Sys%erns
Udt ~ma#oaumP R q h d u p t ~ a mof acid gas ahsorbtrs, glycol conmetors and dcrslcant bed
dehydratws. Can ba incarporated into base of towcr for weight and spa= saviw.
Always
.
USE
dcrnuter pads.
Produetian W r a t o r s (Vertical or horizontal) Liquid separation from eas not as critical as compr-lor
KO drum unless a
ewnpreswr is located immediately downstream of separator. Always stpr_t*
2.2.
--dm
C
O
~
and prvcas slu&swhen des-
3 P W E -TORS
.
3
production separators are g ~ ~ l hlo ry i ~ @ l .If good liquid-vapour dc
entraimntnt is rqulrad dmisters arc usualjy stated. Oil scparatfon kom the water.must be sufficient sa as not to overload water treatment units Chemkd additives (demulsiflers, anti-Enam, pour point dcprasants) may be added to aid m a t i o n .
9
~
W
I
PDTAL,
Revis~on: 0
-
Page NO.
.
YAPOUR LIQUID SEPARATORS
TEPIOPIEXPISUR
Date:
2/85
2.2
3. HORIZONTAL OR VERTICAL DESIGN
.
Vapwr velacity! in a horizontal drum can exceed the llquld scttIlng velocity provided
LID ) 1. Far vertical drums the velocity cannot. H
.
y
.
Horizontal drums arc more effective and geometrically more practical for a heavy liquid phase removal than vertical drums. A rising liquid level
in a
vertical drum dces not alter the vapaur f k w area.
Cmsqucntly vertical drums are preferred for compresmr and fuel gas KO drums. y
, Vtrtlcal drums utilise a smalkr plot and
arc easier to instrument with alarms and
shutdown controls. For (floating installatiom) they are preferred as less "sloshing" occurs.
.
Each design case must be evaluated separately but in general the Iollowlng can be u9ed as
-
a guideline : Qwtlcaldrums
Cm~~pre~sar KO drum
Degassing boots
Fuel gas KO drums
Absorber fctd K O drums
FCwtlfq instellatlmm '?
-
.
Horizontal drums
P r d u c t h n sqwatars HP 3-pharc separation
Reihrr drums
Flare KO drums
Try to avold v e s ~ l swith wall thickness grea#r than 100 m m as th-
require special
fabrication and can prwe expensive. I
6- CALCULATION THEORY AND EQUATIONS (for use in calcuIation sheets)
(Valid only for pure gravity settlers with no intcrnals to enhance q a r a t i o n )
4.1.
LIQUID-YAPOUR SETTLING VELOCITY s
=K
[yp
pv- liquid or yap- density kglrn3 V$ - settling velocity m/s K
(2) K ' =
0.003616(g) k
D
r
correlating parameter mls
- particle diameter -microns
- drag cocfficicnt P - vapour viscosity - centipoise C
la vs
=
o.oo3616(ff[
rv
P - PJ J
%
10 A
TOTAL
VAPOUR
- LIQUID SEPARATORS
TEPIOPIEXPISUR
Revisiori :O
Date :
2/g5
Page No. :
2.3
For medium and low pressure with gases af viscosity less than 0.01 cp Figure 1 can be used t o estimate Vs.
-
For higher pressures (> 50 bar) or viscosities i n excess of 0.01 cp it i s necessary t o calculate Vs. The drag coefficient C 1s calculated using Figure 2 (curve 2) where
CRe 2
(8)
=
t
f . ~ O ~ ~ , ~ o ~ " - ~ ~ ~ ~ ' ~ ( ~ - ~ v )
PL
Equation 3 1s then used to calculate Vs.
- 2
LIQUID-LIQUID SETTLING VELOCITY (based on Stokes law of terminal settling) The fallowing equation can be used for calculating the settling velocity of water in o i l or the upwards "settling" of o i l i n water. The important fact is to use the viscosity
of the continuous phase 1.e : for oll s e t t l i q upwards through water use the water v~scoslty,for water settling i n oil use the oil viscosity.
Ut = L
Ut =
8.D 18
a
(p--fL)
p c
I
(3)
densIty heavy fluid density light fluid
kglrn3
= D=
viscosity (continuous)
kg1m.s
particle diameter
m
rnls2
kglm3
125 microns and using more useful units gives :
( P;I?-)
Ut = O . ~ ~ O S
U t in mm/min
)& in centipoise
.
I
70
= l =
f h
*PC
Setting the particle size
4 s
E
terminal velocity gravitation accet
3
The above equatlon 1s valid lor REYNOLDS number of 0.1
- (1.3
If calculated settling velocity is > 250 rnmlmin use 250 rnax
VESSEL VOLUMES
.
Partial volumes of a l~orlzontalcylinder can be calculated using the partial valurnt charts i n Figure 3 or estimated using the following equations : (for vessels with a diameter
< 1.2
rn ignore head volumes)
TOTAL
Revision : 0 VAPOUR
- LIQUID SEPARATORS
TEPtDPlEXPlSlJR
Oste :
(see p a ~ c2.13 for sketch)
Page No. :
2/85
9-(;-h)PK"Z
A~=D'A~CCDS
HORIZONTAL CYLINDER
2 DISHED HEADS
7
Vc = A1.L
m3
Arccos
2.4 rn2
i n radians
-
Vdh = 0.21543 h2 (1.5 D h) m3
2 ELLIPTICAL HEADS
Veh = 0.52194 hZ (1.5. D
2 HEMISPHERICAL HEADS
Vhh
=
-
- h)
1.047 h2 (1.5 D h)
VOLUME UP TO BAFFLE (see page 2.23) 0.52194 hf for depth h Ielltptical heads)
(1.50-h)
my (most common)
rn3 (gives extra vol)
+ AL.B
2
.
These formula are accurate enough for general design and are easily programmed
.
on to 4 calculator for time saving. More accurate formula are available, ace ref list, but are often too complicated t o be useful for multip1e calculations.
.
For greater accuracy the l e n g t l ~L should bc the tan-tan length and not the
flowpath length between nozzles. This is especially true w i t h large vessels and a tight design. 4.4.
CALCULATION PROCEDURE VERTICAL VESSEL (vapour-liquid separation)
A guide for filling In the attached calculation sheet.
.
.
Decide i f Figure 1 can be applied i.c P
< 10 bata,
Y < 0.01
cp
lpplicable use the 500 micron curve to evaluate settling velocity (this assume? a inist eliminator will be installed) or 150 micron w i t h no mist cllrrilnator. I t is
recommended to install a mist clirninator for most applications. If not calculate Vs using equ 3.
.
Derate the calculated settling velocity by 85 % design margin to give a maximum allowable vapour velocity.
.
Calculate drum internal diameter and round t o nearest 50 mmb (further adjustment of I D : OD can be made to l u i t standard head dirncnsions).
.
Check if wall thickness i s less than I00 mm (See para b.8).
t2
-
-
TOTAL
Rev~sron: 0
VAPOUR
- LIQUID SEPARATORS
TEPIDPIEXPISUR
.
Page Mo. :
D ~ t c : 2/85
2J
calculate v e s x l height based on following criteria :
h l :max (15 % of C or 400 rnrn)
h2 r 100 rnm i f mesh selected
n hl
150 mrn for compressor KO
--
/ /;
I///
h2 7-
a
-
.
h3 : max (SO % of 0 or 600 mm)
h3 .L
I f no mesh use h l + h2 + h3
F&
= 60 % d
or 800 mm
hl
h~ : 900 mrn + dl2
ma mu -
hS
- - -nLL
h6
h7
h5 : calculate based on 1-2 minutes residence time at
maximum liquid inflow (rnin 200 rnm)
u
7
~
-
.
WL
-
h6 ! base on follow~nghold up times r (min 350)
-
he i
= inlet nozzle
-
TL
L
-
-
rcflux drums
4 min
product drums
5 min 3 rnin
heater feed
8 rnin
HP sep.
Y min
to LP sep.
with pump
no pump
h7 : 1-2 rnin residence tlme (rnin~rnurn150 mm)
h8 : 150 mrn tor bottom connected LC
300 mm for side connecred LC Note :
Far compressor suction drums that are normally dry set HLL at b 5 O mm
above tan line and u x bottom connected LC. This will reduce vessel height if required. No specific
I
a
HLL-ILL hold up
t~rnerequired.
TOTAL
Revision: 0
YAPOUR
- LlQUlD SEPARATORS
TEP~DP~EXP~SUR
4.5.
Page No. :
mate:
2/85
2.6
CALCULATlON PROCEOURE HORIZONTAL VESSEL (2 phase) A guide on how to fill in the attached calculatEon sheet.
1. Calculate settllng velocity Vs far partic4Ksize 5 0 0 ~(use Fie 1 or equ. 3.) 2. Ckrate this by F
Vm =
= 0.85
and calculate required vapour
P x Y s x (LID) mls
vclwit~Vmm/s
use LID of 3 t o 4 max (3 first est)
3- Evaluate required vapout cross sectional area, Av 4. Assume drum is 70 % full i.c h/D = .I and evaluate drum 0 to give required Av (to nearest 50
mm). For "dry" vwwls use h/D = .3>
5. For required(Jiqold surge volume) calculate vol at HLL, 1X insufficient adjust D or L (note 11 L/D changes signliicantly recheck Av using new Vm). 6. Set position of LLL in drum and confirm required surge vol between HLL-LLL, If volume & Insufficient increase 9, L or h. Include volumes in heads. 7 , When setting LLL height take into account any LSLL, LSL alarms and vortex breakers which may set mlnimum value usable. Usually 300-350 mm.
8,
~ t i o n a l i s eall heights and dimensions to nearest 10 mm.
-
NOTLA :
.
For high volumetric flows of gas with small liquld volurnes consider using split
flow arrangement. Design ia as above but with half vapour volurnc
Haw.
Normal design is with top entry, exit nozzles, However if spacc is limiting
(primarily offslrorc) head mounted nozzles can be used to increase flowpath.
.
L
i3
daignated as the flow path length i.e distance between inlet and outlet
nozzle. L' is the tangent-tangent length. For 1st estitnates L' = I + 1.5 9i + 1.5 82 02 c outlet nozzle diameter Q i = inlet nozzle diameter
-
"Normal" liquid levels are taken
as midway between the high-and low levels.
r4
-
TOTAL
VAPOUR
- LlQUlD SEPARATORS
TEPIDPlEXPISUR
4.6.
Page No. :
Datm: 2fb5
CALCULATION PROCEDURE HORIZONTAL
.
~evision:O
2.7
VESSEL 3 PHASE (See Figure 4)
Sufficient residence time to allow separation of the ail-water mixt!trc as well as the o i l surge and vapour
f l o w areas
must be provided.
1. Proceed with steps 1 t o 0 as for a two phase separation. Use L / D = 3 (1st estimate) and evaluate L.
2. Provision now has to be made ta accommodate both oil and water surge volumes.
Use Tan-Tan Jength 1'and not rrozz-nozz distance L. 3. Calculate L'LL required to give approx 4 rnins oil surge capacity (minimum). Inspection will reveal whether sufficient height exists below LLL to include the interface levels. I f not, adjust the vessel Qor L to give sufficient room.
Note:
If the water cut is very small, consideration may be given t o using a water boot instead of a baffle arrangement ace step 10.
Having dstkrnined HLL and LLL now set both position and height 01 b f f l c . Calculate terminal settling velocity of watcr droplet (equ 5 sect b.2) and settling t i m t at both HLL and LLL; Volumetric flqw of llquld h i n both cases the oll plus
the water. Calculate fall distance of a droplet across length o f the drum. Baffle height and positlon can now be set noting :
-
the baffle should be a t least 75 rnm below the
the baffle should be a t
LLL least 213 down the length of thc drum Irotn the inlet
In some cases the water droplets w i l l settle t o the f l m r in a short distance.
The baffle should s t i l l be s e t at a minimum a1 213 along the vessel.
. 6.
-
k l the HIL a t baffte height 7 5 mm. The LIL according vortex breaker + LSLL use a minimum of 300-390 mm.
t o height determined by
Check If an oil droplet will r i s e through the water layer (from drurn floor) to LIC
before reaching water outlet. Use area at
LlL
with normal oil + water flowratcs.
(Thls criteria is very rarely governing but must he checked).
7. Calculate water surge time b e t w t t n HI1 and LIL, snd residence time between NIL and outlet. Remember t o use only one head volume, and length 01 drum upto baffle. Minimum acceptable times are '4-5 rnins. I f calculated times are very long consider using a watcr boot arrangement.
8 . Rationalise all dimensions and "tidytt levels to standard values if possible i.e : 150 mm, 200,250, 300 etc. This allows use of standard displacers.
9. Rtcalcutate a l l residence times based on "tidicd" levels (if required). Note :
i n calculating the final residence times make sure that the vcsscl tantan length is used and n
g
the nozzle to nozzle distance L.
/5
i
Revision : 0
TOTAL
Page No. :
VAPOUR - LIQUID SEPARATORS
TEPIOPIEXPfSUR
Oate : 2/85
2.8
L.
10. Boot calcuIatian (See Fig. 5)
.
If the water volumetric flow is
50
$mail as to not warrant a separate belflcd
settling campartement as detailed above a water boot should be used instead. 70 design p r w e c d as follows :
1. Prmeed as previaua upto step 3. 2. Calculate settling distance of water droplet when vesstl Is operating at LLL.
Water droplet should reach floor
gf
drum before 011 w t l e t . Remember that
the all e r l t nozzle w i l l be raised above the floor as a standpipe. Adjust drum
fl or
C to achieve &ttling.
3. Check that ~ t t i i n gis aim possible when operating at HLL, droplet to fall below d r a w d f nozzle level.
4 Size water drawoff boot fl
(try to use standard pipe diameters). Celculate
rising vcloclty of the oil in water, set downward velocity of water in boot at
90 % of this and evaluate bwt q. Boot length b y inspection (use standard displacers). Note -
Boot fl must be less than 35 % of vessel 0 When heavy walled vessels are used a remote boot may be more
economical t o prevent large cuts in the main vessel.
4.7.
NOZZLE SIZING (see section 10.0 also) Inlet nozzle
Size bawd on normal volumetric Ilow + 10 % (liquid + vapour flow)
-
L i m i t inlet vclocity t o 7 13 rnls Round nozzle diameter up or down to nearest standard sire
.
Can outlet
.
Liquid outlet
+
Size an normal flow
,
Normal flaw
Velocity limit 15-30 m/s
.
Velocity limit
10 %
1-3 m/s HC 2-4 m/s water
Manholes : 450 mm or 600 4.8-
,
Min. diameter = 2" (avoid plugging)
VESSEL WALL THICKNESS
Calculate vessel wall thickness usin8 the ASME VIl1 div. I formula. The wall thlckness should be calculated immediatly after t
<
100 mm.
D is knowtr t o confirm if
I
1
Revision :O
(TOTAL[
VAPOUR
- LIQUID SEPARATORS
Date : a185
Di = diameter t
:
Page NO. :
2.9
I
mm
wall thickness
P = design pressure E = jolnt etficlency
rnm barg
ure 1 for seamless shells -85 otherwise S 3 rnax. allowable stress bar
C
z
use 1220 bar for CS plate 1000 bar for 55 plate
corrosion allowance mm
-
use 3 m m unless stated
oth,erwise by EXP/TRT
for 100 <
t C I00 mrn t < 150 mm t
>
130 mm
;
no fabrication problems
c
vendor advkc may be needed
: Major labrication problems
In order to meet standard vessel head sizes and wall thicknesses the followlns ranges shwld be observed :
- I250
n m in increments of SO m m i.e. 250, 300. 350... 1300 4000 m m in increments of 100 mm i.c. 1300, 1400, 1500
Vessel diameter : 250
Srandhrd wall thlckn=tser
:
1
...
-
- 30 mm in increments of 1 mrn
-
30 60 m m in increments of 2 rnm 60 140 rnrh in increments of 5 mm
-
i.e.
1,2, 3;4... i.e. 30, 32, 3(r, 36..,
i.e. 65, 70, 75, SO...
Vessel weights either MdsontaI or vertical can bc estimated udng Flg. 6. 'This tigurt is for the steel shell Including manholes, nozzles, Iittings etc but nut the removable internal5 or support skid. The heads can be estimated by using weight of 2 heads z e2 (m2) x wall thickness (mm) x 20 ks.
I I
I
1,
5. VESSEL INTERllALS
1.1.
MIST ELIMINATORS
,
Mist tlirninatars or
mesh pads are located under the vapwr outlet nozzles at all compressor sucrion drums and fuel gas KO drums. For production separators it is slways good practlce to install an exit mesh pad.
I
I
- ..--
TOTAL
Rru~ritrr~ : 0
YAPOUR
Page NQ.:
- LIQUIDSEPARATORS
tEPIDPIEXPlSUR
2/85
Date:
2.10
A
.
Mesh is usually made from 304 SS. YORK DATA as follows : Types of pad :
York ng
Thickness
Residual*
mm
-
entrain~nentPPM
General purpose
43 1
144
100
1.L- 1.2
High efficiency
021
192
100
.I5
- -61
115 80
1DO
Dirty service
326 931
110
.I7 1.6
-
150
-8
604
.
- 0.19 1.8
- -87
The engineer should speciiy type, diameter and thickness of pad required on
the vefisel data sheet.
.
For particle sizes of 5 microns or less use two pads spaced 300 mm apart eg : glycol contactor.
5.2.
I N L E l 'TERNALS Inlet internals can be specified l o aid feed distrlbulion and promotc uspour-liquid separation. Generally for prt-project stage dctalla are not required.
5.3.
LIQUID PHASE INTERNAL5
.
Vortex breakers should be dctalled for each oiIlcondensate nnd produced water outlet where the oulet flowdirection is vertical.
.
Vendors wlLI sometimes specify internal packs of tilted plates or baffles or other arrangements to promote phase separation.
-
Sand jetting facilities should be provided for on services where there is a rBk
of
silting or sediment build up in the vessel. Generally jetting facilities are not requlred On gas-condcnsatc systems. 6.0.
SHORTCUT METHOD FOR
HORIZONTAL DRUM SlZlNG (2 w 3 phases)
1
Y
-
2.1 1
EQUtPMENT N*
I] Calculate settling velocity V s 2) Calculate vessel diameter required lor drapltts separation :
s 3) Calculate vessel dlamcter reqdlred for sufficient liquid residence time :
"2
'
c 16 QIfres
4) Select D = max (Dl,02). Round ro upper value Qg =
gas flowrate a t P,T
m3/s
Ql
z
m?s
Vs
I
total liquid [lowrate settling velocity
D
z
m/s
vessel diameter m vessel design ratio (L/D= 3-41 security factor (0.85) -
LID = F
liquid residence tilne
ires :
5:
'7
mIL3 TOTAL IC17
SHORT CUT METHOD
T~P~OWWP~IXP~IUR
nv
1 I
CHU
I
..
PROCESS CnCCULATlON SHEET
OAT€
HORIZONTAL DRUM
1
1108 I I ~ L E
ITEM
Na IOUNO
1
REV
I
TOTA'
YAPOUR
Rovitio~l: 0
Page HI
Oat% : 2/85
2.12
- LIQUID SEPARATORS
TEPtDPIEXPISUR
7.0 REFERENCES AND USEFUL LITERATURE
7.1.
LUDWIG VOL I CHAPTER 4
7.2.
PERRY CHAPTER 6
7.3.
Program calculates partial volumes Pierre Koch
OC3 Dec. 3 1983
2u
.
CALCULATION SHEET FOR VERnCfiL TWO PHASE SEPARATOR
EQUIPMENT
1e3~
D
NO
B E W S S ; N ~&oor
Operatinp data : Pressure (operating)
bare
= ~.WI
Temperature (operating) Gas MW
'C
= 31,
Gas flow rate
kdh
Gas density
Liquid description : C l l ~ b LD;L
= 51.4
= ?PI0 k g h 3 = 3.1
(T,P)
Actual volume flow Qg
m3ts
-
6-97
r
kgh
Liquid flow rate
10290
Liquid density (T,PI kg/m3 Actual volume flow m3/min
2 10 = 0.t 3
Plrticle size
= !So
microns
c
.
Esdmate Vs usin8 Figure 1 and 500 micron curve : , If P < 50 bar and p < 0.01 u x Fig. l and 150 microns
Mesh pad
:
No
'
1. Yapour-liquid ~ t t l i n pvclocltv . :from Fig -1
. c :
VS =
&
m/~
vs =
rnls
* Delete as applicable 2. berating % = 85
=
1
Drum flow area
3. Actual volumetric.
as flow
~m
maximum velocity
0 . 57
=
Calculated drum 6 =
~ . q qm3/s
m/s
1.7
2s:
m2 mm
5. Required liquid hold-up tiines
h>:
HLA-HLL
h6:
HLL-LLL
h7:
LLL-LLA
5. Mesh pad:
1
@no
= = =
e
mi"
=
min
r
(.1cm3
~ . . / , 6 m3
thickness =
. TOTAL ma3
a
0 . L 6 d
min
30
. = =
mrn
lgoc 700
mm mm
mm
21 Sheet 1 of 2
PROCE~S CALCULATlOM S H E E T
:
IrrM:
TLFIOOP'O~P~IKP SVLl
VERTICAL YAPOUR-LIQUID SEPARATOR w,
I Y
QSrt
CHK
700
lbl1111€ I
SAM*?~L
,
.
c.".--
D I ,: i;.
101NO
RtY
1
hl :
I5 % of fl or lr00 mm (Use mar)
h2 :
mesh pad
h3 : 50 % of d or 600 mrn With mesh :h l + h l + h3 N o mesh : hJ + hZ + h3 1 60 % @ or 800 h4 a 400 mrn + d / 2 t d = inlet nozz fl
hJ
h5 a
From step 4 or 200 mrn
h6 :
From step I or 350 m m
h7 : ha :
From step 4 or 150 rnrn
-
rnm
e
5SO
mm
= =
700
mm
I
mm
150 mm for bottorn LC
I S
300 mrn for side LC
mrn
For ''dry" vessel
h6 + h7
+ h8
= $650 rnm
TOTAL VESSEL HT TANITAN L L
7. Wall thickness
.
DESIGN PRESSURE
*
CORt
P c 2.5 . C= 3
;ION ALLOWANCE
barg
Diameter
D =
?OO
mm
mm
Max st1 :s : 5 =,I220bar CS 1000 bar CS
Joint eiflciency f.85)
.
t
S = 1?r:3
E=
PxD
I
2xsxE-1.2P
+c
Z A . 1
C l.j
Vessel weight (Fig. 6) t =
5
mrn
L=
6
m
(s+I)
D = s.-I m
r
IPCO kg
Head weight =
80 kg
She11 weight
(t
x d x 20)
1340
TOTAL WEIGHT r
kg
22 TOTAL
-71
PROCESS CALCULATION SHEET
VERTICAL VAWUR-LIQUID SEPARATOR 1TEM.
TIP'DWOR.IXP.SUR Ir
cnn
NO
ma IE
l ~ O Q ~ I ~ tL I
.1:
L
.
IOU uo
!\I :.dv I
'*J.-
Sheet 2 of ..
Z
-
. atv
I
-.
2+1J CALCULATION SHEET FOR HORIZONTAL 2 PHASE SEPARATOR
I
. Head type elliptic all^ Indicate on sketch if demister mesh requlred Delete as applicable
EQUIPMENT N u ! v$oio
DESCRIPTION : I""'AS~ S f Prtplf! l o *
Omrating data :
= %a Operating temperature .C = I g Operating pressure bara
Gas density T, P
= h.,4 k d h = 14qSo kglm3 = 1f.u
~g actual vol flow
m'f5
Gas viscosiry
CP
Gas molecular
weight
Gas mass f l o w rate
L.
Vapour-lquid settling
0 ; ~ .
Liquid flowrate
kgfh
'
!?b6iu kgfln3 = 7CS
0 . !y?
~ l ~ u dendry id T,P ~1 actual vol flow
m3/rnin =
e.O\o?r
Particle size
microns
. =
Liquid nature :
z
-c
~nls
vm=
1.8
mls
a = 3.'sh
m2
v5=
*
velocity : frorn Fig. 11-
2
G.
1
C =
* Delete as applicable 2. Max. vapwrr velocity
Vm=YsxFxL
B
LID = 3 3. Actual vapour ~olurnetricflow
Q g = 6-2-77m3/5
Av
V rn
2'5 PROCESS CALCULATIONSHEET
1-
TOTAL
ITJT7
TE~~O~P,~IWEIPIZUR #I
CM*
CALCULATfOH FOR HORIZONTAL PHASE SEPARATOR
o d rt
z
,on
rlrLr
1
r oS3
' I f L ~
No
106 no
I
.-
.dl,
r
to
Sheet 1 01 3 : , r * " ' "' '
1
RIY
-
4.
Nozzle sizing I velocity limits (rnls)
8
Inlet : 7-13, Gas outlet : 15-30, liquid outlet 1 - 3
Nozzle ID =
B i : Inlet flow = 0.31' m3/s (+ 1 %) c.3b 82 : Gas c. 'let = 9.2 $ m3/s Liquid outlet = a.Ci. m3/s
8
Actual vcl =
I'
lo-5 tn/s
NozzIe ID = " Actual vcl = I T mls Nozzle ID t & " Actual vel = .'. 1 m/s
5. Drum sizing = 4 mln
For trial I t,,,
vol required = 4 x Q1 =
I Selected h/D Vapour area % fotal area {Fig. 31 Total area Liquid area
Av
17-12
At A1
m2
D
mrn
Calculated drum Selected drum
fi
-
I
I I If 1 31 I c.GrC I a.ft62 I I I 1 t I I I :ro I t c n ~ 3 I 1
m rn
LID O 41
I
L
mm
TanlTan length
L'
mm
HLL height Volume at HLL LLL height Volume at LLL Surge volume (HLL
Calculated
1
180r I 2.68 t I I I
m rn
m3
m3
I 3.3E I
I
d n
1 NOTES :
I I SELECTED DRUM : DIAMETER 0 ?o.v
1
1
1 I I 2
1
I I I
1 I I I 1lt00 I 1 l?.q% I I 350 I 1 1.36 1 I I..SC II
I
m3
tres
3
1 3 1 . C ~ j LO--3 I 1 !1'34 1 cs30
rnm
- LLL)
i0.c
.
1 a*4
mZ
Flowpath length
0
.I 1
" I
I
TRIAL
I
1 I I
I I
of.
I I I
I 1
I I I I
I
I I I I
I I
I 1 1 I
I
I I I I
I
I
I I
I I 1 I
I I 1 I
1 I I
I 1
I
I I I
I I I
I
m m x ; Z : , mrn tadtan
a1
f anltan length L' iL + l + x bi + I t 62 (ignore this correctidn if D C 1.2 m and use L for volume calcs. For trial I uae t and ignore heads). .
b)
If VOL HLL is less than required surge increase D, L or h/D or reduce ires (by
Inspection).
2 4
'
EZ3
TOTAL
1717
rEPIDDPrDIP.EXP~SuR
IY
I I
I
ID,^ m3
ctix
l
PROCESS CnlcuintloN SHEET
CALCULATION FOR HORIZONTAL 2 PHASE SEPARATOR
onrr
I
I 100 TI ~ L C
.
..n
,.
.
'rtM
-_
Sheet 2 of 3
'
Uo 100
wo
I
I
I
RLv
6. Wall thickness
, DESIGN PRESSURE , CORROSION ALLOWANCE
P=
22
barg
C= 3
Max stress
55 = 1000 bar 5 . l2:o
mrn
Joint efficiency
t.
ig
L
rC.53
D
Shell weight
m
Head weight =
rn
(t x D=X 20)
=
E=
0 .f l
= Il 0 0 0 kg
mm
TOTAL WEIGHT
CS = 1220 bar
JdaO k~
1 3 OOc
..
kg
-
PROCESS cnLCU1ATtON SHEET
ltP'DDP,DIPtt XC'SUU
CALCULATION FOR HORIZONTAL 2 PHASE SEPARATOR
, ~ ~ p . q , b!'
L,qp.pi
n o L'!:
to
5heet 3 of 3 1 f.:!
t
'
!.
,...
1
ntv 1
I-
-
TXEllfAN'tENCTH L' ;$00 FLOW PATH LENGTH L = +*am
I-
.Amend ske~ehif h o t requitad inrtwd of baffle . Indicate on sketch if mesh rqulrtd
. Heads :2 :1 elliptical EQUIPEMENT No : D 5 0 1 0 DESCRIPTION : 0F-y-
T L S 7 SLIAMT*&
Operating d a t a . Operating pressure ' Operating temperature
Ad
barn
:
'C
= so
CONDENSATE Flowrate Density T,P
PC
Mass flowrate
kglh
Density
kglm3 = 31. o
T,P
Qg Vol flow
=
PC
bi04
WATER CUT
m3/h = = 0.0I03
Y
1. Vapour-liquid s e t t l i n ~velocity
t
719.h
=6.7S
Viscosity
cp
Flowrate
kg/h
44fs
kg/m3 = S t % Vat flow TIP m31min = o. 16P Density T,P
PW Qw
rw
microns= I a:
Particle size
kdm3
Val flow T,P rn3/min x 0.3 I
Ql
CAS MW
-
= 3 1~ 3 3
kg/h
from Fig, llc-
= 17.54
cp
Viscosity
Vs = 0.17
r
1n/5
-
C
* Delete as applicable 2. Maximum vapour velocity LID = 3
Vm
= Vs x
0.85
rL I3
3. Liquid-lit: I settling
Ut = 0.110l[&lf?]
Oil in water
Utall =
rnrn/min
Pw Wa~erIn oil
&water
-
rnmlmin
\IT
mrnlmin
.--
Sheer 101 4
26
mZY
TOTAL
a
L P I W P : ~ r t Y P5ua
v
CMK
PROCESS CALCULATION SHEET
-
CALCULATION FOR HONZONTAL 3 PHASE SEPARATOR DATE
j rosrlr~t E n n r r r t i
ITEM
no
orc~~:,~
> So10
108 wo
~r
,,I
1
I
RIV
9-
2.19
I.
:qelocity
*Olz~a
,
....
I. Inlet [low : (+ I0 %)
2. Gas outlet :
3. HC outlet :
4.
outkt
Water
:
0.6 .
5. Vessel siring tres oil
trial 1
(HLL-LLL)= 4 mln
1. f 4
r
.-
1
"
OIL SECTION TRIAL
I
I I
Selected h/D
calculated (QglVm) Av as % AT (Fig. 3) Total area
Av
rn2
At
m2 mZ
A1
Liquid area
--
Calculated Q Selected P
I 0.7 1 0.38 I I 1 rr I Sr 1 r4.r I \.u+ \ 3 I n-3L I o . Z k I o-6bh I 1.383
mm , ,
D
1 I1 1ObO 6So 1
1
LlD 13
41 Flowpath length TanlTan Length
L'
HLL height Vblume' a t HLL LLL height ' Volume at LLL Surge volu~nc(HLL
1
mm mm
L h1
mm rn3
hZ
mm
I jLS0
,
I I goo
Calculated tres
.
I
I
m3
- LLL)
3
m3
I
rnin
I
I
I
11 \IIQ I I
1(
CO-Q
0
I I 1
1
1 3 . 2 I lFPo 1 io-0
1 1
I 1 I I
if00
1100
b.63
I 7.-
LOO
1 300 I II t
\.q
tlk
I
I
I
I
1 I
I I
I I
I
I
I
I
1 1 .I I I II
1 1 I
1
,-,.
I I
I I I I
I I
c=L+ H
I.,@
I
1
I 1
Notes or comments :
),
I I I 1 I
+
h)mm
- Ignore if
<
'-2
27 ~ROCESSCALCULATIOH SHEET ITEM:orftwvt
CA~.CULATIONFOR HORIZONTAL
3 PHASE SEPARATOR
If PIOOPIMI~~XP'TUR
UY
CHI:
OAT€
)tostnu
i*fiit;.r-
wo.. D iolo 100 NO
TI!'
Sheet 2 of 9 ' I.fifi**': 8 ' : a
I
Rtu
1
WATEK SECTION
B = 213 x L = 3 f 3
Trial I
mm (rounded)
T
Total liquld vol flowrate Qw
* QI
i
Baffle distance Liquid area at HLL
B A1 Vl
Horizontal vel at HLL
I
TRIAL
1
n
m2
Ut water (step 3) Verticdl fall from HLL = B X Ut/VI
rnrnlmin mrn
fSPd
HLL vertical fall
mm
I
A1 VZ
'
Selected baffle height h3 Selected HIL level hq [adjust h3 and B if necessary)
Chw.k oil r i w :
I 1 mmfrnin 1 I rnZ rnmtrnin
I??.$
1240
rnm
I I
,400
mm
[
3fo
1 I I
Horizontal vel at L L L Y2 Ut oil (step 3) Vertical rise within dist B m B x UtlV2 = max. outlet htlght
rnmlrnin 1 0 1 1 ~ rnmlmin I fk+
h5 selected LIL level
rnm
h6 selected outlet height
m rn
q l water vol at HIL (upto baffle)
m3
92 water vol at LIL (upto bmfflt)
m3
q3 water vol a t NIL (upto balfle)
m3
qU water vol at outlet (
q Eurge
1 I I I I 1
mm
1
1 2L7 I I qcT
I I 1
I I l.a\
1
I
I
I
l0.01
I 0.69 I 1-3c I 1 o I
I 1 0 . I 1 0.&5 t I I I . I
surt 'irne q surgelQw min r c s i ~ ce time q3-qQIQw rnin
..
I
I
I
I
1.s
-*a
I I I I I
I I
I
IA
Y~XC
I I 1 I I I 1 I I I I I I I I I I
I 1 I I
I 1 I I I I I I I I
I
I
I
I I I 1 I I I I I I I
I I I f
I I I I
I I I
1
I I
I I I
I
I I
I I I I I
1
I I
I I I
I
I
I
1
I
I t
I
I 1 I
I i I I
I 1
-
I I
I
I
?r
I i.17
9
calculated oil residence time (upto baffle) Yo1 (NLL NIL)/QI min
?r0
I I -0 1 1 ?.I&
I0.6L
m3
-
SO
I Za3
m3
= vol (ql - q2)
boo
I I I I I
1
I ST0 I I
1 0 0
1 I I I I
4
I
I
I n I I Clf
I I
I
I I I
I f 1 I
I95r
dl10
I
I I I
I
I tra I I a.82f 1 loC? I 1 I
I
I
CSI
I I7q.r
Q4l-t
mrn
1.Jtt
I
0
I
Liquid area at LLL Horizontal vel a t LLL UJ water (step 3) Vertical tall'from LLL = 0 x UtiV2
I
I
3
I I
IJClao
I b.S$L, I loff I 191.r 1
mmlmin
I I
2
II
OPS
I I3.Ago
mm
-
I
1
1
I
I I I
I
1
0Y
2 2?' TOTAL
m T LP'OOPlOIPltaPlIUR I
I I
CHK
I
PROCESS CALCULATION SHEET
CALCULATION FOR H O R ~ ~ O N T A L , 3 PHASE SEPARATOR oArc
1
I~
<
~ T I ~ KAI L F
r n ~
,
:1
Sheet
r ::
51
,:+t
.',
3 o f 4. 11
U O . r01o ~ ~ ,nm W-
I
aru
i
6. Wall thidntss
, DESLGN PRESSURE
P = bf.9 barg
.
C
CORROSION ALLOWANCE
= 3
Ma* stress
55 a lD00 bar
mm
5.
.
3
L=
D=
l
o
m
1.r m
Shell wclght
e
Head weight = (t x DX' 20)
lo Po0
kg
kcP
k&
TOTAL WEIGHT = 12 me)
I'll0
E = o.rJ
Joint cf llcicncy
t
CS = 1220 bar
kg
24
a
m
rc~~nnm~nmm c11n ~r~o
PROCESS CALCULATION SHEET :C~(ir.cr;.r
CALCULATION FOR HORIZONTAL 3 PHASE SEPARATOR
rva. 3
~ 0 1 3
5heet 4 of 4 Tf4T
~ C ~ P ~ ' , ~ . ~ < I L
-.
TOTAL
PROCESS ENGINEERING DESIGN MANUAL V A W U R AND
LlQUrD SEPhRATOAS
fhviliol! : U
Pmgc NO :
TOTAL
PROCESS ENGINEERING UESlLiN MAIUU-L VAPOUR
I,L~B..W~.
.
AND LIQUID SEPARATORS Date
TEPIOPJEXPISUR FIGURE 2 DRAG COEFFICIENT iCI
vs
RI or
c(
~ 4 2
: 2/85
2.23
3,
COLUMNS
Revision : 0
TOTAL
Page NO.
TRAY COLUMNS
TEPIDPRXPISUR
Oate :
2/83
3.1
1. p.pP~1chBfLlTY
It
is not expected that a hand calculatjon of a tray distillation or absorbtion column
be
performed by the engineer. For the purpose at a feasibility or pre-project rtudy any required r i g o r w s column sizing would be performed using SSI PROCESS simulator, or similar. Should, however, a quick tstlrnati~nof tower diameter and height b e required one of the most common methods of hand calculation for valve trays is the "GLITSCH
METHOD". An
example of the procedure for this method is given in Section 3. A detailed mechanical design of a tray column i s beyond the scope of this ~uide.For details
o) see packageunits. on ~ ~ l y ctowers, 2. DESCRIPTION AND NOTE5 2.1.
TRAYS
There arc basically three types of tray used Ln dl3tlllation columns ;sieve, bubble cap and valve trays. Each type has specific applications and flcxibilities dependant an the process criteria. Some of the major aspects a r t detailed as follows :
Bubble caps Operation
: V s p w r passes through "risers" i n t o the bubble cap then bubbles into
the surrounding liquid on the tray. Bubbling action effects liquidvapwr contact. The liquid exits the tray via outlet weir and
downcomer arrangement to the tray below. Capacity
i
Moderately high t l l i c i e w y (minimum 50 861 is maintained a t varying
rates due t o weir maintaining liquid head. Etficiency
: For many years was the most common type of tray-consequently many publlahed tray eifielencies are available from vendor
aources.
Note : most expensive type of tray.
Application
:
A l l major services excepts coking. pmlymer formation or other high fouling conditions. Ideal lor use i n low f l o w conditions where tray must remain flooded to maintain a v a p u r seal.
Tray spacing :
18" Is normal. Consider 24" to 36" for vacuum conditions.
2
q
-
TOTAL
~ a u i s i a:l ~ 0 f RAY
Pago No. :
COLUMNS
TEPIDPIEXPISUR
oate:
2/85
3.2
Sieve trays Wlth downcorners Operation
:
W l t h w t downcorners
Vapwr rises through 118" to 1"
Vapour rises through holes in
holes
and
and
bubbles
through
bubbles
through
liquid.
forces
liquid
through
Jarnc
liquid. Liquld flows across tray
Liquid
over weir via downcomer to
countercurrent
tray below.
holes t o tray below. Flow is
head
generally random and does not form continuous streams from
each hole.
Capacity
1
As high as or higher than bubble cap trays for design rates or down t o 60 % o i design. A t lower rates cfiiciency falls and performance
h poor. Generally unacceptable t o operate below 60 % capaclty. Efficiency
,
: As high as bubble caps at design capacity. Efficiency becomes
unacceptable below 60 % design capacity. Not5ultablc lor variable
load columns. Application
:
Syste~ns where
high capaclty near design rates are to be
maintained in continuous service. Handler wspendtd solld particles we11 flushing them down t o tray below. Can be problem to run with salting-wt sysxerns where trays run hot and dry, holes may plug.
Not recommended for oil Tray spacing :
t
gas rervice due t o paor flexibility.
15" average, 9" to 12" accep-
table.
Use 20"
to
30"
vacuum.
for
12" average, 9" to 18" acctptable. Use I S " t o 30" for vacuum.
Vaive trays/ballast cap
Generally the same aspects as [or sieve trays. Most valve trays are specialist proprietry design for specific operation problems and capacities. Specialist vendors
include GIitsch, Koch (flexitray), Nutter, Union Carbide. Best choice of tray for distillation application. Tray layouts N o t only may the type of bubble caplvalvefsieve hole be specified for a particular
design but also the tray hydrauljcs by liquid path. Common arrangements are shown i n Figure I.
0
---~~
TOTAL
Revision : 0
Page NO. :
TRAY COLUMNS
TEPIOPIEXP/~UR
Dale:
2/85
3.3
Tray eliiciencies General tray cfflclencles t o use :
Stripping
Absorbers
Hydrocarbon oils + vapour 33-50 % 15-20 %
Amine units Dlstlllatlon columns
2.2.
, 60-80 %
Hydrocarbon oils + vapour 50-80 % (Arnine towers ucually have 20 actual
trays)
CONDENSERS
.
Condensers are usually installed on the overhead of fractionation towers t o recover llquid product and provldc internal tower reftux. Design of condensers is covered i n shell
.
+ tube exchanger section.
Basically two types of overhead condcnscr txlat, partial and total. When uslng a total condenser the heat load is equal to the latent heat of the saturated overhead vapour. The resultant bubble point liquid is split with some returning as
reflux and
the remaining portion as distillate product. For a partial condenser the vapour withdrawn from the accumulator is in equillbrhm with the returning reflux arfd consequently the condenser is acting as
an "external" additional tray. The vapwr is normally withdrawn under pressure control with a l l or part 01 the llquld returning aa rttlux to the column.
2.3.
REBOILERS
.
Generally three types o f reboiler exist for light hydrocarbon iractionarars. Internal rehoiler
therrnosyphons
external "kt?tltn type external "heat exchanger" type rnmt cases the "heat exchanger".type -
.
furnace, electrical
is preferred for elficiency.
The heat cxchanger should be located 2-3 rn below the exit nozzle from the
column so that sufficient head is available lor thermal circulation.
-
Reboilera may be heated by direct lire. electrical coil, steam, closed !>eating medium or process fluid exchange.
.
Values of U overall (lncl. fouling factor) for various types 01 reboller and deslgn tnethods are given i n the heat exchanger design guides*
-
4/
TRAY CALCULArtOlJ SHEET ~ o l u m mitem :
ray number : to =
1
a b\G
Name :
8
L
Number 01 passes :
Po = I f b a r a
\AaC
I. VAPOUR AND LIQUID TO TRAY
I
I
1
I
I I
FLUID
I I
kglh
I I
1
MW I
kmolfh
I
I 1
T,:
I *K
I I PC I bera
I / I
d I5
b/mS
I 1 I
i
-
i
I
I I 1
I 1 LIQUID I
I
ii6rtoQi 31 L
VAWUR
I I TOTAL I
I
I
I I
1
I
i s
i 304 i
I I I
I
I
1 1
I I
I
I I
I I I
I I
I I
I
Comprcssibillty factor Z
Reduced temperature Tr
R e d u r ~ dPrt!shure Pr
From charts Flgure 1, 2 or 3
Z = 0.6 7
page 15- 1 5 Yapour density
DV =
12.03 x MW Z x (to
Vapour
+
xP
273)
-
12.03 r 3 1 . L
* Ld
0.6't r
actual rate
7
PROCESS CALCULATION SHEET
a 3
TRAY COLUMNS
rc ~ ' D D l ~ b l PXP.$,JR ,i BI
CHU
ITEM
Sheet 1 of 4
3 21d \ i
uo DATE
I ~ o r r ~ r ~I *tf i r f ? t C
ran NO
1
t
i
3.6
2. LlQUlO FROM TRAY to = i a
.c
use flgure 10 page 15-20
= 384 kglm3
DL at to
=kt\
kg/m3
Liquid flowrate = 4 F b s ~ kgth
--
= qgooo = 239 m3fh
C, = & k
DL
All
3. WWNCOMER DESIGN VELOCITY YO bE n
TS =\? =hfo mrn "TRAY SPACING" DL D, = 3% kg/m3
-
-
YD drgo = 3b rn3fh/rnZ From ilgure 2 P a ~ e3.10 System factor KI 1.0 from table 1 Page 3.9 VD dsg = VD dsgo Y K1 = 3 t o rn3/hlrn2 4.
Y APOUR CAPACITY FACTOR CAF T!j .,4.hmm 38 f r ~ m (Fig.3) on page 3.10 from (Table 1) page 3-9 System factor K2 = CAF 0 CAF
50
= CAF x K 2 , l
0
,u.~t.
o.IB
5. VAPOUR EFFECTIVE LOAD V L w d
.
v Load = c . J ~ = m . DL - Dv
=
x
3 r6
=I164m3/h
6. APPROXIlAATE COLUMN DIAMETER DT =!.S-m
from (Fig.4) page 3.1 1
_-__---
__II_______I----------
4Y PROCESS CALCULATION SHEE1
TOTAL
m
ITEM
~EPIWPIOIPIIIIP'SUR
6I
CUY
OhfE
TRAY COLUMNS
wo
1 IOB tart€
100 N O
<~411i-L
4 !,
st!cel 2 01 4
-.-. 3.7 3.2.
COL ,:1N HEIGHT ESTIMATION
-
7
1
i 1 62
1 '1
"a
I
.
1\
' I
[LI
I
1 I
I I
lnnlilion
a. H1 :
5 -
See design details on vertical vapour-liquld separalots. Minimum distance for H I will be one tray spacing. Minimum distance between inlet nozzk and top tray 300 mm. selected H I= 6 0 0
mm
b. HZ: H2 : Tray spacing x (number of actual trays - 11
No.actua1 trays = theoretical traysltray efficiency far tray
= 50%
efficiency see section 2.1 page 3.3. Assume
Actual trays
- if the column ht = q ( # l Note :
=
16
diameter changes over the length, the transition piece will be
long and H2 will increase by this amounl
Selected HZ = Cqro
mrn
$5 PROCESS CALCULATION SHEET
.-.....----.-.-
btrM
T R A Y COLUMNS
3:crG
___
Sheet 3 ut _ ___. --,. 4
-
.
-.
3.8 c. H3:
H3 = h l + h2 hl
=
tray
h2 = h6
spacing x 2 = 900
+ h7 + h8 (see vertical
rnrn separatar sizing]
h6 = hold up time For production flowing to :
. . . . . hb
another column
t
= 15 min 2
storage
a furnace
10
anorher unii
a
5
I
reboiler/heat exchanger
:to00 mm
h7 = ip0 mm
h8 = 300 m m
4 h2 = 2500rnrn
H3 c h i
t
h2 = 3 7 e 0 rnrn
Selected H3 = 37 0 a
TOTAL COLUMN HEIGHT = H I
t
rnm
HZ + H3 = I I 0 f 0 m m
46
Ex3 m2Y
-
TOTAL
PROCESS CALCULATION SHEET ..I _ _ _ _
I I CuK
I
_ ....- Slieet -4 of 4
> lCl<
___I_
11IM
T R A Y COLUMNS
ItPOOPrblP E I I P I S U ~
Cmv
- -
oAtr
1 ronrlttt
TNQ
irnt-*ri
1100 Ha
I
ntv
1
Hev~siurr:
TOTAL
T R A Y COLUMNS 2/85
Wale:
TEPlDPlEXPlSUR
TABLE 1
SYSTEM FACTORS Service
System Factor
.............................................................. BFj. Freon...................................................... 0.9
1.00
Non foaming, regular systems Fluorine systems, e.g.,
Moderate foaming, e.g., oil absorbers, amine and glycol regenerators.,....
.85
Heavy foamlng, e.g., nmine end glycol absorbers
.f
................................... 9 Severe foaming, e.g., MEK units........................................................... .60 Foam-stable systems, e.g-, caustic regenerators.....................................-30
TABLE 2
Minimum recommended Tray spacing :7 5 m m
Column diameter mln
< 1 zoo 1 200 C 2 100 <
I
Q
~ s q cNU. :
< a roo <
4 200
g s
4 200
43.
3.9
P R ~ L S ENGINEEH~NC YESIGN MANUAL
TOTAL
TRAY COLUmS
TEPID PI EX PIS^^^
I
lleVlsJYll
Date
: 2/85
Fig. ~ O A L L A S IT R A V O l A U C T E l (FOR
APPROYlMlTlON
PURPOSCL O U L I )
.a,. Y LO80 -=Ch
low-
*
-
mass : T t
---
21M
-*Dm
PI-
r ?-.I%
----
:
ror r w n oars r n ~ v s
--. ma4 -. -
li.-r.r
-
ISL
-
110
*$O
ODD
- ssa - ma -m v - >w 4 s
-
IOaa
a00
ZlO
-am
-
d
-
--
ISP
?W
-*
-
-
-
*
0
IW
-
w
Ism
5-
-
-
11 Dlrldr Y Lm.4 k l II LnPY LmmL h l 1, D.l.l. dl.n*lW l l r k*.L*.l h.7 Ik* 41 MWIUI,~,
LrnUlO
44
l
.ye
mru
3.11
.
TOTAL
Revision
.
0
Pege Na. :
2/%5
3.12
PACKED TOWERS
TEP/DPAXPISIJR
1. APPLICARILITY FEASIBILITY;STUDY : PRE-PROIECT
Under normal elrcumstances the deslgn of a packed tower would be detailed by a vendor based on process data supplied by the engineer. The detailed design
of packed towers is
complex and requires spcclljc information regarding both packing type and size and mass
transfer data for the fluids contacted. For the purpose of this design guide detalls are given on the general arrangement of packed towers, various types of packing and loading and pressure drop correlations. The determination of the height of a packed tower should be evaluated b y a vendor or determined by the engineer I! required using methods outlined i n design literature (set references).
A detalled description is beyond the scope of this guide end is normally
unnecessary tor Ieasibility and pre-project level. 2. PACKED TOWER DESCRIPTION + NOTES
A general arrangement of a packed tower is shown in Figure I. Packing The correct selection of a tDWe1 packing w i l l normally be made by the vendor M
d on the
required process, klowrates and fpressurt drops srated~Details on pecking are given in :
-
Table 1 Packing service applications.
NOTES AND GUIDELINES
.
Carbon steel towers rnay be lined for corrosive service with rubber, plastic or brick deptnding
an the nature at the iluids being processed and the temperatures encountered.
.
Towers are generally loaded by dumping' the packing rather then stacking. Stacking is !nore
expensive and gives inferlo; liquid distribution but smaller pressure drap. Certain packing types will be stacked at vendor request.
70
-----
TOTAL
II~vi~inll : 9
Date t
.
Packing heights per suppwt platelgrid should not cncted 12' (3,6
15-20' (4.5
..
P a q Nn. ~ .
PACKED TOWERS
TEP/DP!EXPISUR
.
---..
- 6 rn) lor other packing types.
21~5
3.13
rn) for Raschig rings a!
Individual bed heights are normally limited t o 8
column diameters or 6 m msxlmum.
.
GoOd llquld distrlbution over the packing is necesssry to promote adequate p h w cmtact
-
within the bed. The streams of llquld should enter the bed on!3" 6" square .centres for small towers with D < 36". For larger towers the number of streams s h l d not be l e g s than (01612.
.
Llquld re1
tributors should be installed after approx. 3 tower diameters for Raxhlg rings
and 5-10 d: ~netersfor other packing types. Redistributors are not generally required for stacked packing as the downward liquid flow Is vertical.
.
In order t o reduce ceramic errd carbon packing breakage accuring durlng flow surges holddown or floating 'bed limiters are installed on top of the packing. The limiter must be heavy enough t o hold down the bed and be able t o resettle as the bed mavts.
For plastic or metal packing the bed limiter i s boIted i n place and doca not rest on the packing. Packed towers are not recommended
for
dirty service fluids nor for glycol dehydration.
Packed tower should be considcrcd i n preference to tray towers tor :
il srnall columns with fl'< 2 f t ii) acids or corrosive liquids iii) highly foaming liquids iu) low hold up times
v) law pressure drop requirement
.
51
TOTAL
Revisloti
0
PageNo
2/85
3.14
PACKED TOWERS
TEPIDPIEXPISUR
Date :
6. REFERENCES AND
USEFUL LITERATURE
4.1 Applied Process Design for chemical +
LUDWIG
-
Petrochemical plants VOL I1 pp 129-239 4.2 Design I
NORTON Co.
ormation for Packed Towers
Blrllctln DC-I I 4.3 Tower Packlngs
Bulletin
Packed Tower Internqls Hy-Pack
TA-8OR MY-bO
Interlox saddles 4.4 Dcslgn Techniques
TF-78
" I.
to
CI-78
for sizing
Packtd Towers
4.5 No mystery in packed bed Design
John 5. ECKERT
Chcrn. Eng. Progress Scpt. I961 VOL 57 John S. ECKEKT Oil and Gas Journal Auk. 24 1970
4.6 Calculator Program for Deaignlng
Packed f owera
4.7 Packed column Design an a Pocket Calculator
kd Packed Columns
V,I. PANCUSKA Chcm. Eng. May 5 19110
T.J. HtXSON Chem. Eng- Fcb. 6 198U Ptrry Chemical Eng. Handbook pp 18.19 4 18.47
.
f2
J
,
TOTAL
PROCESS ENGINCt+ia~u r-f)KlrBD
%xm3
D8te
TEPIDPIE WISVR
:2/85
( 0, 0.1111
Ir twllhlhw -0
F r r l * M cnlv
mt.l.re hrplr *M Pmribdw .mu
W l u ' a hnl TUN ?h.lH b.. vtw C Irar ilk *I- I.(t*.
--
-
-wh " psk;q
eartsct t&iiney; ewient; hrr-t,
mudly, the tmdlrr
p m u r c dm? in.
TOTA
~ w ~ t:i oa
P~OCESS ENGINE~R~ND DESIGN YAWL PACKED m
P-a No :
W
Dl10
TEPIDP/EXP/SUR
;2 / 8 5
3,16
3,o
Techniques for Sizing Packed Towers Reproducer 'rom NORTW 'Design 111, -matLon for Packed muera ' B u l l e t i n DC-11
hsMIrKw
F
--.-
-
.-.00
W
01Y M
01
02
k
Packing Factors (DUMPED PACKING)
0.4 06
K
tO
ZQ
40 W
2. bnw c m k u m ~ qth. v r l w d K comull th. ElrrrmLTmd pmnw~ drop m h m n .ban. It -I! br noled that h+rm m r r.rin oc m 4 . d pavam*tm PBWLnl tRnn 0.mm 1.5 Imhlln 01 mior pusurn dmp #r lwl at pmcW d.Mh (4 rn 123 mm oi *mrar pmrwe dm@ Wr nwtu d p c h M
.
E%,w. p c m o m m *mu k Owlnod to, at nudmum uonorrJU1 pruswa dm& Th. d n s n mu-
-
n m m w a a t d n m Un b W b . l m m m W w n n h i m a p r b l hrrlrnmni n bnt m m m t rsllt i n IO*. p ~ . bun drap ban. and law clOlul Lmwh~M r*. h4h.r m m ~ can u iw imwn r p n w u wan- p . l r u n a&, O;binmriI,, ~ c h m U mn.W -1.a a m 1.0 huh d n h r o r m m dme F M I d rcW d*Wh (W mm el wrbr pr+uun amp mmtm q mchd 0mL.pth). H M h t pnsnun #OM In pn* rMn rmbMnlaimn is wcn an to mJnWm a mm~lnl mrvsrum amp. -1 rb e n and rclmmrrlan bm W m d la h m w t r bram bns g.00 opiabm, ir. IMU d w a r prrun d.l. p QI wehd kpM (17 a d SO nwn el - M u lmrm d m m d u 01 ~ J m d wptnl. mmmpk.nc w m m v n d ~ r i l h n am d..isrwd h r F..lum dr4m ai 0.50 IO 1.0 W k r rllU gr4llun d w p.r W d p l e k d Moth (a2 mn rn U mm 01 *tar pfwlun d m mr rrulm d p.ehmV dm*). Y . o l u h dhaib !Am nm U ! a c m p l r l r mnm . Ipnwn dmp mnd l a w n d u d an rh.1 tw Um .5cmpllshad .nd w M h u tk lwumbadml)k~glo*.dupnn.nor*haukk a mduer I m p n a m d s*mntan b h n m produd qua*. fhm a n y w r uu m p in m W mrt m. prumurm 8-0 parrm.hn S # J * m tho r e n u 8 l l r . d prruun drop wrmb- in in tm M rbtmr (mm d r b h r l . fh.rdorr. M n a n i g n l q ~dnrmr rlh OUn M ~ a s * .P d m 1 eom~arntlons h a m bo m-n. n & a k w l r n lk. saell[c imvltv d tM b i d h suwunn.Yr i n s ih.m tkrt
tna nublishma the aibmrt.r
01 the tmr *nich. whm lh. ).Chin[ srtuned nnd oprrrtrd r t aaaI#m lkuid earn rmf- d d*rmIb# tnr re1cet.d mnaaurr amp.
nrw ~h
4 mr arplh d h m bw r w u l r d mltl bm d m n d m t upan thr, a#prwch Ia mml m a n trOn*fnr nsurnd r l l h lW% mlr. tnnllY tfmrrlk.lly rmuMI* r b d d innnil* depth.! Rm(ara 1R.m .81 IMPS dnr8n.d 10 owmtm mt m a : nun -1 m m lr*nsIaf. In (re abwrutbn pmblam~.thm, b.d h uwmlw ~lleueyllledlmm the mala mmln c*,
*I&
c
bream4 thr d n w H from th.r u I 0 Mm Hauld ph8n. n i h m ma$¶tm-8.
Or d dnpprn# aperatan m lnrOhM h mar c v ~ r mbecanal: l
fw
-
*.
b c c m ~th ~m. d r il ~Ivq~d la rnq S # I phma. Thm M n i l k t u ol tho t e r n tor the v b v a q u m l k n l lor w nna I..r n r n f0IfC-w k m t M.U tnmia co-.mtient lb. rnom/n.a nr. ~ t m .
h m M H ~mmfn c m m d m t m. rnowlfl.)nr )I s b. tmnsRrdlHr. H n h c droth ~ of towr wchbmL ft. 4 = tcwruwar -1 wmr, Ity C r h m r r u u r h 4tmorWarn v, ;-&tr;pniu%h ItdG. cmupanmnf i itn eh.se m e h m h n of m m w m iLn
I,.
~sui#lrrivnd t h liguid bulk H a w mom lr8dm d &rnpm-d lXB X, t liqul4 ohms# WI rraetipn. eunpovnl i X.* = * I d mas* mob Irmctbn m i tornpnnmnt i I* qrriHtiurn rlth E n bulk phrra motr mmmar CpmW"."t I.I 0
3. anr* h d n # d d m i n e d tha mlu4 oi
X 1s D. mbrchu *r U.p 1 . m d uMld mn o # r r t i y wrrm amp in f e p 2. a r mku at Iha erdlrrrm. I.m q b. datnrmiw by lhr urr gT IM # a ~ n U r m dm w r e or- -Ua. Locrtm thw
-rum d me m b ~ l an s lhil ~ Cr n * . ( t ~ ~ n umtu y the p p m r prbsnum apramrtur a Centme*d: IkW m -tmlV hem rn, paint b (h. WI iund +qr d ttm ehrt m d nM ma v u w 01 w mdir~tm.1411 nkn q - I m this smuv d *.firbin:
rn~
mrrr mu rwbstriptr 1 4nd 2 n l r r to thm mp rM bonffn mi tlw wkrnn r c r p d i w * E l Thm qwllon 01 &XI. ir .n.)qOu¶
ro itm q u r ~ b r lor r av~.i l w n r m .
b a d hr dm* a r m Wmilmbh fofmalt abarDlbn and -ping omnfkm. b K l ~ 8 mIh.I a U On a h a m t b n M COI wilh ~ l u 8 t krod. Mlutlmn mm r w mmvMt* tw mm v-riaua p e w , N k ire( # all I unusual tm me ttm -10 m a I mllo in-m wunm tor orlrgn wilh whar p c Y n p 04MMr nln wn tha. W rmeh OI& inlOmtiOiOn nfltl. Pdlilnlbn unth m ganwrlb d n i p M m tM b.bh ul M T P tnaifh~.~U~Y.IWI10 I~ ~ C O I ~ @ T .I*).~ I numind. d -11. barn n w l r n m l r l studlrs h r w u u r d UI lo cMLa ihbt tnr d n # 8 apturn mu ml. a rtlh tlw H I T ? *I&. (rmacd ihmt jcd d l l t n b u t i in nmntlimd and iha WebM w m ammtao wth p m w n wow d r l hmrt 0.20 mrm @ u r a r p f n w e amp mi IW . I prkdm (17 rnm ot r ~ ornrun n amv uw m& at W e U d mpch). Mars m n s l u tmkl~##elm m p c M Oms. whmR m ) r lubrmmial amd msuvm dmp aalwF.. -11 aecw i n d m r M l * f # I r mull d brbuhnl t0-i . Ip a am %tid miner man 4 r 1 d f i s m n l 00.rvlmn gwmrwd b y Rlm mlutmnCn 11 lhm
*
dlul al r l u 8 h h n l i m n ere*# Iulha nswrty Of r M YqW, 1 l u mckhq l a c l a r m d inn nr nle a. tho viraq c4 Ihr hldd a n C. dat.rmimd FtanNm. uwrlmtm or m m r r m w a Th. W U r I n n o n d bI1 YI.L 61 naelim am i m n m tna an* on p e a 4. Orordb I W a W W U n * mmlkr Uun 1 imh .Inm 4 m t l d . d lor tw.n om trrr or s m l k r dm*-, p r h t n p 1 ,men w L'H inch in un b r ton- mr ow M lo t n m hi 10.3 a 0.9 m a w ) m Mrrnwr urd z ot 3 rwh W P I . I ~ ~ arm u n d la l a r m n Ulrn or mole In(( 0 9 m u n l in awmH N Thc d.rrlrm rnouY urn tha m m i raa of erkmn. Th.
a n d thanlora .----.-..
lk p . ~ p rp u h u n ~f m o r
10
lkrs Rst
eu .n l..M l--.
om. ma told ~ . dgmn d
hmw bt.n amtarm~md.t h damn or
~-&rhurOwr must be rstab1,shd. O1Mral(l. hdlndua4 Dtd damn D hcu 10 csIumn d ~ m e t a r rr fO *nhoucn
n..
..C.,,..lr
3. Har that mH vmrublll hew rmsqnod vrlues. O mar k clkUktW mnd me u~arnelurd ikm te-w aet.rmlnM by
C l O O l lOrw bnimmlls br* rmur4d to r*llltD 1111 lull p l e n tirlol lhm p ~ ~ u m na any .por!crlion. (3.. [email protected] rnanu.1
TA.W.1
4,
HEAT EXCHANGERS
R c v ~ s ~ o: n u
Date:
TEPIOPtEXPISUI
rry:++r
2/85
4.1
1. APPLICABILITY It
is not expected that a hand calculatian of shell and tube exchangers be performed by the
engineer. For the purpose of a feasibility or pre-project study any required rigorous calculation would be performed using computer pr%rams HTRI or HTFS.
A qulck estimation of heat exchange area, shell diameter and tube length should be h e by hand calculation. An example of the procedure is given in Section 3.
A detailed mechanical design is beyond the scope of this guide. 2. DeSCRlPTlON A N D NOTES 2.1.
DESCRIPTION The flow of fluids inside the txchanger varies according to requirements and
can be
single or multi-pass on elther tube or shell side. Figure 1 shows the types of tubular heat exchanger manufactured to TEMA standards ;
The following types are irequently found t
2.2.
-
Exchengers (Heaters)
Candenserr
Reboilers [Therrno~yphonor forced circulation)
-
Evaporators (Kettle)
Chillers luring refrigerants)
SELECTION OF SHELL OR TUBE 510L FOR THE FLUIDS a. Tube side :
-
Most of time highest pressure fluid
-
Cooling water, steam
F w l l n g or corrosive fluid Sea water (it ir always recommanded t o install the sea water on tube aide)
b. She11 side :
-
3
Evaporation (refrigerants in chiller)
- Condensatian - Lcagt fouling Iluid
Most of time lawest pressure Iluid
SELECTION OF TUBES
. .
. 2.9.
Fluid with the highest viscosity
Standard length : 12'. Ib', 201 but longer tube lengths are possible {upto 00') Diameter commonly used :3/0", 1" Pitch commonly u x d : triangular or square. E~tcrnaltube cleaning is possible with square pitch only.
TUBE SIDE VELOCITIES
.
&
.
IIK tube side velocity for most materials and services should be held bcrwecn abour 1.3 to 2.5 mls. Below 1 to 1.2
mi5
fouling w1I1 be cxcessivt, much above 2.5 m/d erosion can
become a problem, 5 q
.
Rc~lsion. 0
TOTAL
'
pap* M~ :
SHELL AND TUBE EXCHANGERS
2/89
TWIOPIEXPIW~
4.2 >
CHARACTERISTICS OF
5
TUBM BWG = BrRMlNtHAM WIRE CAGE
I1
I
I lnmM1 SECTION 1 THICKNESSl R E/ dlamcter lmml I (in el mm) II B W G j (cm) I (cm21 1 1 External 1 I I I I I I 1 l Z i n I 14 I 2.10 I 0 . U 1 0.563 1 0.0399 I 1 (12.7 mm) I 16 I 6 1 0.950 1 0.694 I I I 1 18 I I I l a 2 1 1 0.819 I I I I I I 1 I I I 3jU in I 10 1 3.40 1 I.2Zu I 1.177 1 0.0598 1 1 (19.05 mm) I 12 1 2.77 I 1.351 1 1.435 1 I I I 10 1 2.10 I 1 1 1.727 1 1 I 1 16 1 1.65 1 1.575 1 1.998 1 I f I & 1.2P I 1.6% 1 2.159 1 I I I I I I 1 I Iin 1 10 1 3.40 1 Id39 I Z.7lb 1 0.0798 1. 1 (25.4mml 1 I2 1 2.77 1 1.986 1 3.098 1 1 I I 14 I 2.10 I 2.118 1 3.523 1 1 1 I 16 I 1.6 I 2.210 I 3.136 1 I I I 18 I i.20 I 2.291 1 9.122 1 I I I I I I I I 1 1 1 I 4 i n 1 10 1 ?.PO I 2.994 1 4 0.0997 1 1 (31.75 mm) I I2 1 2.77 I 2.616 1 3 7 I I 1 4 1 2.10 I 2.743 f 5.909 I I I I I6 I 1.65 1 2.845 I 6.357 I 1 I I 18 I 1.2@ I 2.921 I 6.701 I I 1 I I I I i I I 1l/Z in 1 10 1 3.40 I 3.120 1 7.661 1 0,1197 I 1 (38.1 mml I 12 1 2.77 1 3.251 1 8.300 1 I I I I k4 I 2.10 1 3.378 L 8.962 1 I I I6 I 1-65 1 3.4110 1 9.5t2 I I 1 18 f 1 1.20 1 3.556 1 9.931 1 I I 1 I I I 2-6-
External
I
1
1 [nlond
I (kg/rnl l I
0.0266
I 0.W
I 0.0295 0.0321
0.0384 0.0424 0.0166 0.0495 0.OSZO 0.0584 0.0621 0.0665 0.0694
I I I
0.b90 0.384
I t
0397
1
1 1 I
o.orm I I 0.0783 1
I I 2.021 1 1.696 I 1.321 1 lart I 0.~11 I 2.609 2.158
23-
0.862
0.0981 0.102t 0.1061 U.1093 0.1171
I 1
3.185
1 2.635 I 2.039 1 1.622 1 1.237
I
DESIGN MARGlN 10 % on area in recommended.
PRESSURE
.
DROP
n!Jawablc
id
A P varier with the total system pressure and the phase of fluid.
pressure drops of 0.7
t o 1.0 bar per exchanger arc common. The
cquilralent gas drop is about 0.2 to 0.5 bar.
.
hrne cxchangerr have low pressure losses and as rcboiler and condenser tless than 0.1 bar) trpccially those in vacuum system.
&J
I 1
1 1 I 1.682 0.0894 I 1.340 0.0918 I I d 2 4 I 0.0822
TEMPERATURE APPROACH AND PINCH
.
1 I I
1 1.416 I 1.216 I I 0.963 1 I 0.772 I
mlnimum temperature approach 5 'C. minimum pinch for condenser or chiller 3 'C, 2.7.
II
i 1
,
li
TOTAL
SHELL AND TUBE ~XCHANGERS Oat* :2/85
~w/DP/cxPISUR
2.9.
1.3
CHOICE OF HEAT EXCHANGER TYPE (Figure 11 a. Front endstationary head types
.
. .
Type A : Used for frequent tube sldt cleaning due to the easc o f dismantling the cover.
Type B :
Cheaper than Type A but the dismantling of the bonnet is more difficult. To be used for clean products.
Type C : Cheaper than Type A for low pressure. The price increases quickly with the pressure. This type Is pracrically never used.
Type D ; Special for hlgh pressure P > 200 bar. b. She11 types
. .
Type E r . In general the most commonly used.
.
Type F : Advantage
; Fluids flow
.Disadvantage : -
at perfect counter current (F = 1).
Leakage between the longitudial befile and shell decreases in
-
-
value.
Mechanical problems from expansion. Low prcsmre drop t g : < 1 bar (risk of d a m a ~ e
01 the longitudinal baffle). This typt should be avoided. A greater number
oI Type E shells in Series is
preferred.
.
Type G 4 H :Used tor low AP J. 50 mbar as lor thermosyphon reboiler. Vertical balfics are not installed lor t h c x types and due to that the length of the shell must be limited.
,
Type 3 : Uaed for high flow or high
AP for
Type E and also sometimes on
condtnsates to avoid the use of vapor belt.
c.
. Type K : Used for vapor separation i s required ie chiller, some reboiltrs... Rear end, head types - Types L, M and N : Fixed tube sheet, used for clean fluid on shell ride and lor Iow
.
.
.
AT
< 30 ' C . i f AT > 30 * C
use other head types or install an expansion
joint on the sheil. Typc L and N will be used for dirty fluid on tube side. For the other cases the t y p e M wlll be urcd it is the cheapest. Typc P : Generally not uscd.
Type 5 : Used very frequcnlly, no restriction& Type
T : For frequent dismantling, enpensive, she11 diameter larger than t y p t
S far same number of tubes generally not used. Typc U z For ckan fluids on tubrsidc no other restrictions, low cost.
Type W : Generally not uscd. d. Conclusion
Tot most frequently uscd types are I BES, BEW, AES, BEM, divided [low,
6 1' 7
-
.
TOTAL TEPIDPIE"~~SUR
--"- ..-
-
m u . "
PROCESS ENGINEERING DESIGN HANWL
k.i*' : 0
P.g. No
SllELL htJD RlBE EXCHAWSRS a
: 2/85
4.4.
3 DETERMINATION OF ESTIMATED HEAT TRANSFER &REA
I I I
DUTY
I I
Outlci temperature T2
HOT FLUlD
I Inlet temperrturc
I I
TI
4
II
I 1 1
T2-tl
'c
I T1-tl I I TI-T2
I I I I
O.fr10
6
*C *C
13J-?S=g
I I I
I8 16
(fr-1Br+
*C
I 1 3-r I I ?&-ti=? I I st.19=16
'C
1 3b-t5-4
I
-
2/11
I I
q/l
I
=
---
-
I Ir CORRECTED - LMTD - CORR. - Ir i
HEAT TRANSFER COEFF. I TABLE 3 Page 4.10
r-----
I HEAT TRANSFER AREA
ui
.
kcal/h
i
mZ
1
A=+ U.LM D CORR
I
ESTIMATED TUBE LENGTH CT(m) ~ T ~ M A T ESHELL D DlAM Iinr(rnm)
1I I
I 1
1 ESTIMATED WEIGHT Bundle I tonnes
1
1 I 1
f
1 I I I I
I
I I I
r
T
- c-[ -II
,
- rI 7----i
I
t I I 1
-
I
I -
-
-2ifI
sea a.0 ( LOO r S.cC
20
I I
i
including foulin8
I
I I I I
F = D.111
I
(c.1 1
3 1 [tqo)
13hlI
ruh* L
' I& t dY 6
;C 17
tA*s I1
3 .C)
I
L.o
Shell
-------
1
I
----
J tannes I Total I tonne~ I I I
I I t
1
I m2 *C III factor I r ----------I I 1 I I
I I I
I
I I I
I I
~ - F T ~ - carrection !D I factor (3) t
r--
I I I
I 1
l.llf
~TNK-BFROFS ~ELLS------
I
i?
I
o,f
-,---[ L I
I
I I I I I
I
' C
I
I
I I 1
*c
I
a&
I
-C
I
NOTES :
I Indicate temperature I I
tr
I
'C
I I 1 I 1 I 1 I I I I I I I
(1)
I I P-U-tl I TI-tl I I R~TI-TZ I tZ-tl
'C
I I 1
I COLD FLUID I Inlet temperature t l I Outlet temperature t2
formula
kcallh
I I
VALUE
I
I I I
Q
I I . LMTD from I I t2-tl I
I
I I
ITEM :
--
q .o -
--_
1 __---.l
- - -
-
--
I
----
I 63
PROCESS U L C U U ~ O H SHEET ITEM ; i l - ; < . . L . , -
~WQO? MR~KP'SUI
1 I
CI.
I
SHELL AND f UBE HEAT EXCHANGER no n ~ t ri
I lnm rartr
.
a .tz ,?t
L
~ n un n
L*t*',.*
.a%.
,II!, i
rrv I
Revhion ;
TOTAL
0
Page No. :
SHELL AND TUBE EXCHANGERS 2/89
Date:
T€PR)Pf€XPlSUR
4.6
(1) Use following formula
- -- -
if T2
- t l > TI - t 2
- t2) - (T2- t l )
if T i
-
LMTD. (T2 tl) 1T1 tZ) LnT2 t l
T1-t2
LMTD
.
(TI
'12-tl
LnTt
t2
t2 > T2
- t1
Remark : If tht htat exchange curves are not linear the LMTD should be determined step by step w l t h the lintarisation of the curves and with the ponderation of the
partial LMTD by the partial duty on tach Iincar step.
(2) For total condensing TEwmnPJ .c
3y
26
5 hmpratur. *WW+h
I
I
>
I*m l
- 2
Dm
D.np.h*ariw
Eond.amlnp
I d l l Y
/r 1
0
%.tm
In this case -alculatc the heat transfer area for each zone, the sum of these areas is the
surface for the exchanger. (3) See LMTD correction factor (Figures 2 ) the number of shells should be chosen in order to have 0.8 IfF
(
0.8 add shells (2 exchangers in service)
1. ESTIMATION OF SHELL DIAMETER With the heat transfer area, selected tube sits, pitch, tubes I e n g t h ' i t is
possible to
determine the number of tubes and. w i t h table 1 or 2 hereafter the approximate shell diameter. Take maximum shell diameter abwt 60 inches.
6q
( TOTAL I
IROCESS,ENGINErnlNG DESIGN MANUAL
I
Revl$inm :
0
I
Papa No
.
SHELL AND TU8E E X C W W M
-
TEP1IOPIEXPISUR
Dltl
: 2/05
4.B
1
TOTAL
P R O C E S ENGINEEAINII DESIGN MANUAL
TE~~DP~EXP~SU~~
SHELL
R4n.m :
7WBE E ~ ~ ~ ~ G E R S
,-
OLtm
.a
: 2/05
i ayr
IVU
4.9
L
1 I
TLWLI k MI' PITCU
1 I,
u
rruusr~o r v ~ r r r sruar
s
)IDL
I
3
*
I
!I
n
10
>1
11
I
I
C I T ~ A 1-
I
I-
NVMOLIOF C
I
rumS SIDE
~
I
1
r
10
Y
I?
H
31
10
64
%
17
I?
Tb
$8
W
82
76
95
+n
az
161
104
M
IJI
LIb
146
1%
I17
111
12. 1U
131
111
lm
IS I I ~
1%
120
am
nm
13
111 21 .
11 I/* ZJ l i b 13
Z7*
??a
186
JID
MS
ln
JIJ
111
301
H1
Wl
3s
a0 I
W
$70 +Jl
111
*A
*I9
3%
JIC ILL712
119
bm
1% WI
*If
19 I 113
m
7SJ
111
477
I
IS
~fi
I?
n $1
II II
LbU
10.
1%
UY
199
a10
77:
I?> 111
111
170
I67
301
110
1071
917 1017
U Y 1011
lolb
iOJI
3lJ
LrM
ll t l
1129 1110
rni Inr
1172
1/15
t2lZ
1111
ZDI?
m9
8117
1Yl
1111 I0
111J
2JY
tW.1
a
Ib
I7 $7
>a
61 14
37
I a3
Ill
110
11Q
In
I77 115
.I IC
I 6b
nr ).I
151
I
Ma
m
,n
171
a31 117
J>l I10
*I
6lh
131
tbb
*?I
9m IO>I
YI
IIH
lola
llOI
In,
llJS IIS?
I%*
If*?
I I
TABLE I
p
.
kdh. m? Y
rnrrl* vsr.rl*rtr "h. I< l rs
(includinp foul LW factors) nrn#ndtmUq
..
C~~,SS
w-i n r r *
C&3
chlllrr d
It0
r.tsh...,n.C
11 110
.-1wsltr ' I C P
a30 - 6 1 n
1C p
x 0.2047 ' ~ ~ i p f t ~ * ~
r 1 .I62
W/m
*x
>O-)W
r n h m b - v *il
sl.~.rrr.le slE.&nr,
nx. Y'Y""~
* "C"
n.c.0.9 CP n.c. wbc-ibr
(
*imW 1 CP
1 lC P
-
I IW 13 1M m-1-
9 0
Itrsmlral*l ,U,,,,/U'bi
-- bm
H m 100
m-x4
putkmll.*
*.dlu
-w
rm. 190
I.~M HL. I wircsrlr ~I 0 3 c P v.le,..r.,e H.C 0.9 c p c vw-ill
kc.l/hrm2'~
-
W-1100 2-0 Y P
am-w w.m
TpTAL
PROCESS ENGINEERING DESIGN MANUAL
Revhion : o
pwe N. :
SHELL AWD TUBE EXCIIANCERS
Dale
TEPIDPIEXPISVR FIOURE 4 TYPE BEU
WEIOHT ESTIMATE
:2/BS
9.12
TOTAL
Revision : 0
P8gs ?Jn '
AIR COOLERS htc:
TEPtDFIEXPISUR
1.13
1. APPLICABILITY For both the feasibility and preprojcct study i t would gentrally be required to state the requlrrd duty of the air -let, the overall dimensionn yld weight and an estimate of required fan power. A calculation prmedurc sufficient for a preliminary estimatt is given I n section 3.0.
2. DESCRIPTION AND GUIDELINE NOTES Water or Alr Gaoling ?
.
Air cooling offshore is sometimes prohibited due to the modular layout 01 the platform.
This may require installation of the air cmler 1na rcrnoke from the associated equipment. Use clorcd loop watcr cooling.
.
A i r caaling ia cheaper, simple and fkxible when compared to rumter cooling. The cost and
nulsancc of water treating Ii eliminated If air coolers are used.
.
h warm climates
will not be as tffcctlve as watcr which will produce a cooler product stream. Air cooling is apprax 50-70 % as effective as water. gg&ng
Fwced on induced draft ?
.
'Forced draft, pushes the air a t lowest available temperaturc~~highcst f
hence lower
pow-. requirement.
.
Acces billty to motor and driver are better on lorced. Structural and maintenance cmts
arc lower.
.
PassIbllity with forced draft ai hat alr recirculating into suction of fan thereby reduclng efficiency.
.
Induced draft gives better air distribution due to lower inlet velocity with less chance of rtcirculatlng of hat air.
.
Indudd draft coolers can be easily installed
4 h v c piperacks or orher equipment.
Protection is given by induced draft coolers from effccts(oll rain, wind mawlpn&md tubes. Important i f fluid in tubes is sensitive to suddsn tamp change also freezing 0f tubes can occur i n cold ckirnates or heavy snowfal!.
I
0
Page No. :
2 ~ 5
S.lI
Rcvirion :
TOTAL
SHELL AND TUBE EXCHANGERS
TLP~DWEXPI~UR
Finned tube elements (see Table I)
. .
I"OD tubing t most common w i t h 0.5" to 0.625" fins* Fin spacing 7 to 11 per inch. Exten. ' surface area is 7 to 20 times bare area. Standard tube lengths from 6 f t to SO It I2 m t o 15 m). Lonser tube designs are less
costly than short ones.
.
Bundle depth may vary from smaller units. U l c
.
U as first
9
rowr so 30 rows of tubes, 4 or 6 r o w r is common l o r
estimate.
Fin material most commonly AL. Adequate vpto 400 ' C operating. Use steel for higher
.
temps. Fans and motors
.
Fans arc axial-flow large volume low OP devices U s e l o b 1 fan efficiency 65
%. Driver
efficiency 95 %.
-
Fan 0 equal to w slightly less than bundle width. Normally 2 Ians preferred. Fans have 4 to 6 blades. Max fan diameter 14'-16'.
.
Distanct between fan +.bundle 0.4-0.5 01 inn diameter. Ratio of tan ring area to bundle area must nat be less than 0.4.
.
Fans may be electric, steam, hydraulic or gssoline driven. lndlvlduaf driver site usually lirnlted t o 30 hp, (80 Kw), 3110 V.
.
Face velocity of air across a bundle is 300-700 LVmin (1.5-3.6 ms-11. A 10 % change in alr flow rate results in
* 35 % change in power used.
Temperature control (Fig. I )
.
For c l o control ~ of process outlet temperature auto-variable pitch fans, top louvers Or variable spe@
.
. -
rno.tws.are required.
Vmrlablc pltch fans are more efficient than louvers.
Louvers can be manually adjusted for winter
or
night time operation.
For p r a c l s fluids that i r e c r e or gel at temperatures above the winter amblent a recirculation system is necessary t o maintain air temp enreriw the tube bundle.
-
-
General approach temp to ambient air is 20-28 'C. Absolute min is 10-12 'C.
- Air Note
I
coolers are noisy. Keep fan speed as low as posslble and consider relative 1ayOUt
carefully.
72
TOTAL
~ P U I ~ I I I :~ I{J
AIR COOLERS
.
f EPIOPIEXPI~UI
: 2/65
4.0 REFERENCES AND USEFUL LITERATURE 5.1.
Air c w l c d heat exchangers
PERRY
pp 11.23
13.
Air cooled heat exchangers
LUDWIG
pp 1 7 7
3 .
A i r cwled heat exchangers
GPSA
1.4.
Aerial coolers
4 .
Design of air coolers
-A
b t i m a t c air cooler size
HP QICV program
- 193
chapter 9
R. BROWN
Chem. Eng, Mar 27 1978, p 109 N. SHAIKH
Chern. Eng, Dee 12 19S3, p 61-70
73 >
- 11.25
CAMPBELL pp 207-209
Prcrcedure for estimation
1.6.
I*.rcJrc d r j
4.15
4-16
OPERATING CONDITIONS AND NATURE OF PLLriD : Duty
I Q = 11 w to6
Fluid inlet temperature
ITl=l
100
Fluid outlet temperature Fluid iniet pressure Air ambiant temperature Overall k a t transfer cgeff. Table f andlor aruchcd
I T2= I
r0
1
kcaIih
,C I *C I FLUID A r t = TI
- TZ =
SO
-C
l P = 1 10 barabr I I t ] = t 3a *C IINLETPI = T I - t l s 7-0 l U = I zoo kcalfh m2 *C I
C
w w k sheer) (Based on bare tube area)
I
NOTES
STEP I
8
I
(curve N* 4) P:?.
0.8
I 1 I
{curve N. 4)
t * ~ptirnrrmnumber oi tube rows fat U selected 2 R = dt airldt m 3. TI TZ/Tl tl
IN=
4. Y = A t a i r / T i.-, t l
I Y = I 8.35 Idtair.1 1 . I t2 = I S
-
IR- I 1 'qjn 1
-
5 btair r % ( T I- t i ) 6. Exlt air temp t 2 =Atair + t1 7. Average dillerentlal temp. dtm
.*
1- Bare tube surface A
z
&-
1 Idtrn.1
I IA:
10. 11 12.
I
I I 326 I
mz
m2 1 m 1 3, 4, 1, 6 , 7.5 or 9 m are I (1" 00 tubing)
IL= I 7s fubcslrow TR = Fa/LnO.OS 1 TR = I L 8 Cooler width V=TRx0.0635 ) w I jl,l Tube length
-
1 16.
Powerllan F Q ~ N F
17.
Estimated wclsht 4.88 (36.bX9.35 NIxwxL
1 I
I
i,r
Totel lan power ~ F W . 7 9 5 ( Fp = 1 3t I, Number of fans INF*I t Fan diameter I F 0 . l 3.r
3. 4
'Ct
30.d
1 Fa = 1
(curve N' I )
I
.C
I
1 9. Bare tube areafraw Fa=AlN
*C
Q.2IA
m
1
kw
i
I m 1
1 PF r l L I M r I ilrfio I I
kW
common
man. fan diam = 4.6 rn
I (including motors)
kg(
I
Notes : Curves numbers refer t o Process Design Manual Chap. 4.
70 PROCCSS CILCUCATION SHEET H*hl&@,cr*
AIR COOLER f I t f W C Q M X L IUI.
.
av
CWN
DATE
1 INttrit
. ,L
'2
Li'-.
-
UO
LI(A~?PC~-
100NO .
REV
1
4.17
1.
rlQUUCOQLlNG LIQUlD VISCOSITY AT 1 1 + T2
i ;
GLOBAL HEAT TRANSFER COEFFICIENT r U
e
--T-
(Read curve n* I) 2. GAS COOLING MOLECULAR MASS :MU' =
GLOBAL HEAT' TRANSFER COEFFICIENT r U = (Read curve no 2) 3. TOTAL CONDENSATION
71-T2 =
'C
GLOBAL HEAT fRANSFER COEFFICIENT :U = (Read curve ng 3) 4. PARTIAL CONDENSATlON
I . w1Tnou-r L~QLJIDAT inlet gas flowratc
INLET
=
WGl
---
outlet gas flowrate WC2 outlet liq flowrate
-
WLZ
T I T2 GAS MOLECULAR WEIGHT AT T i
+
12 =
2
--
HEAT TRANSFER COEFF. Uc (Read curve n' 3) HEAT TRANSFER COEFF. Ua (Read curve n' 2) GLOBAL HEAT
I
TRANSFER COEFF.
U. W L ~ X U C + W G ~ug X prtl
m
I
SELECTED GLO8AL HEAT TRANSFER COEFF. r U
=
?z PROCESS CALCWPTION SHEET
AIR COOLERS
HEAT TRANSFER COEFFICIENT 108TITLE
ITEM
no. 100 no
rtv
I
kla
4.2.
WlTH LIQUID AT INLET
Inlet liquid flaw rate
WLI
-
kglh
outlet 11quld flow rate
WLZ
I
kglh
=
LIQUID MOLECULAR WEIGHT AT LIQUID SPECIFIC HEAT AT QL =)-I
x
CPl =
-
CPl x IT1 T2)
inlet gas flow rate WG1 outlet gar flow rate WC2
QC c (WGI
-
kcallh
-
kgh
kgrh
I
GAS MOLECULAR WEIGHT AT GAS SPECIFIC HEAT AT
kcaVkg *C
TL + TZ = 2
v. CPg
wG2) x CPg x (TI
*
kcallkg *C
- T2)
kcallh
CONDENSATlON HEAT
-
Qc=Q-QL-QC LIQUID
VISCOSITY AT T
I
kcallh
CPB
LIQUID HEAT TRANSFER COEFF. (Read curve c* 2)
UI
=
kcal/h rn2 ' C
GAS HEAT TRANSFER COEFF. (Read curve n* 2)
Ug =
kcallh rn2 *C
UC =
kcallh m 2 'C
U =
kcalfh rn2 ' C
U =
kcal/h m2 * C
CONDENSATION HEAT TRANSFER COEFF. (Read curve n* 3)
GLOBAL HEAT TRANSFER COEFF. "=
& UI
Ug
Uc
SELECTED GLOBAL HEAT TRANSFER COEFF. :
76
& -
PROCESS CALCULATION SHEET
AIR CQOLERS HEAT TRANSFER COEFFtClENf
lI?IDD?'M?lIW3VR #I
CHk
OAIE
.
10I llllt
nru
106 No
I
arv
I
TOTAL TEPIDPIEXPISUR C L r I~
P I Q E P ENGINEERING DESIGN MANUAL fix4 COOLUIS
- ceoune IIYD~WIRUOH
LIWIDS
I l m v i ~ h: 0 Date
I2/8S
P-
NO: 4,ZO
--
TOTAL
PRDSLS
ENGIWEFRINO DTSIW MAMUL
inision :
o
PW* NO
AIR COOLERS Dotr
TEPIDPIEXPISUR
I.? I
: 2/85
snr/hrft2*r - 2 Fintub. 1.h h r t-in. OD . k h * ~ l l r hl l l ( l k ~ APF. rq k/k
+
3 S8
3.60
AR, q k ~ h
tub. PI* A P Y 13 ,I4 nrrl
kb.1 h*.h)I
14.5
11.1
1 in.3
1% h
11.4
60 4
a
A 2 % in, 3 IQ I I0 1
2% m ,
11.2
80.1 1 1 1 1 107.1 I . 114.0 101.0 id15 1340 lbrrd 134.1 1 178 2 140.0 k ~ A p r t l u r t ~ u r r J w n d f i * r . k i n . ~ nA# r ni. . ~ . w u ~ I * u r b r ~ ~ 4 h ~ ~ino4 Dri . k r r r~ d. ~ d I *hid b u *.MI q R I f L APSCb l k n v r u l a m in q hrb 01 b.nd& I- w.8,
.-
I
*-
. ". .....
2r....,.
-.
U*.m I . . " , . 1m.1n-
",
I*#* -,> 98.-1.2
4-.1 r - a
I,,
-a*
u, %I,#
I
FII
_.___.I-
TOTAL
p ~ l r f E H.
GK
Revis~on: 0
Page No. .
dric d a o k m
Date: 2/gs
l~p~~~~EXPfSUn
4.29
C
1. ~~PPLICA~ILITY FEASIBIL~TYSTUDY r PRE-PROJECT
Under normal c i r c u m s t a ~ t s ,the design wl plate type exchangers wwld be detailed by a vendor b a d on process data supplied by the eqinaer.
Two types oi plate exchangers could be used z
.
. or
Plete i l n exchangers ;
Plate exchangers.
the purpose of this design guide, only a quick description and
some charseteristlcs are
sivtn. For plate fin exchsngtrs, the size could be done only by a vendor.
For plate eschanger3, the size could be estimated if some vendor {ALFA-LAVAL, APV, VICARB) inlormation are available. An estimation of the heat transfer area could be done i f the hcat tranrier coefficient is known using the same formula as lor 8hil mnd tube hcat exchanger w i t h factor
= I.
4
LMTD correction
The heat transfer coelficient is difficult to clrtimate; it depcnds on many factors
as flow rate 01 different iluids, pressure drop, plate spacing, etc,..
2. DESCRIPTION AND NOTES 2.1 PLATE FIN EXCHANGERS
Thee exchangers consist of stacked cwruyttd shrcls (lins) separated by flat plates and an outer irarne with openings for ihe inlet and outlet oi fluids. This core Is immersed In a liquid salt bath t o b r a z ~all the separate parts together. Flow in adjacent iluid passages can be coeurrent. counter current, or crossflow and Sever?
uids can be erchangin~heat at the $am time.
In case of the inlet fluid & a
two
phases flow a drum is requlrtd to separate the two
phsses in order to hsve a good distribution.
These plate iin exchangers arc used only with clean fluids.
L
81
TOTAL
Rwision : 0
Paga No.:
AIR COOLERS
TEPTZIP#XP~UR
Qstt :
~fif
1.25
Figure I ahowr *t principle of coratruction of a platelin exchanger. A large amount of
surface can be accomodatcd in a small volumt (1,000 m2/m3). Maximum design pressure r
59 bar&
Temperature range
r
- 195 'C
Size rnsx.
I
1,220
Ttmpersture approach
Applicability
2 :
t o t 6 1 'C
m m x 6 096 m m x 1 340 mm
*C
LNG, LPG recovery,
...
Prc~sur top as for shell and t u b heat exchangers. 2.2 PLATE EXCHANGERS
Plete exchangers a r t an assembly of metal plates stparated by gaskets to give a small clearance between each plate. The two fluids pass in opporha directions each thrwgh every alternate plate. Refer to flgure 2.
Tht exctmnger Is easily dismantled for cleaning ii required. A good overall heat tramfer cotfiicicnt is obtained and small tempcraturc differences can be u e d . The plates can be made from exotic malerials such as riianiurn which are redstant to
corrosion and u e used for sea water coolers. They are v t r y compact eschangerr find aeupy small i l w r area.
Maximum pressure
:
Maximum temperature
: 250 'C
10-20bars
(Need spcelal gaskets) Overall heat transfer cotfficint
-
5 000 k c a l h m2 ' C
Vatcrlwatcr
: 2 000
Maximum surface
: about 1 MO m2
Maximum ilow
: 2 500 m31h
Applicability : Sea water
.
Prtswrt b o p s
I
- service water, water-TEG, TEG-TEG,..,
allowable pressure drops vary according to the total system
pressure and the ~ r v i c otf the flulds.
-
-
water #ervict water r 0.5 to 2 &r (high transfer caeflicitnt), lor sea
lor water-TEG or TEG-TEG the dP cwId be very low such as 10 to 20 mbar.
3. REFERENCES AND USEFUL LITERATURE +
>
A P increase the overall heat
Vendors iniormatlon.
2?2
/
~0Tf\ '
-
PROCESS ENGINEERING DESIGN MANUAL
Rwision :
0'
Pwp tdo :
1
p=m U C n m C Z R S
cww
~~P~DPIExPISUR
: ?IB5
4.25
PMTE F I N EXC-ILS
!
IIWCIPU OF mnstnucTKm 1. A . u * ZV d Y 14. *.dm I.-.1
I.*m t
slaw hrm
I. LR) 1.P W W ovtW 10. El-
ih.t
i l . P * M I Z M U W ~ W *
I2.wmMbr 1b.-II
Llr**r
i
Y'3
D r n I t S OF PU'PE
TYPE EXCR*NECR
. TOTAL
--Rcvirlon : 0
Pmp. Nc. :
FURNACES D a a : 2/83
~ ~ ~ ~ o P I ~ x ~ ~ S U ~
4.27
1, UPLlCABTr'TY i s not exy. -tcd that hand calculation of furnaces be performed by t h t engineer. It is normally done by 4 manufacturer based on p r m u s data suppllcd by the cn&inecr. Furnaces are
used
to transfer heat directly to the process fluid md generally have a large
duty and produce high process tcrnpratures.
OESCRIFTION
2.L.
A iurnact consists of the Iollowlng :
. .
A cornbustibn chamber lined with refractory shd burners
Tubes which .re located within the combustion chamber and where heat is transferred to tht process fluid by radiation
. Tuber which is also . which
arc I ~ a t c dexternal to rhc cornbusion chamkr in a convcctian zone Iintd with refractory.
Stack for dirpasal of flare gas.
2.2.
.
Alr supply system by tan ar induced drajt.
+
instruments and controls.
TYPES OF FURNACE 23.1.
Cabin furnace
.
This
ifia
rectangular furnace and contain$ t u b a which can be horlzmtal or
v t r i i c ~ l .The burners are rituated in the walls o r floor, and the cmvectlon
zone is laated above the furnace.
.
Flue gaser discharge to a stadt tither directly ar arc driven by an induced
drait fan.
.
Burners are normally arranged in raws on two wails and a r t spaced SO provide a rad~atlon zone of constant tcmpcratun a d avoid
aj
to
flame
impingcment'on the Tubes. An alternative arrangement i s burners located In the floor ai the furnace as shown in Figure I .
.
The connection bsnk conbins raws of tubes acrms which the flue gas
.
leaving the lurnace 1s d i g e d to pass A small negative preswrt is maintained to prevent hat gas leskagc.
,
There
is a pressure lw in the flue 8as syste~nand this h l s to be made up
either by we ot
fan discharging to a s b r t stack or by natural bwyancy creating drait in a tall stack. +
&
$5
TOTAL
nrv~rion:
0
~ a g ~ ~ o . :
FURHACW
tEPIDPlEXPISUR
Date :
2/85
b.28
1.2.2- Cylindrical furnace (see Figure 1)
.
These furnaces arc vertlcal and contain rndistion and convection zones or
KI~CIJ
. . 2.3.
4
tadistlon zone.
The burners are h a t e d in the bottom and the radiation zone tubes can be vertlcal or hcli&~dal. The convection bank is located above the radiation zone and contains rows of horizontal tubes. Cenermlly the stack ls vertically above the convection bank wlth no f u k
BURNERS
.
Two types nf burner are used in furnaces, induced air or natural draft burners and lorccd drait burners.
2
. Induced air burners These can burn gas or fuel oil simultane~uslyor independently. Excess air required 1s 15 % to 20 % for gar and 30 % t o h 0 % lor liquidsl If fuel oI1 is burned 0.3 k@g
2
oil of steam is required for atomisi*
Pressure burners
The air far prrs8ure burners is supplied by fan. I t is therelore capable of control and the burner can operated wlth less excess air 5 to iS '16. 3. EXCESS AIR
.
Determine the excess air recommended by the burner manufacturer and the type of burner air system proposed. k t 1 2.3.
.
From thk determine the kg of flue 68s per kg of fuel fired remembering that air
contains 21 96 Vol 01 oxygen. I.f TACK GAS TEMPERATURE
This i s controlled by 2 iactors :
. .
The process fluid inlet temperature w i l l dewrminc the temperature of the gas Jeavhg I h t convection bank. Condensation is to be avoided. If sulphur 1s prcaent in the fuel the stack temperature i s raised to avoid the possibility of production 01 corrosive sulphuraus wid. This would result in a minimum e x i t temperature of about 120 ' C .
5?6
Rev~sion: 0
TOTAL
Pagc~o.. :
FURNACES Date:
ITEPIDPIEXPISUR
2/85
0.29
t
-
EFFICIENCY
\I
3 I f Hc =
-
IOD IOSWS,
-Tbb.
Hf
- HC
Hf
flue gas enthalpy at exit
Hf = enthalpy of combustion (net calorific value + sensible heat in futl and air) + heat bclng furnished by atornisalion steam if required. L a s x s include radiation and unaccounted, e.g. unburned fuel (2 % is a good figure). For a furnace which is all radiant duty the efficiency is of the order of 50 to 55 %.
.
.
A furnace with a convection bank will be from 75 to 8 1 % efficient.
P R W U R E LOSSES
Pressure is lost in :
.
.
: 3
Burner air regulation Convection bank
: 5
- I 5 mm water
- I$ mm water
.
Ducting Stack
:
variable : variable
Pressure is gained by natural buoyancfof hot stack gas. For r system using natural draft burners a low pressure loss is required across the burner and the furnace operates under negative pressure. FLUE GASES VELOCITY The flue gases should leave the stack a t LO
- 70 m/s velocity to ensure safe dispersal.
CHOICE OF TYPE OF FURNACE
.
Above
a capacity of
60 r 106 kcallh the cylindral furnace gives construction problems as
t h e maximum diameter is about 10
.
- 11 m.
A cabin furnace requires much more floor area fian a cylindrical furnace the length can b t as much as 27 m. If the tubes are horizontal then a withdrawal space for tube
replacement will also be required. However for offshore applications the gpace requirement tends not to favour the cabin furnace.
.
With a cabin furnace it is possible to obtain a uniform heat reicasc across the radiatlon Zone. The helght can be a b w t I 5 m.
-
With e cylindrical furnace it is not possible to obtain a uniform heat above release across
the radiation zone. The height can be about 25 m. For remote locations in oil field sppljcations water bath fire tube cyl~ndricalheaters a r t often used (consult vendors NATCO, 85 & B etc...)
g?
-
The I o l l o ~ ~! is lor a very preliminary sizing
D in m Qa =
absorbed heat in 106 kcalfh
9 H
Dtlinm 2.5 D in rn util radiation bank
r 5
/ TOTAL
PROCESS ENClnlERlNO DESIGN MANUAL
1 ~EPIDPIEWBUR
Aarklsn : Dmra
I
5,
PUMPS
:u85
Pwe No :
rOTAL
Revision:
0
Page Ho. :
PUMPS
-
TEPIDPIEXIISUR
Date:
2/83
XI
1.0 APPLICABILITY
For both the feasibility study and a pre-project study the engineer will be required to cvJuate a pump selection and fill ln a data sheet with the basic Information. In order t o provide the basis of a good cost and layout estimate it is important to understand the type and number of pumps-for the service in consideration, and the associated power rquirements.
2.0 DESCRIPTION AND GUIDELINE NOTES TYPES OF PUMPS
.
Generally there are three classes of pumps : Centrifugal I . Centrifugal 2. Propelkr
3. Mixed flow 4. Peripheral 5. Turbine
.
Rotary
Reciprocating
I . Cam 2. Screw 3. Gear
I. Piston 2. Plunger 3. Diaphragm
4. Vane
S Lobe
A pump select~onchart is shown in Figure 1.
GENERAL USAGE Centrifuga!
. . . .
~
U
(Process J Pumps)
Medlurn t o high capacity far low t o medium head requirements. Higher head requirements can be met by using multistage impclltrs. General service for all liquids, hydrocarbons, products, water, boiler feed.
Simple, low cost, even flow, small floor space, quiet, easy maintenance.
s/
1
Revision : 0
TOTAL
Pag4 No. :
PUMPS Data : 2/85
TEPIDPIEXP/SUR
5.2
Rotary pumps
.
. . .
Many proprietary designs available for specific services. Essentialty can handle clean fluids only with small suspended solids ifany. Can pump liquids with dissolved gases or vapwr phase.
Can handle wide range of viscosities
- upto 500 000 SSU at high pressures.
Typical fluids pumped : mineral, vegetable, animal oils, grease, ~lucose,viscose* paints*
.
molasses, alcohol, mayonaise, soap, vlnegar and tomato ketchup 1 Generally specialist pumps for specific requirtrnents.
Reciprocating pumps
.
Pumps p r d u c e virtually any discharge head upto limit of driver power and strength of
.
pbtonr:
.
.d casings.
Overall ~.Iicicncyis higher than centrifugal pumps. Flexibility is limited. Piston pumps : can be single or double acting. Used for l o w pressure light duty or intermittent services. L a s expensive than plunger design but cannot handle gritty
. .
fluids. Plunger pumps : high pressure, heavy duty or continuous service usage. Suitable tor gritty or foreign material. Expensive. Diaphragm pump : driven parts arc scaled from fluid by plastic or rubber diaphragm. Ng
seals no leakage. Ideal for toxic or hazardous rnaterlal. Can be pneumatically driven at
.
slow speeds for dellcate flulds. Triplex pumps :commonly used for TEG circulation.
4. REFERENCES
AND U S f f UL LITERATURE CHAPTER 3
4.1.
LUDWIG VOL I
b.2.
PERRY CHEM. ENG. HANDBOOK
1.3.
CAMPBELL VOL 11
4.4.
"Centrifugal pumps and system Hydraulicsn Ugor
4.5.
I.
CHAPTER 14
Karassik Chem. Engrng Oct O 1982
"New Program Speeds up Selection of r Pumping unit" M. Seaman
4.6.
CHAPTER 6
O i l and Gas J. Nov. 12 1979
"Rapid eslculation of Centrifugal-pump hydraulics" W. Blackwell
Chem. Eng. Janv. 28 1980
f2
Revision : 0
TOTAL
Page No. :
PUMPS Date :
TEPIDPIEXPISUR
21g5
5.3
1. FLU10 CHARACTERISTICS
.
Always quote at pumping temperature ie : normal suction
T.
2. SUCTION PRESSURE ,
Evaluate at pump suction flange
-
Ps = Pop + Static head line 1 0 s Pop = minimum vessel operating pressure bara. Static head :evaluate a t LLL always,take statjc head above pump centreline. s u l f ~ cravlt Static hcad (bar) :h2 (m) x w Line loss I evaluate APline for bends, fittings, e t c I for estimate use 0.1 barl100 rn.
3. NET POSITIVE SUCTION HEAD
.
NPSH available (NPSHA) is evaluated by the engineer. NPSHR required is stated by the vendor. Always try to providdp.6
.
- 1)rn NPSH more than vendor states.
Vapour correction is calculated by substracting the Vapour pressure of the fluid being pumped from the calculated suction pressure. Convert this to rn head. For a fluid a t bubble point the vapour pressure r Pop head (m)= bar x 10.197/SC. NPSHA :static hcad line loss + vapour correction
-
.
DISCHARGE PRESSURE
. .
.
Delivr pressure :use maximum Pop of destination vessel Static head h3 : height of delivery point above pump or if a submerged discharge into a vessel the height of the HLL. A P discharge line : calculation based on line length, fittings etc or use minimum of 0.5 bar. D P exchangers, heaters, etc I use allowable AP from equipment data sheets. Estimate 0.7 L.0 bar ii not available.
-
b
P
Rev~sioti: 0
TOTAL
PUMPS
TE?IOP/E)[PISUR
.
. .
Page No. :
Dale :
A P orifices I for flow meters use 0.2
2/65
5.0
- 0.4 bar.
A P control valves :use maximum value of 0.7 bar, or 20 96 of dynamic Irlction l o s x s or 10 % of pump
AP.
TOTAL DISCHARGE PRESSURE :sum of ail above A P values.
5. DIFFERENTLAL HEAD
. .
-
Differential pressure -. discharge preswre suction pressure Differential head = Dif ftrential pressure x 10.197 Spec, gr.
6. FLOWRATE
. .
.
Normal flowrate is maximum long term operating flow (rnllh) Design Ilowrate is normal flowrate + design margin.
Design margin
I
10 % for feed pumps or transfer pumps 20 % ' r reflux pumps and boiler feed water pumps
Use
7. POWER REQUIREMENTS Note :although the term "horsepowtr" i s still used,power requirements a r e given in kW for metric calculatlonr
.
Hydraulic horsepower
I
theoretical fluid HP = design flow x Diff. press136 (kW)
Brake-horsepower (BHP) = hydraulic HPi q p pump efficiency IkW)
.
Optrating load =
.
Connected load :electrical power to motor a t cated motor qize (kW1
+
Note pump s p e d are either 1 450 rpm or 2 900 rpm
electric& input to electric driver a t normal pump qxrating load = BHP/ motor efficiency k W
vrn
UO HZ electrics1 frequtficy)
8. MAXIMUM DISCHARGE PRESSURE (shut off pressure)
.
Estimated shut off pressure t max suction preswre (design pressure of upstream item head calcuiatdat HLL and SG maxi) + 120% x(norma1 pump AP) 9+ PUMP MINIMUM FLOW
.
For an estimate
use 30 % of normal flow.
10. PUMP WEIGHTS For an estimation purpose only Flgure 9 can be used to determine t h e welght of centrifugal pumv package.
.
.
$?f
a
+
-
--..
6-5 ' 5 0 4, 1
HLL
~ Kq!-i:~
.
--7 .
4,3.4 :er c
I4 m
CCL-
i ? -~ ~
rnr2
i . i~ : :-a
Pump - A .CC-.Xw
Indicate pressure, elevations and system sketch
LUlD PUMPED :Liquld : Pumping temperature T I .par pressure at T r entity at P, f dpedfic gravity a t P, T :
1
.C bara
40 i,04
305 kdm3 0,395
I I I
SUCTION PRESSURE kin. Origin Pressure. ,Static head at LLL = (rn x sg x 0.09S11 L A P suction line
PUMP TYPE : Z L I I - b Speed : 1232 Z.iV
CtuDE 3 i C
baral rn 1 bar1 bar I
I
-
TOTAL AVAILABLE NPSH
m m
m rn
MAXIMUM SUCTION PRESSURE Vessel PSV setting Static head at HLL
25
%
<8?
m3/h
.
(I):
DISCHARGE PRESSURE
I I 1 bsra 1 bar I bar bar bar bar bar
cP
I NET POSITIVE SUCTION HEAD I Static head a t LLL' L l m loss + vapour pressure correction
Design margin DcsignflowatP,T
1 APorific s) AP II dp 1 Other ; :oht:r,;r-.%l)
42
4,20
I
!,I7
I I
z
I I I
bard1
bar1
Q,5?
I
-
I
I I
I
I
I
TOT DISCHARGE PRESS bara
I
I
DIFFERENTIAL PRESSURE
1
I 1.43 11 I I I 4,5Q 1
1
.
I
bar
1
I 1
:-:;= CP {WC. cnnd 1 m3lh
I 1 Delivery pressure 1 Static head 0 3 I A P control valve(s) C , !O A P exchan efts)
I
~;r.
Viscosity at P, T ?, 2 Spccif ic gravity a1 8:: ._,_ 0 a?? Normal flow Q at P, T : 151
l ,D! 4,20
1
PUMP SUCTION PRESSURE
:
1
I
Suction pressure
bara bara
Pump AP
bar
m
1
1 I 1 1 I
I I Brake Horse- wer = (t)x(Z) k W 1 MAXIMUM DISCHARGE PRESSURE I I kW I Max. suction pressure baral 5,03 1 Estimated motor slzc I Normalpump A P x 1 2 0 % bar( 3 , 3 ~1 1 Design operating laad (4)lrlmkWI 1 L (Fis3for 9,) I net bara I I I 6,53 1 kg I I Estimated weight I 5,03
0,75
1
I
I
2,Y I 4 3.50
1 I I 1
I 4.42 11 I
I
1 POWER REQUIREMENTS
net bara 1
1,O.I 1 ,
I I I I
<.Zb 4.d?
I I 1 1 I
3.16
((2)
40,o
I I 1
1 I 2 3 1 1\31
j ~ + I , I 1
-
75
30
1141
34
H51
4230
I I
1 I I 1
PROCESS CALCULATION SHEET T X b ~ , S T E i . PLlWF
lttM.
PUMP
~EPLWliOlPltVlSUm
v
i
CHX
D~II
1 tor
~ITLE
~ - X A L : ~E:
'
NO.
JOB ~o
.
2270
A l t
I
MU
(0
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
n * ~ i :~ 0~ n
wm5 TEPlOPlEXPlSUR
: 2/85
Datr
5.c
*IC* Y I l O CI*IaHUCIL .LAN-.
C"I"LC.L WICYIO*
m m
loo. nncwnw.lla= r m a n r # rwf
7
b
b-*
-_-
-*
,a
~ l l l
-.._ _ --._
..OTEY
CYYl
2 #1bGESn 3-a
a*m
. R X I Y NIYI I I I B C I Ill.Y
z Y
I.
-
+
I
I FIG. 1 - * & I
FIG. 2
I0
w
m
llD
A ~ ~ N C E0Ss I P P C I C ~ ~ I FOO~R O l f f
01-
l L l M IY'IHL
EeCnl PuuP 1 Y P U
ESTIMATlON OF CENTRIFUGAL PUMPS EFFICIENCY
a I m m m n l I m I m m I DOTTED LINE FOR PUMPS WITH H ,I
7
H III
(96
TOTAL
P A O C E U ENGINEERING DESIGN MANUAL
Revision :
Data
TEPlDPlEXPlSUR r
701
: 2/85
Pwpa NO:
-
--
OTAL
----Revision : 0
-
Page Ho. :
GAS TURBINES
WDPIEXPISUR
Date:
2/85
6.1
1. APPLICABILITY Fearlbllity and Prc-Project study :
.
The purpose o f this design guide is to give some information
to the engineer in order t o
be able t o select a suitable gas turblne.
. .
The' gas turbines do not cover the f u l l range of power and sometimes the process is adapted t o the choice of the engines. The ioca
bn is an important factor.
INDUSTRIAL APPLICAT!ONS OF GAS TURBINES
The two major industrial applicatior!s of gas turbkne drivers are power generation and gas compression. The gas turbines are also used for liquid pumping [crude oil, water injection, .I but these applications depend on thc ratio between power generation and pumping station capacities. In Industry, three types of gas turbines are available :
.
.
.
heavy-duty (one shaft, suitable for power generation not recommend for comprtswrs or two shaft3)
jet engines or aeraderivativc (two shafts) turbines light industrial
Heavyduty turbines are generally used for large onshore plants where weight and space are not a problem. Aeroderivative turbine or light industrial are predominant lor smaller installation$ offshore where compact, light-weight drivcra are required.
BRIEF DE!5CRIPTION OF THE TURBINE There arc two parts for the gas turbine : a. main system b. auxilliary system.
3.1.
MAIN SYSTEM
- Figure I(two shaft machine gas generator)
It is composed of :
..
.. .
the air filter air compressor combustion equipment
183
HP turbine LP turbine Exhaust
-
TOTAL
Revision : 0
Page No. :
Date: 2/85
61
GAS TURBINES
TEPIDPIEXPlSUR
3-2- AUXlLLlARY SYSTEMS These are :
3.2-1.
. . .
fuel gas or liquid fuel system lubrication 3yatem
. .
hydraulic system start-up system
air cooling system
Fuel aas system
.
A gas turbine i s designed for a certain heat release. It is recommended to
- 10 % magimum) of the design value. avoid large flaw fluctuatians (+
.
It i s also recommended t o provide a safety margin above the gas dew
point (generally
.
+
I5 * C ) and t o have a minimum temperature of + 5 'C.
The fuel gas pressure depends on the gas turbine, a range of 15 t o 20 bar g a t turbine inlet flange is common. For the new generation of jet engines which have high air compressor pressure ratio the pressure could be as high as 30 bar g.
.
Certain trace components must not be present i n the fuel gas in order to avoid corrosion in the hot parts of the turbine :
-
-
Vanadium : less than 1 ppm
Sodium and Potassium r less than 2 ppm Calcium (not corrosivt but causes deposits) : less than 2 ppm
Lead: less than 1 ppm
-
Remarks : a. The fuel gas quality and net heating value range to be specified to the vendor.
b. It is recommanded to install a K.O. pot and filtration (10 F) at the fuel gas turbine inIet (most of time a rafety filtration is included i n the vendor package)$the basic filtration is normally included in the fuel gas supply Skid.
3.2.2,
Llquld fuel system Filtration is required depending
on the gas
rurblne type and manufacturer.
Generally the required level of filtration has a severity higher than for diesel engines. The liquid fuel pressure at the turbine flange is about 3 to 5 bw &
10 4
-
-
TOTAL
Revision :
---
0
Page No. :
GAS TURBINES
TEPIDPIEXPISUR
3.2.3.
-*
Date :
2/85
6.3
Start-up system
A gas turbine cannot simply start-up by firing fuel i n the combustion section : for its gas expansion power after combustion t o be effective, the turbine must attain a certain starting speed first using a starting motor. There arc several kinds of drlvers whlch are used t o start the turbines:
. . . . . 4
electric motor, pneumatic expansion turbine [air or gas) diesel engine or gasoline matar hydraulic expansion turbine hydraulic motor.
OPERATING ASPECTS The powcr is generally defined in cataIogues by 13.0. that means power at
. .
t
Temperature air in take I 5 ' C Atmospheric pressure 101.3 kPa (sea level)
No loss condition on intake and exhaust ducting No auxillarics driven by the turbine (except lube oil pump required by the turbine itself) The main external criteria for the performance of a gas turbine are : the site conditions (location, air temperature) losses on intake and exhaust ducting, operation of the machine at conditions other than design, mechanical powcr to drive auxillarics.
4.1.
AIR CONDITIONS The compression powcr requirement l o r the air increases as the air temperature increases. The consequence is that the available power recovered from the LP turbine decreases as the air temperature incrcaxs (+ 1 ' C 01 air
=
0.8 % of power :average
value). See Flgurc 2 for an example* 4.2.
LOCATION
If the turbine is located above sea level, the site pressure and the available power decrease by about 1 % per 100 metres e l c v a t i m See Figure 3.
/Q6
TOTAL
I
Pbgs NO. :
Date : 2/85
6.4
CA5 TURBINES
TEPIDPIEXPISUR
4 3
Aevlrio~i: 0
LOSSES ON INTAKE AND EXHAUST DUCTING Under certain conditions plugging of the airintake t o the turbine may occur. This w i l l result i n a drop in available turbine power. A similar drop will be seen if the exhaust duct pressure also changes average figures are :
.
.
Inlet duct :pressure Increases by(l0o mm i-120)~owerfalls by 1.4 % Exit duct : pressure increases by 100 mm
H20 power falls by 0.6 %
For estimation take 100 mln HZ0 d p for inlet and exhaust ducts (2% losses)
I
4.4.
DESIGN CONDITIONS I f the power turbine Is running at 80 % of the design capacity, the reduction in efficiency is about 6 %. If the turbine 1s running at 60 % design the reduction in efficiency is about 17 96. Since fuel gas consumption is very much affected.
I
II
Fir.
tpproximate for t alnbiant
P site =
t
-
H =
P lso x
>
I5
O C
1
m~15x*1
l+O.OlH
ambiant t e m p t r a t ~ ~ in te-C elevation above sea level i n metre divided by 100
5. IELECTiON OF C M TURBINE For preliminary selection use table 1 which give 150 turbine shaft power. Table 1 gives the commonly used gas turbines but for more information consult the "GAS TURBINE WORLD
PERFORMANCE SPEC" published each year.
I
6. THERMAL EFFlClENCY AT 1-
RATUK.
Thermal efficiency depends on tlrc gas turbine but for a preliminary fuel gas estimation the followjng v'alues could be taken
t
7. REFERENCES AND USEFUL LITERATURE 7.1. 7.2.
CA5 TURBINE WORLD PCRFORMANCE SPEC VENDOR documentation
7.3.
CAMPBELL VOL 11
7.4.
"Consider Gas Turbines for ilcavy loadp
each year
- K. MOL~CHChem. Eng. August 23. L980
-.
TOTAL
P I O C E ~ ENGIHEE~ING DESIGNMANUAL
P q e NO :
GAS 'NRB1m.S
Dmte
TEPIDPIEXPISUR
1
R ~ * * i o n: 0
FIGURE 4
: 2/05
6.6
3
.
-
**
--.
--*
Revision
TOTAL
0
Page NO :
STEAM TURBINES
TEPIDPIEXPISUR
Date : 2/85
6.8
1. APPLICABILITY For either the feasibility study or the pre-project study the engineer may need to estimate
the required steam consumption of a steam turbine. Details of turbines for guidance and consumptons art detailed in section 2 and 3.
2. DESIGN NOTES
. .
Single stage turbines eenerally used for small applications, multistage for larger. Conslder using steam turbines far pump drivers if residual HPlMP steam from larger drivers (compressors, gcntcators)
.
is avallable.
a
w'
Small
1
Standard size turbines :
Medium
1 or 2
Large
2
+
.
Speed range : usual 2 000 rpm to 15 000 rpm
.
Efficiencies :
Power r a t i n ~kW
Power kW
Steam k ~ l h l k W
0.5-190
350-30
9-2980
30-9
370-7Q50
15-3
Efficiency %
kW
%
L -40
20
750-1500
60
40-250
30
1500-2250
65
250-375
40
2250-UP
70
375-750
50
3. CALCULATION OF REQUlRED STEAM LOAD 1. Theoretical
wt=
kg,hikw
(hsr860
steam load
2. Actual steam load Was Wt
r
100
= steam inlet en4halpy kcallk = steam outlet kcallkg ( ! a tboritical urntropic ph brtwun inht a d outkt WW)
EFfirienq (%I 3. Required steam Ws = Wa x kW I 4. USEFUL REFERENCES AND
4.1.
4.2.
d
wh
LITERATURE
LUDWIG VOL I11 CHAPTER 14 pp 422-435 "Use steam turbines as Process Drivers" Richard F. Neerken Chem. Eng. Aug. 25 19110
-
110
TOTAL
PR~CEP'ENGINEERING DESIGN MANUAL
I
:
P*.
NO :
ELECTRIC MOTORS
TEPIDPIEXPISUR
I
'
R v i i:
Oat*
-
, Z/ZS
6.9
1. APPLICABILITY For both feasibility and prc-poject studies the engineer will be required to estimate
electric loadings for utility consumptions. Fig. I details motor efficiencies for varioufl pomp horsepowerr.
I
I
2. POWER ESTlMATlON
I
I
.
For pumps the driver horsepower is estimated en the pump data sheet.
.
For rcsptciiying of drivers or checking purposes use Fig. 1 to rate power.
.
Power rating at 380 Y 3 phase 50 hz. ffiUPf
1
~CTRIT MOTOR* RECOMMLHOED azt a rmc~urcr (11
Pump RequCemcnr
Prab.blr
A~. t b - a..h n
Mara
~
-
Cdh?io;\r OHP
-
Norart ( I I
(11
-
nl;is
&YAW
EIflcienq
% - a l~Cull -.- LMd
Pawcr ractsr(2) S oi full Lord
BHP
Applies 14 tvtully cndor
cap4c1r)
100 -
I I
--
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
TEP/DPfE)(P/sUR
Rwvirion r
08tr
7. COMPRESSORS
113
: 2/83
Paw No
;
Reviyion : 0
TOTAL
Page No. :
COMPRESSORS
TEPIDPIEXPISUR
Date :
2/85
7.1 7
1. APPLICABILITY For both ftasibility and prt-project studies the engineer w i l l be required t o evaluate a compressor selection, discharge temperature, power and complete a data sheet. To evaluate thc discharge temperature and power i t i s more accurate to use 551 instead of the manual method presented here. I n order to estimate the basis of cost and layout i t i s important t o understand the type of compressors for the service i n consideration, and the associated power requirements.
2. DESCRIPTION AND GUIDELINE NOTES 2.1,
TYPES OF COMPRESSORS The principal types used l n the 011 and gas processing industries are :
. .
reciprocating (volumetric) rotary ~volumctric)
. .
ctntrifugal
axial
A compressor selection chart is shown in Figure 1.
2.2.
GENERAL
2.2.1.
USE
Reciprocating compressors Reciprocating compressors arc widely used i n the oil and gas industry f o r s ~ d l i o medium gas flows and high carnpresrlon ratios. For example :
. .
2.2.2.
Instrument and service air compressors Low capacity/high pressure gas compression for maintain the gas l i f t capability.
re-injection of field gas t o
Rotary compressors The types o i rotary compressors most frequently employed i n the petrolcum indudtry arc as follows :
.
. . . . 2.2.3.
Lobe compressors ("ROOTS' type) Screw compressors The reliability factor is generally higher than reciprocating machines. "Roots" type compressors are used where a high flow rate wlth a relatively low-pressure is required. Screw compressors arc sometimes used in low flow gas service or for instrument and service air for instatlatlons of small t o medium size.
C e n t r i i u ~ acornpressars l
.
Thcse Centrifugal compressors have become very popular offering more pQw?r pcr gnit weight and esrcntlallv vwation-lrcc, lnitial costs normally are %than rcciprocatlng comprtswrs but efficiency Is Its? and utility c W may be higher. Frequently used in the o i l and gas process industry.
Revision : 0
TOTAL
Page NO.:
COMPRESSORS
TLPIDPIEXPISUR
Oste.
2/85
7.2
Axlal compressors
2.2.0.
Thew machines are particularly useful where a very high gas ilow at moderate pressure increase is required. Such applications remain relatively rare in the industry, the exception being LNG plants. DISCHARGE TEMPERATURE LIMITATION
2.3.
,
Discharge temperature is limited either for reasons of gas stability, gas condensation or compressor (or upstream equipment) mechanical resistance
limit.
.
For reciprocating compresxrr the maximum gas outlet temperaturc t o be d h d
is usually between 160 to 180 * C .
.
For centrifugal compreswr used in gas and oil extraction industries the discharge temperature is limited t o 1701190 *C.
.
Normally intercoolers are used t o maintain temperatures within t h t above limit$.
DESIGN MARGINS
2 4
I f the ilow is constant, no margin, but i f the flow is coming from a production eparator a margin of 10 % is recommended in order t o take i n t o account the possible slugs at the inlet of these production separators.
5. WEIGHT AND SIZE For weight and slzc wc rccomrnend to ask the manufacturer as vendor catalogues detail
only the size and weight of the compressor itself. As the compressor package also includes also the seal and lube o i l console^ control cabinet and sometimes the driver and gear box, the use of vendors catalogues could be misleading in estimating the installed weight.
Figure 4 could be used for a very preliminary estimation. It is established for the dry weight of a centrifugal compression package including :
.
.
compressor skid (aeroderivatlve gas turbine technical room
, overhead tank (seal oil) 6 REFERFNCW AND USEFUL LITERATURE 6.I.
LUDWIG
Volume3
Chapter12
6.2.
CAMPBELL Volume 2
Chapter 14
6.3.
GPSA
6.4.
SSI Program
Chapter 5
1979
f/6
+ compressor)
c(mPwss0Qs TEPIDPIEXPISUR -
-
-
_
_
_
l
_
_
_
Data _
_
l
_
_
_
l
_
_
_
_
_
_
_
I
_
C
_
_
_
_
_
_
_
:2/BS m
_
C
.
4% C .-
en
i r, 33
___________________---_-----___
3
$ 2E
A d
v n
3 v
-*- _ - __
-5 --
Y
_
5
zg
-
-
-
- - -
!m
4
~~~~~~~~~~~~~~~____
-------rO
-----------------
r?
I1
x
.-x
'-
3
E
--_---.--------------
c
2s r u
I-"
----------------
..
~8 ?Irn
N
v\
a
1.; E
x
E
11
3
z
L
E
-----
F -u =a
X
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - - - + - - - - - - - 4 - - - - - - - -
5; s
______---_-___---------------------+ B
NA 5 0 I ----------------d-------------------
-- E u
t11
C
-2
3
0
E
i;
- - - - - - - _ ----------------------
s)6
c.
-?! Y
u:5u
CI r
0
2
-------._-----d----------------d----
A
113
I
OPERATING
I I
.
7.0
IlDlTlONS
PI = 7.a bar a DISCHARGE PRESSURE P2 = 3 , O bar a
SUCTION PRESSURE
I
5'3 *C #It
SUCTION TEMP-
TI
SUCTION FLOW ACTUAL VOL F L O W
W = 5b000kbh V = 9400 m Ih
I
z
= 32:
GAS DENSITY fir SUCTION = ', 36
.,
I . GAS PROPERTIES
pe ~c
= =
45.9 230
2. POLYTROPIC EFFICIENCY
3~
=
0,79
3. AVERAGE 8 = MCp/MCp-1.99
8
=
4.
3
DLSCHARGE TEMP 12 =TI(%)
5. DETERMINE Z AVC
5UCT DlSCn
84
=
15014
21
r
0.91
22
=
0
=
AVC
bara
.
'K SEE
IdlG
E S T LTZ~ ~ ?5oU~'i r ~ dBL
*21
T2 =
.
kg/m3
REIII,hT STEP 3-Q If TZ IS D1rfI ~ R E N TFROM ONE "'I'I I IN STEP 3
K 'C
a37 0,975
6. CALCULATE GAS HORSEPOWER
C H ~ = Z X R X W X ~ X ( T ~ - T C! ) H ~ =32h0
' 11,314 k3/ kgMOLE
kW
-
MWx3600x(g-1)
7
CALC SHAFT HORSEPOWER p5 = CHP x (1
F
+ F11001 x 11 7,
taker : Fr 3 5
.
*C
4
PS im * 5.97
=
3d80
kW
C ' l l l kW ~ ~ 5.0 ~ s(ht I <( ~MW 3.1 )LO MW 1.0
'lm 0.96 0.97 0.90
8 . ESTIMATE DRIVER POWER
PS x K PO -GAS TURBINE PS x (1.14 + K) PO =
kW
ELECTRIC MOTOR
4040
kW
' 1.15
41.02 TO 0.04 WlTH
1
GEARBOX
-
3:
2 32
9. E S T ~ ~ A T EPACKAGE D WEIGHT
I
= 9° Oo6
M
COMPRESSOR-DRIVER-LUBE
($1:(1~16 4)
kg
NOTES :
CENTRIFUGAL OR AXIAL Tt?~O?mVffXMUU
-nr
JJ;~FJ
cnr
I
;&z
CoMPRWS?R O~TI
\ rornrir
.
no.. 1om WO
i~ibt
//g
XMF~~,S:~C
It. :,>I6 ItV
'
7.5 OPERATING L f4DlTIONS
SUCTiON PRESSURE PI = 0.0 bar a DfSCHARCE PRESSURE P2 = 27.0 bar a SUCTION TEMP.
T1
PRESSURE RATIO PZ/P1 =
40 *C = 3 3 +K
:
d
GAS DENSITY AT SUCTION s 7 5%
= 549 rn / h
V
?5,0
MW
W = 41DP k h
SUCTION FLOW ACTUAL VOL FLOW
STEP
kglm3
NOTES
L G A S PROPERTIES
Tc PC
2. AVERAGE 8 = MCp/MCp
3 . 33
- 1.99
-
= 247 45,s
mK bar a
8 = l12D
AESUW..~? T 2
2
It7 'C
orl
3. CALCULAT f DISCHARGE TEMP T;L
s
TI x
5. DETERMINE Z AVC
-
T2 = 383,4 'K
m)+J
(PI
=
SUCT DISCH AVG
Repeat 2 3 ti T2 differs from that used in STEP 2
44
21 22
s: s
0.97 0.45
Z
=
0.5%
3g =
O,@?
6. DETERMlNE OVERALL EFFICIENCY
'IS
See Fig 3
7. CALCULATE GAS HORSEPOWER
* *
CHP = Z ' R 5' 5 x (T2 - T I ) m W x 3 6 0 O x ( $ - 1)
8 . CALCULATE SHAFT HORSEPOWER
= 454
kW
PS=14?
kW
CHP
PS = GHPlf x r)g
R = 8.314 kJ/kgmole.*C
i = 0.96 to 0.97
9. CALCULATE DRIVER POWER Electrical Motor
Po = [.I5 K PS
#!'+#(
PROCESS CALCULAIION SHEET nLH: FUEL GAS COMPRELC3K
RECIPROCATING COMPRESSOR
I~CIWCOPPRXCI%UR II
cnu
Po + ?-Z"~W
DArc
Ilorn r ~ t i .r
E xs, M P LE
no
.
IODMO
K 7323
I arv
19
-
-
TOTAL TEPIDPIEXPISUR
PROCESS ENGlNEEAlNG DESIGN MANUAL
ddcs
Rodlion :
Dare
120
:
Pwm No :
7 a6
-~ ...
TOTAL TEPIDPIEXPISUR
P D C E S S ENGINEERING DESlGN MANUAL
Revision : 0
PW No :
~ R E S S O ~
Dale
:lies
7.'
8,
EXPANDERS
-..,..
Revision : 0
TOTAL
Pngm No. :
EXPANDERS
TEPIQPIEXPISUR
Oatc :
2/85
g.1
1. APPLICABILITY
For both the feasibility study and a pre-project study the engineer will be required to fill i n a process data sheet with the basic information and to estimate the expander horsepwer. Outlet conditions and horsepower estimation r a n be calculated accurately by computer. Hand calculations for pure component systems using a MOLLIER diagram are OK.
2. DESCRIPTION AND GUIDELINE NOTES
.
The turbc-expander i s a mechanical device which is designed according t o the laws of thermodynamics end aerodynamics. I t remover energy from a process ga; which results i n a drop in pressure and temperature of the gas. The energy removed i s converted into mechanical energy which is most often used t o drive a single stage cornprcsm.
-
.
T urbaexpanders could be used for : +
cryogenic pressure let down
.
dew point control
.
. .
CZ recovery ethylene processing, etc...
C3ICl recovery
Thermodynamical principal. See Figure I.
, Expanders efficiency The expander efficiency is the ratio of the actual energy removed to the maximum theoretical energy on Figure 1 :
-
'I=H B A A
HBI-HA
Expander efficiency depends on :
.
-
mass flow rate
-
inlet temperature
-
inlet pressure
discharge pressure gas composition speed
Generally a value of 80-85 %can be used for estimation purposes. See Figure 2. Liquid content a t the outlet of the expander varies from 10 t o 30 % (weight) Inlet gas must be free of solid particles and water (sometimes COZ), ice formation is prohibited.
.
Maximum horsepower of the manufactured turbo expanders is about f 2 000 HP. This figure should not however be considered as a limit. Turbo expanders can be used in series. Efficiency Is a f l u t e d by the variation of the design flow rate See Figure 3 for an ntlmarion.
/>'
--
"
*
TOTAL
Revision : 0
P a g l NO. :
Date : 2/85
8.2
EXPANDERS
TEPIQPIEXPISUR
3. REFERENCES AND USEFIR. LITERATURE CAMPBELL VOLUME I1 Engineer's guide to turbo expanders
HYDROCARBON PROCESSING APRlL 1970 Pagc 97...
Turbo expander applications in
JOURNAL OF PETROLEUM TECHNOLOGY
natural gas processing
May 1976 Page 6 1 1 etc...
What you need to know about gas
HYDROCARBON PROCESSING
expanders
February 1970 page 105...
Turbo cxpanders offer processors
THE 011 AND GAS JOURNAL
a way to conserve energy
Jan. 23, 1978 page 63...
Use expander cycles lor LPG
HYDROCARBON PROCESSING ~ o c 1. 9 7 ~ Page 89...
recovery
VENDOR DOCUMENTATION
i.c. : ROTOFLOW, MAFI-TRENCH..;
la 6
PROCESS EMGINEEHINU utslun MfilUUl&L
TUTAL
t$evrrroft :
rb
I
d y I~U U
EXPAtfUEW
Datr
TCPIDPIEXP18UR
: z/n<
8.3
FIGURE 1
PRESSUAE
t
H ~ l H~
PA Inlet prssaure PB Outlet prusure f Bl Outlet theoretical tsmpcrrruw
HA
TA Inlet temperature Tg Outlet temperature
ENTHALPY H A , tnlot enthalpy HB Outlet enthalpy
ktBI Outlet theoreticel tnthstpy
FIGURE 3 ESTIMATED PERFORMANCE AS A FUNCTION OF DESIGN FLOW RATE
FIGURE 2
PERCENT OF DESIGN FLOW RATE
I
APROXIMATE PLANT FLOW RATE M M X F D
.
IIUIMb
~ ~ U L C W CN~IN~LI(INV U L S I ~ NMANUHL
TEPIDPIEWISUR
9.
FLARE SYSTEMS
'2 4
HIYIIIQO
:
Date
: 2/85
r80lN O
:
TOTAL
Revision: 0
Page No. :
FLARE SYSTEM
TEPIDPIEXPISUII A
Date:
2/85
9.1
1. APPLICABILITY For the feasibility and preproject studlcs, a detsllcd design of the flare system is not needed. Required information for either study will include ;
. . . .
.
Evaluation of number and levels of flare system Determination of maximum relieving (and hence flare design capacity) Flare KO drum
Design
Estimation of height of flare stack or boom length and type of t i p required
PSV sizing (not always required, depends on project). For further more detailed specification and design requirements consult thc CFP DESIGN GUIDE ON FLARES-YENTS-RELIEF AND BLOWDOWN SYSTEMS.
2.
DEFINITIONS (see section 3 i n DESIGN GUIDE)
-
Relief system
includes any prtssurc rsjirrf valvelrupture disc downstream piping
t
and liquid separator
-
Blowdown system
I
includes any depressurlng valve, downstream piping and separator (normally the pressure relief and depressuring systems utilize common piping and separator)
-
Flare system
: a system which ensures the combustion of hydrocarbons
Vent system
:
the
rdcasc
of
hydrocarbons
to
the
atmosphere
without
combustion
-
Design pressure
:
the pressure used to design the vessel and calculate the wall thickness (see section 1.0.)
-
Set pressure
:
the pressure at which a safety device is adjusted to open under service conditions. Usually equal t o the Design Pressure
-
Accumulation
:
maximum allowable increase in vessel pressure during discharge through the safety device. Normal accumulation is 10 % but 20 %
is allowed for external fire due t o hydrwarbon liquids. For HC gas fires an accumulation of 5 % is recommended.
3. FLARE 5)'ITEM ANALYflS AND GUIDELINES This section details how t o determine the number and levels of the required flare system for a feasibility or preproject study and other guidelines.
.
-
A system of items of equipment and piping can be protected against overpressure most economically by considering it as a single unit when calculating the relieving capacity
/21
TOTAL .
Revision : O
FLARE SYSTEM
1EPIDPIEYPISLIR
. .
Page No. :
Ostc: 2183
9.2
Block valves should not be present in the system so as to isolate a unit irom its relicvine point. Special casts may warrant a car-sealed open or locked valve. However such a r r , .ements should be avoided if possible Interconnecting piping should be of adequate sire and not subject t o plugging. The system should not be of such a size that t w o separate systems would be more economical
.
tn specifying the design pressure of the individual items and safety valve setting there a r e two approaches
-
Set t h e design pressure of each item independently. Then specify safety valve
scttings to protect the weakest link in t h e group of Items
-
Study the items as a single system initially. Thls is preferable as it avoids having an unexpected "weak link" limit the operating conditions.
.
Consideration should be given to possible abnormal conditions viz :
-
Light hydrocarbon systems can reach low temperatures during depressurization Heat exchange trains may be bypassed resulting in higher than normal downstream
temperatures
.
-
Fallure of cooling medium can cause excessive downstream temperatures
-
Production separators may have a varying feed temperature, especially offshore.
I t i s often required or beneficial to provide two or more separate piping systems from
t k items of equipment t o the flarc $yatem eg I high and low temperature headers. Consideration should be given to the following
-
-
Relief gases below O°C must be kept apart Irom warm moist gases t o prevent formation of ice within the flarelines. Thia could cause a system plug up Segregated systems may be economically desirable to minimize the extent of low tcm+rarure piping
-
-
By segregating t h e flows irom high and low pressure sources into two separate flare systems greater use of the high p r e s u r t drops can be achieved without lmposing severe backpressures on the low pressure systems The molecular composition of some streams may warrant their segregation irom other streams. eg moist C02 or H2S is corrosive. I t may be cheaper t o fabricate a second smaller vent system to handle there rather than fabricate the entire system in corrosion resistant material.
02 A
---
TOTAL
Rerrs~on: 0
Page NO..
FLARE SYSTEM
TEPKlPlEXPlSUR
2/85
Dstc:
9.3
Determination of t h e flare system and levrl can be summarized in the following step by Step analysis.
I. Does the facility contain process areas with distimt pressure levels eg :HP compression, LP c o ~ -ession, atmospheric separation ? If so, c sider two or more flare levels if sufficient limitation is imposed by the LP section
2. Does gas exist at high pressure that on depressuring will fall t o below 0 vC.Lf so, it must be segregated from warm relief gas. If the temperature falls below 29.C may have to consider low temperature steel headers
-
3. ldentify any corrorlve relief sources and consider if n t e d to pipe up separately 4. Is a vent system required for tank breathers, regeneration vents etc... 5. Identify on the PFMs) the set pressures of each PSV anticipated and consequently its maximum allowable backpressure [MABP usually 10 % 01 set ~ r e s s u r e ) .Locale the "weak links" in the process i.e. :the low design pressure vessels. If only 1 or 2 exist within the
system conslder installing balanced relief valves IMABP = bD % set) so a s to incorporate them into a higher pressure flare system, or even alter the design pressure of the weak links to acheive t h e same. This may be more economical than specifying two flare levels. Having determined t h e configuration of the flare system, it is necessary to size the headers only and t h e flareline itself. For thls, an idea oI the maximum relief load gcnerattd will be required. For the studies a full "risk analysis" af upset conditions is not necessary neither 1s a listing of every relief load and condit~ons. The sizing case of t h e flare system can usually be judged by inspection. Invariably, the largest vent flow will be s full flow reliel off the first separator or compres~londrum or a total electrical failure. This may be supplemented by a simultaneous depressurization of a compressor or equipment loops resulting in a flare design flow higher than the normal plant throughput. Generally fire generated loads do not dictate the sizing of the flare system, but may influence the sizing of laterals and subheaders. A certain degree of experience will help
in identifying the possible one or two cases ihat will size the flare system without havlng to perform a fuH plant rlsk analysis. In some cases, the resulting flaring loads may be minirnised by using ESD isolation valves or autamatlc controls t o start back-up equipment.
133
Revision : 0
TOTAL
Page No. :
FLARE SYSTEM
TEP~DPIEXPISUR
Date : 2/85
9.4
I.HEAOeR SIZING 8 STACK AND TIP CHOlCE I n order to estimate the main flareline and header slzcs based on backpressures, 3 pieces ot inlotmation a r t required :
-
9.1.
Design llowratc,temptraturc,MW Length of flareboom or height of stack Type o f t i p and stack t o be used.
DESIGN FLOWRATE
TEMPERATURE AND M W
This has already been determined from the previous sectlon. 2
TYPE OF TIP + STACK T O BE USED (see section 10 in Flare Design Manuay The rhoice of stack and tip type wilI obviously be dictated by the location of the prar,
nder design.
For onshore plants in remote areas i t is usually suflicient to use a remote vertical
stack with a conventional pipeflare tip. The height of the stack will be determined by the radlation limitation on the designated sterile area round the stack. For non occupied areas, this figure could be high as 5000 BTUI~.!~~(15 700 ~ / m 2 )resulting in a short stack height. For cases where high flaring loads s t i l l result i n a tall stack,
a further reduction in height can be achieved by using a Coandaffndair or similar type high pressure sonic flare tip (see section 10 i n FLARE DESIGN MANUAL for dixusslon o f each tip type). Offshore the choice is somewhat more complex in choosing between a remote vertical
flare or similar, or an Integral 45' mounted boom itare or even on board
vertical sta&.
The decision between these is more often than not governed by
economics, structural considerations and specifics pertinent t o each platform Iocation eg r water depth. Generally, however sonic flare tips are used where pressure levels allow (2-> bars) a t the tip entry i n order to reduce stack/bom lengths, by reducing radiation levels, and associated support structure weights.
4-3.
FLAREBOOM
- FLARE STACK SIZING
The flareboom or stack (hereafter termed flare) length
Is determined by the
maximum allowabIe thermal radiation tolerable on the platlorm or surrounding area.
A detailed calculation of this value for vertical or inclined flares on or offshore under a variety of wind conditions and temperature5 can be performed using the computer program SUPERFLARE. For itasibiliry and preprojecta, however an estimate of radiation level can be determined using the method as derailed in AP 521. Set Appendix 1.
134
.
,-
TOTAL
Revision : 0
FLARE SYSTEM
TEPIDPIEXPISUR
Date : 2/85
Recor~ nnded Radiation levels are given
I1I
Condition
1
I Allowable radiation 0tulh.ftZ
I I
I
1000
I
I
I
I I I
1
Exposure
period Infinite
I
I
2000
1 I
L minute
1
I I
3000
I
(Emergency flaring only)
1
I I 1
5 seconds
I
1 1
r DO0
I I I
I I 1
I I I I
1
I
1 I
I
I I 1 1
I 1
1
I1
I
1
5000
I I
I I
1
I 1 mediate shelter i s available 1 1 I I I I Areas where personnel are not 1 I permitted during operation I I t Helideck
I
I
I I Arear where personnel may be 1 I located from which escape is I I possible and shelter is 1 1 attainable 1
I I I Areas where equipment is I located and personnel are not I normally present during opeI ration, but if present im-
9.5
below :
I1
I 1 1 Areas where personnel may be 1 located and expected to per1 form rhejr duties continuously I
I I 1
Page No. :
I
1
I I
I
I 1
D
I
I
The above figures are maximum allowable radiation lntcnsities inclusive of solar radiation t 250 BTUIhr ftZ). I t should be noted that the following recommended values o f F radiated and mach numbers at the ti^.
-
Fraction of heat
a) Pipe flare
LOWM W gas F = 0.2
-
Ethane
F
:
0.25
Propane
F
r
0.3
F
i
0.1
Mach I
F
s
0.05
Mach 1
Velocities
-
max at design relief
normal continuous
0.5 M = 0.2 M 8
b) IndairICoanda
All gases C)
Mardair
Having calculated the flare length bawd on radiation analysis and c3rabllshed both the design flare rates and tip type the main header can now be sized.
i3 i 7
Atvision : 0
TOTAL
FLARE SYSTEM 2/85
TEPIDPIEXPISUR
4 .
Page No, :
9.6
HEADER SIZING T h e major criteria governing the sizing of the header are backprtswre and gas
velocity. Flare headers must bt both large enough to prevent excessive backpressure
on the plant safety valves and to limit gas velacity and noise t o acceptable levels. Sizing procedure I)Identlfy "weak link" wlth respect t o MABP on safety valuea. (this should have been done when determining t h e levels of relief). This is the maximum upstream pressure tolerable in the rystcm2)
culatc the
4 P acrws the
flare tip for the relief design flow. For sonic type
ti1 the backpressure will be 2.0 t o 5,O barg depending on
For plpeflare tips use :
- 2.0 0.2 - 0.5 0.5 - 1.0 0.5
Flare tip Fluid seal Molecular seal
load.
-
psi
(0.034 0.lb bar)
psi
(0.014
- 0.034 bar)
psi
(0.034
- 0.07
bar)
3 Estimate the equivalent length of piping from the tip to the flare KO drum. (Allow generous margins, flare headers are complex and rarely straight). 4) Calculate the mnlc velocity of the relief gas
Vsonic
= 91.19
c -
K :CP/CV T : *K
rn/s
This will gTvt a first estimate of required pipe id based on maximum relief flow.
The stack diameter should be one or two slzes less than the tip diameter. LIMIT
VELOCITY JN STACK TO 0.85 M A T DESIGN FLOW.
AP
5 ) Using thc estimated D calculate the from tip to flare KO drum. The Conison equation is recommended for isothermal f b w : 2
P, Where :
1
:
p2
+
4 V p22 (39.4
= upstream conditions
2 = downstream p + pressure bar (a) u
=
relocity
f
fL -
9
= moody frictlon factor
1 = equivalent length rn d = pipe id inchs
= s p u l f i c vol m3/kg This calculation requires a degree of trial and error as- y
I, 9 6
2 in
"1
mls
v
+
-
lo-'
.
. TOTAL
Revision : 0
PqcNa: .
FLARE SYSTEM Oat@: 2/83
TEPlDPIEXPISUR
9.7
6)Examint the P l (calc) at the relief drum and decide if the stack + header diameter is adequate I t is PI (cak) drum approaching the maximum upstream pressure allowable at the plant ? if so increase the diameter and repeat the AP calc. 7)Oflcc sathfied with the drum-tip line,proceed can
back up the flare header and
late the next section of Une diameter.
8) Continue along the headers, adjusting flowrates as necessary if sources disappear,
untU t k '*weak link" criteria has been satisfied. 9)lf the project requires,sub headers and laterals can be egtirnated from the main line static backpressures calculated above.
EXAMPLE :
@ PS$
I
0 B
-t
Fn4 Hrbr
.
h3 1.1 br:,
0P< t.2 k3 I 1
L. l o o n
4
I a.?
0.6
I. Flare design is based an vent [low from source (1) 2. Weak link in system 1s set by PSV a t source (2)
3. System must be designed for a design flow from source (1) not giving a backpressure at point (3) of more than 1.2 barg. 4. Size line from tip to drum (1 = 150 m) to give P drum O,5 barg (say) site lint from drum to point (3) (L = 100 ml to give PI < 1.2 barg. 5 Check that source (1) can flow from (I) to (3) with pressure drop available.
73
a
.
TOTAL
Rev~sion: 0
P C ~ No. R :
FLARE SYSTEM
TEPIDPIEXPISUR
Date : 2/85
NOTE I ) :
laterals
--->
sub headers
--->
9.8
headers must increase in diameter
as the system progresses to the tip.
2)
Max velocity in a line is
3
When calculating
AP
MACH 0.7
for short duration
rdiefs only.
for flare systems isothermal flow is
assumed for each section. For high source pressures with low MW
a
AT v6 AP profile
will yield more accurate results, i.e. adlust
temp a t specific points in the system to account for accurcd.
A
P
5- FLARE K O DRUM SlZlNC A f l a r e KO d r u m Is provided to drop wt and collect t h e liquid part
of
the f l a r e vapours in
order t o :
5.1.
prevent
quid accumulation at the base of t h e f l a r e boom or tower
to mini11 e t h e risk of burning liquid [golden rain) emerging from the tip and falung on personnel t o recover and reclaim valuable product materials. DESIGN CONSIDERATIONS
-
s e p a r a t e knock o u t drums a r e generally required lor earh level of flare system installed i.e. :a n H P KO drum, LP K O drum, LLP drum
-
cold v a p w r lines Le. < O'C) can be introduced immediately upstream of inlet line to a "warm" drum providing t h e resultant temperature in the drum does not caH below design. This precludes t h e need for two independant drums.
-
FLARE KO DRUMS SHOULD BE HORIZONTAL AT ALL TIMES. Mist eliminators a r e not to be installed. Min design pressure of drum is
3.5 b a r (6)
-
Heating coils should be installed in f l a r e KO drums to prevent freezing of residual liqulds. Typical is to maintain a T min = 4.C LIQUID 3ROPLET
SIZE (per AP1521)
Recommended particle sizes are : VERT lCAL FLARE
INCLINED BOOM
REMOTE FLARES
110
> 45' < 45.
(offshore)
150
I*
boo
I,
600
ug
Revision : 0
TOTAL
Page No. :
FLARE SYSTEM bate :
TEPIOP/EXPISUR
2/85
93
DRUM SIZING
5.2.
Bawd on the above design considerations the flare KO drum can be sized using the
method outlined in section 2.0. VESSEL DESIGN.
For a flare KO drum, t h e normal liquid level should be kept in the tower part of the drum 1.e. : utHise as much space as possible for the vapor-liquid dt-entrainment. If a large diameter drum results consider using a split flow arrangement with the cxlt noz. r mounted on t h e head. This will rnaxirnise the L/D ratio and give a smaller Iighit drum. This is especially useful offshore where weight + space are a major concern. An LSHH will normally be installed in the flare drum to Initiate a plant shutdown (or wellhead shut in oiishore). RELIEF DEVICE SIZING (For more detail see API 520.521)
6.0.
6.1.
GENERAL
- Safety
valves are either termed balanced or conventional depending upon the
backpressure limitation
-
Rupture discs are less robust than an equivalent safety valve and rannot be relied on to function accurately.
6.2
It is recommended that rupture discs arc avoided
BACKPRESSURE
- Backpressure exists in two forms I
. flowlng backpressurc is
the pressure on the discharge side of a PSV that is
blowing off to the relief system
. superimposed
backpressure, or static backpressure is the p e s s u r e on the
discharge side of a PSV caused by another relief source in the system venting to flare
- For conventional valves the
Maximum Allowable Backpressure (MABP) for either superimposed or flowing is 10 86. For balanced relief valves up ra 40 % can b t allowed for without a reduction in the valve capacity.
6.3-
LIQUID RELIEF
The formula for siring liquid relief A=
gpm 27.2 Kp. K,.
Kv
valves is :
G li 7
Revision : 0
TOTAL
Page NO. :
FLARE SYSTEM 2/85
Date :
TEPIOPIEXPISUU
4-10
Where :
-
A
gPm G P
=
-
Flowrate, u.3, galIons/mIn Specific gravity a t flowing temperature
=
Capacity correction factor due to over pressure (from figure 6.5) Relieving pressure minus constant back pressure (PSI) Capacity correction factor due to back pressure when balance belows value a r e used (irom figure 6.4) Viscosity correction factor (from figure 6.3.)
"d
-
Kw
x
Kv
--
6
Effective discharge area, ins2
VAPOR RELIEF The formula for sizing vapor relief is :
W
A:
Where W
I
T
:
C
=
=
M 6.5.
C K PI Kb
Relief flow, lbslh !i = Compressibility factor Inlet vapor remperature, 'R (1.8 'K1 Coefficient (from figure 6.1, 6.2) Coefficient of discharge (0.975 unless vendor data available) Upstream pressure, psis. Set pressure x 1.1 for blodted outlet, CV failure or 1.2 for fire plus 19.7 psia Capacity correction factor (from figure 6.6)
:
K = PI = Kb
inch2
=
Molecular weight of the vapour
RELIEF FOR GAS EXPANSION DUE TO FIRE (DRY VESSEL) A. A A,
A,
4-F F'
F' =
.
0.1406
CK
effective discharge area of valve ins2 = exposed surface area of vessel ftZ
=
~1.25
~0.6506
T
= 1560-T,'R
T
= temp. a t relief pressure R ' .
C and K as in 6.4 6.6.
STEAM RELIEF
r
A=
inch2 SO
PI K&,
/ 40
-
TOTAL
FLARE SYSTEM Date: 2/85
TEPIDPIIXPISUR
PI
l
Klh
I 6.7.
1
9.11
= Set pressure x 1.03. (ASME Power) or 1.1. (ASME Unfired vesseis)
- superheat correction factor table 6.1.
STANDARD
RELIEF VALVE ORIFICE SIZES
The following table may be used for estimating tho relief valve size based
effective discharge areas calculated
6s
in paragraphs 6.3, through 6.6. :
Nozzle Orifice letter
Effective Area sq. inches
Avoid using 2 1/2 inch outlet flanges
**
Page NO. :
R e v i l i ~ n: 0
Normal size Designation
(F and C orifices)
Avoid using 2 112 inch inlet flange (3 orifice)
won the
TOTAL
FLARE SYSTEM Oatc:
TEP/DP/EXPISUR
7 .
DESlCN CUlDE Flares-Vents-Relief and Blowdown systems CFF MAY 1989 - TEPIDPIEXP
7.2.
API
520
AFI I b C
A
521
API 14E
7.3.
Page No. :
Revision : 0
9.12
2/81
Det Ncrske Veritas :Technical Notes fixed offshore installations
Norwclgen Petroleum Directorate :Guidelines for safety evaluations of platform conceptual designs.
---
-
-
YI
LIO
~ I J
111 1p2
1x1
449
141 733
WB
7 3
141
701 191 131
11+
1.2
141
39923
741 7 n
YII
197
if)
m
rlr
tro
nr
--.
TOTAL
PROCESS ENG~NEERIHGDESIGN MANUAL FU.kE
TEPIDPIEXPlSUR
AND
RELIEF
P W NO :
ierision : CI
Date
:2/05
I
9-13
Rerision : U
PROCESS ENGINEERING DESIGN MANUAL
TOTAL
F U R L UJD RTLlEF
Dl#*
TEPIDPIEXPISUR
I
:
The
lrcornlnrnJ,#
.
curre ma, k Whtn a h mrbr rot ~ h c LOIICCIU~ pigYm
. .
.
Page No :
: 2/05
9.11
NOT,: ~ h. b t d ~NW. *LOW t h r ~up to and i ~ l u d i ?LJ~pi. e*rrpl-rm, caprcilp 11 r l e c t d by L IK chbnlr m lilt. lh* cur.* rtpt#nn#rr sornp~ornirrof lhr *llWr ~ i kdri ~ h v r pr w f i i e r n . rnd hr shrnw in ow*I numb.r 01 rrlet.ralws m r n u i x l w m . This c l d df LI lh. 1 *hmn tha ma** or lb v * I w nc4 bnfiwm p,=~,.,.. A b . . 21 p ~ s e n l .csp.cily It rlllnll in o*.rplrUUIe. \nOwll. I h l ~ b n u l r r l u r tll h d d br C Q I~ IU~~~ Vrlvrr -ratin# low ovsrprruurrs und " c h ~ k r " :l ? r r r latiw for,. orarprnrur.r 01 k r c l h r n 10 p r c m l muuld br r*odcd
ar Censrant Barb.?rrssur~ Silin9 Figure for 2) plrtr"t arrrpr.,~~r. on Ilabnr.d B b l l o r s s o f a ~ ~ - l r l iVdO ~ * * S
.votiobl.
torlorI ( .
(Liquidr Only)
*I
&5
.Capocity C o r r t c l i o n l a c l o r - Due prcrlur.
Volr.1
lor
Rcli.1
ond
in l i q u i d Scrrlcr
10 0v.r. Salefy.Rrliel
I
. -.
TOTAL
Revision :
PROCESS ENGINEERING DESIGN MANUAL
0
P a ~ s N o:
: 2/~5
9.15
FLAW AND RELIEF
TEPIDPIEXPISUR
Dbrc
I
1
I;:
5
0
I P
LO
15
20
GAGE BACK PRESSURE
x
25
30
35
BACK PRESSURE
40 PSlC
45
50
,IPSIG
Norr: Thc abov curvcr trprrprnl rn romprnmlu or lhr ralun rcromnnded by a nvrnkr 01 rclicf wal*e mrnvi=rlutcr~ehd may be uwd when lhc mabr or ral-e or the aclubl trilical.l?aw presrvre p i n t I01 ihr rapor or # I 3 i5 unknown. When thc makc i l Lnom. Ihc manufacortr nhwld h comrulrd lor Ihr corrcLlion f ~ c l e t T l n r curves r r r tor rt pnrurc. of 54 pounds p l r sqvmrr #nth *oar and abort. Thty art lirniled to h c h prcnurc klm cril*alnow p*.rure ter r ~ i w n r r pwsure. Fw wbtrfilaczl.flor bmct presrurm b l o w SO paundr p r quare inch -PC. rtu manvfrctu~rr mual br cmsultcd rw ihr v r l u a of K..
I
Figure b,(k-~.r~abl. o r Conrioni 8ack.Prcrrur~Sizing Focror K. for Bolontcd Bellows Sofr!y.R*lirf pars and Gases)
VaIvrr (YO.
1 .o
0.0
09
0.4
0.2
0
0
60 70 80 90 100 BACK PRESSURE. PSI* ABSOLUTE BACKPRESSURE' SET PRESSURE OVERPRESSURE. PSIA XI00 = r X
10
./0
Figure 6 * 6 L ~ o n ' l o n i 8o.k
Only1
20
36
40
50
+
Prelrurc
Siring roctor I(* Far Convrntio,ml ~ . h ~ ~ . r ( e l i sVolver t (Vapors ond Cares
-
TOTAL
PROCESS ENGINEERING DISlQN MANUAL
R n l ~ i o n: Omtm
T EPIDPIEXPISUR
10.
Prp* NO :
: 2/83
?SPES VALVES + FITTINGS
/4Y
A
TOTAL
Revision: 0
PROCESS AND UTILITY LlNE SIZING
TEPIDPIEXPISUR
1. APPLIC,
. -
Datt ;
2/85
'UTY
For a feasibility study a quick e s t i m a t e of the line size will be required. For a pre-project study a b e t t e r estimate of the line s l z c will be required.
-
The purpose of this guide is to size only the lines in t h e process unit.
.
For t h e both the feasibility and prc-project studies a b a q w s AFTP c a n be used :
.
Pmge No. :
.
"Pour le cslcul d e s p e r t c s dc charges des liquidts dans les conduites"
.
"Pour le calcul dcs pcrtes de chargcs dcs g a z dans Its conduitcs"
The line sizing depends on t h e service :
.
F l a r e lints, pipeline end riser sizing a r e not included on this chapter.
2. LIQUID LlNES SIZING CRITERIA S e t Table 1.
3. VAPOR AND STEAM LINES SIZING CRITERIA Table 2.
See
5. T W O PHASE PLOW LINE SIZING CRITERIA The
PvZ c r i t e r i a
f
=rm
as
s t a t e d for vapor lines to be followed with : W
in kglm3
*
W =
WJ + Wv = t o t a l f k ~ wr a t e in kgfh
fl =
W1 =
liquid flow r a t e in kg/h vapor flow r a t e in kg/h
pv
Wv =
and V = Vrn =
=
liquid density in kglrn3 vap?r density in kglm3
mls
Pi = internal diameter of the Line in m. om a n d Vrn a r e respectively the apparent density and velocity of the fluid.
10.1
-- --
.- - Revision : Q
TOTAL
un,,,,
nzlnc
TEPIOPIEXPISCIR
.
Page t4o. :
Datr:
2/83
10.2
The flow regime t o be checked on the figure I for horizontal lines and on the figure 2 l o r vertical lines.
,
For horizontal lines slug and plug flow regimes should be avoided.
, For v t r t i c a l lines slug flow regime should be avoided. Remark : Flow chart fig. 1 and 2 are based on author's experimental results.
5. PRESSURE DROP CALCULATIONS 5.1.
MONOPHASIS FLLID (GAS OR LIQUID1 5.1.1
''ABAQUES AFTP" could be used w i t h the correction of the line diameter
rch as indicated on there ABAQUES.
5.1.2.
Method using MOODY or "regular" Fanning friction factors. a.
Calculate Reynolds number
. -$
R ~ fli . V
Pi
=
line internal diameter in mm
PV
= =
fluid density in kg/m3 velocity in m/s
fluid dynamic viscosity in Cpo Re is a dimensionless number
-
b. Determine the relative roughness :
See Figure 3 -3 & D
Determine i = friction factor :
See Figure 4 4 f =
c.
d. 5.2.
f *=
P=f x7 LOO ;x
&
=
%t
s
bar1100 rn
TWO PHASE FLUlD
Many correlations e x i s t to calculate the pressure drop for two phases flaw, depending of the vertical or horizontal line, ratio of vapar/liquid and pressure and temperature conditions. That is out of scope of this guide and we mention only some authors :
POETTMANfCARPENTER
FLANIGAN
EATON
BEGGSIBRILL TAITELIDUCKLER
LOCKHARTJMARTINELLE quick methods for an estimation are as follaws :
I5 .7
Revilion: O
T OTA L
unuw
PROCESS
slziwz nrtt: 2fg5
TEPIDPIEXPISL
5.2.1.
Pmg? Ha. :
10.3
"ABAQUE AFTP" for gas could be used with the correction of tht line
diameter. Takin as defined in 1 4 and the liquid viscosity as the fluid viscosity. 2 . 2
Method using MOODY or "regular" fanning friction factors.
I t is the same method as on C 5.1.2.
and V = Vm as defined on 5 9
wlth
f.=P" and the fluld viscosity taken as the liquid
viscosity.
5.2.3.
A more detailed method using the Lockhart Martinelli method i s given i n
section 11.0 PIPELINES. i. NOTES
. .
Tubes dimensions are standard and an example i s given on Table 3.
With "ABAQUE AFTP" the correction for the internal diameter must be done and an estimation of the line thickness could be done with the following formula used mainly for
high pressure.
thickness
rnm
Y =
coefficient having values for tcrritlc steels
P =
Design pressure
bar g
Be
external diameter
inch
S
allowable stress
bar
C =
corrosion allowance
mm
e
s
=
E =
:
longltvdial weld joint factor
5, E and Y are not always available so the following iorrnular could be used for an estimation.
t
r
P =
thickness in mrn design pressure in bar g
= corrosion allowance in mm K = 43 for carbon steel and low temperature
c
carbon steel de =
external diameter in inch
54 for 3.5 % Ni and stainless steel
For small diameters upto about 10" usc the thickness given by the schedule on fable 3. For
P do not 'forget to take into account the change in clevstjon for liquld and two
phase 1low.
TOTAL
Reviaion : 0
PROCESS ENGINEERING DESlGN MANUAL
Pw No:
PRCCESS WD ImXLITY
Dete
LXN~IZ~NG
T EPIDPIE XPISUR
: 2/85
30.5
_ _ _ _ _ _ _ _ _ _ _ I _ _
-
fi
9h!
? P? 0
E
4 0
1 5 9 9 N' N-
a
.-,
n
C.hC.C.CA-CICI
s>
3 EUP
NN
= a
22 E
0 0
m*
I?
_ _ l _ _ _ _ f _ _ _ _ _ _ _ _ _ _ _ - - d - - - 4 - - -
e4 &I
2u
b
rn
EC
5 .-
g;aE
9
3
V
G.2
S.$Z E
=if
5:
a
-.'
z 2: 11
0 0 0 0 0 0 O D "
*-=z
=22
+-
$
k
x:3m -___________-_______--------0
I-
i
E E
G
k
ML L U
vl UJ
d
m
w~n
0
= x:!i u OaaS 2
P
5
td
5 n z u ct
0
n < >
'-+vv V O O h a m n a
A
d
RE
w
2 U~ M
~
5oa: .snV gam, o . , .
g .-" U, .*
c
L
8u 2l .-m r a5
go N :
v,,
/3-5
8 8 NP.4 " A
U
g: yg
. ; Z
*0
58 G
E
k k EE 0 0 11 U
.. ; -5 M
4
2
f
v
P
a
..
D rd
On v
M
:
a
n
V
d,
-
.. 5 < s , > _-_________________---------I
EE
W
b 3-k u a v n dVgfi
....
3 z
0
0
A
P I
Revision : 0
f LPIDPIEXPISUR
Date:
2/85
P ~ g No. l :
10.6
7. REFERENCE5 AND USEFUL LITERATURE
,
LUDWIG
.
Flow of flulds CRANE
,
.
"Gas liquld flow in pipelines I Research regults" by A.E. DUKLER May 1969 Publ by A.G.A., API and Union of HOUSTON "Gas liquid f l o w in pipeline I1
- Design manual" by 0. BAKER, H.W.
BRAINERD, C.O. COLDREN, FLANIGAN and J.K. WELCHEN, October 1970,
published by A.G.A. and API
-
.
"Proposed correlation of data for isothermal t w o phase, two component flow in pipelines" LOCKHART, R.W. and R.C. MARTINELL1 (1949) BEGCS , H.D., and
BRILL, 3.P. Manual lor "Two phase
[Low in pipes" 1975 university of
TULSA
.
.
ABAQUES AFTP:
.
"Pour le calcul des pertes de charges des liquidcs dans lcs
-
conduitcs" "Pour le calcul des pertes d e charges des gaz dans Its condui tes"
PEPITE PKOGRAM "CHEMICAL PROCESS DESIGN ON A PROGRAMMABLE CALCULATOR"
W. WAYNE BLACKWEIL, 8.5. Page 22
.
-
"Two phase pressure drop computedqq Mafik
156
SoLirnan, Hyd. Processing April 84
-
TOTAL
PROCESS E N G l N E E R l N O D E S I G N MANUAL
Revirion :
uTmn LINE SIZING
0
.
No :
PROCESS AND
'IEPIDP/EKPfSUR
Date
10qow
:2(es
Iblnr
1
10 .7
.Flsr
rJ.L*m.
*
hvrllonlll t*e-ph~#a no* (b.& m earn hDm I", i'
as& Ha. 10, lBU, D. IhODO I
s, I,DOD
8. Bx.-
210.7
-
0.5
(gO.I66\
WG
BY =
(
0.33
1
SeC P.11.3
7.102 WC
fl V
O E z
OSHINMYO -CHARLES TWO PHIsE FLOW MAP FOR VERTICAL UPWARD f LOW a
D
- P i p Inside durnmHr, inthn
p 1- Liquid dcfisity. L ~ / F I '
xr 4
~ r ~ ~ / f i 1#53[(0, . .
.
+ o , ~ ~ m ~ u]11.5111 [ p ~1'1~0.25 ~ ~
FIGURE
P
1H.I
I TOTAL ( T EPIDPIEXPlSWR
PROCESS ENGINEERING DESIGNMANUAL PROCESS AND UTILITY
LINE SIZING
Fi y r c 3
I
tlevi~mn:
Date
- Relative
: 2/05
I
r *yn
o.tr
.
1
10 .o
rawghnas of pipe
Pip Dim&r, ia Frd -P
-
P i p Djmlel. in lKhn d
I
t
,
.
'
ror mchrdulr 10 9 < 1 4 - m r * mot used n ~ r n . 1 1 ~ mr rolloli.. a i d t . . . are nor c m m r 0 , Y O . I I 31 fox QI lo- lim dl.+rcrr i r c m a n in 2 " incrrrrml.
11
21
>
.______---~
160
2 "2..
3 I/='# 5"
~ e v ~ s i o: n 0
TOTAL
page NO..
PIPING CLASS Date:
TEPIDNEXPl5UR
2/85
10.11
1. APPLICABILITY
as shown on a PID line whtn the f . i ~ i n gmaterial class document does not exist. This is generally the case for
The purpose of this chapter is t o determine the piping class uscd
feasibility arid pre-project studies.
2. CLASS NUMBERING PRINCIPLES (From DD-5P-TCS-112 "PIPING MATERIALS CLASSES") 2.1.
GENERATION OF NUMBER The class number shall consist of a capital letter representing the ANSI series and 5 two-digit number representing the main material entering into the composition of the material used for the valve bodies, tubes, fittings and flanges of the network in question. Example :
-0
.. ............
Series 150
01
. ....,........Carbon steel +
The tables below give the letters and numbers to be uscd for numbering piping
Claases.
2.2.
LETTERS representing the series of the class Series
1 125 1 150 1 250 1 300 1 400 1 600 1 900 1 1500 2500 1 1 1 1 1 1 1 1 l I
Traring
I
Symbol
2.3.
A
B
C
D
E
F
C
3 1
Y
NUMBERS representing the main material of the class 01 t o 20 21 t o ir5
: Carbon steels (ordinary, galvanized, normalized, etc...)
56 to 70
Stainless steels : Special alloys (Monel, Hastelloy, etc...] : Other materials (Cast-iron, copper, copper alloy, t t c ..I
f l to 85 86 t o 99
:
Alloy steels
:
Glass Plastic, cement-asbestos fiber, ctc...
*
H
/61
----
TOTAL
Revision : 0
PIPlNc CLASS Date : 2/85
T EPtDPIEXPtSUR
(
Pagr No. :
10.12
1
3 P R U I U R E TEMPERATURE RATINGS The following ANNEX G is extracted from ANSI 8 16-5 1977 (AMERICAN NATIONAL STANDARD STEEL
PIPE FLANGES AND FLANGED FITTINGS).
Far pressure temperature ratings higher than series 2500 tho Iollowing is used 5000 PSI,
10000 PSI,
...(used mainly for well tubing and wellhead).
WOttS ( e l p*rm.aible bul r M rwrarnnendad lor prolanomd vr. n h r * {dl "01 tab. uwd ova, 65O.f {.I n m l t* b* uwd o7.r I M ' F (h) nol io b. uswd er.r 1000.1
m'f SI
Conv..s*n
-
Llo {go1 6 . 8 V I
plls
_
."
.
..-I-
TOTAL
Revision : 0
Page No. :
SELECTION OF TYPES OF VALVES
TEP1DPlLI(PlSU R
Date:
2/85
10.13
1. APPLICABtLlTY The purpose of this chapter is to determine the types of valves used f o r designation on the
PID.
.
valves are used tor two mains functions, isolation and control.
The following is only a guide line for selection of types oi valves which must follow the piping material class document when it exists. 2. BLOCK VALVES
The main types are :
. .
, ball plug
2.1.
gate butterfly
BALL VALVE
Ball valves can be full bore or reduced bore. 2.1.1.
Full bore u x s
.
flare system : upstream and downstream of PSV, rupture disc, flare line if
required.
.
downstream pig launcher and upstream pig receiver.
.
vents and drains on hydrocarbon equipments.
,
piping valves on instruments for hydrocarbon.
. 2.1.2.
utility except water for diameter larger than 2".
Reduced bore uses
. 2.2.
far block valves on hydrocarbon lines if the pressure drop is critical.
Block on hydrocarbon service without solid particles.
PLUG VALVE USES Plug\/alves have the same use as reduced bore ball valves when used for high pressure ( 6 0 0 ~Plug valves can be as~irnilatedto reduced ball valves, Generally, plug valves are the smaller and lighter of the two.
163
Revision : O
To
SELECTION OF TYPE5 OF VhLYeS
. TEPIDPtEXPISUR 2.3.
Page No. :
Date : 2/85
10.14
GATE VALVE USES
.
Gate valves can be used as ball valves except for downstream of pig launcher and
upstream of pig receivers. The vertical physical space requlrcd by a gate valve is greater than a ball valve.
.
T i t h t shut off for ball or plug valves is superior to that of a gate.
.
For hydrocarbon service w i t h solid particles presentor as wing valves on well
heads.
2..
+
For quick dosure purposes.
,
On utility lines tor low diameters < 2"
BUTTERFLY VALVE USES
.
On water lines for service, utility or sea water, generally for diameters larger than 2".
3. CONTROL VALVES The main types are
:.
. .
3.1.
globe butterfly special
GLOBE VALVE USED
.
Control valve used in most Q! cases except at very high A P as defined by instrument group, or on water networks, and compressor suctlon lines for throttling purposes.
3.2.
BUTTERFLY VALVE USED
.
. 3.3.
On water networks Throttling a t compressor suction
SPECIAL VALVES USED Special valves are defined by instrument grwp :
.
.
for very high A P the angle valve could be used for cornpressor anti-surge cage valves could be used.
164
Revision : 0 TEPIDPIEXPISUR
Date:
Page No. :
10.15
2/15
I. APPLICABILITY The purpose of this chapter is to calculate precisely the pressure drop in a piping network. This may be required for either study phase for situations where
A P is a critical
A PI wil
however calculation of process lint
consideration. For most proj-ts
not be
required. The pressure drop calculations are based on a summation K method. P THROUGH VALVES
2.
YALYES OPEN
2.1.
1 I
TYPE
I
K
I
I
I
I
I II 1 I I
GATE VALVE
I
0.15
GLOBE
I I I 1
VALVE
I
I
0. I
I
1,
1 I
2.4
1
P in kglcm2 : Iluld density in kg/m3
1 bar V
P 2.2.
NALlNE
CHECK VALVE
:1.02
1
kgicrn2
: fluid velocity in m/s
BALL VALVE
A P through bell valve with reduced bore : This extract of CAMERON BALL
A
P depends on the valve vendor. An
VALVE PRODUCTS is given as an example.
The example below gives aomt values of the pressure drop coefficient K Lor fittings cncounterd in cylindrical conduits. For further information, refer to "MEMENTO DE5 PERTES DE CHARGE by I.E. IDEL'CIK, EYROLLES idition, PARIS".
A P in kglcm2
PV I
fluid density in kE/rn3 : fluid velocity in mls :
A P=K
ELBOWS
K values for elbows.
I
RID
1
90'
-I
@I* 0.1 + 8
I
I I
1.5 0.17
t
2-36 f f
I
3 0.12t4.721 0.08
t
2.36 f
I I
I 1
1
5
I
0.09 + 7.87 f
II
0.06 + 3.94
f = friction factor see chapter PROCESSIUTILITY -LINE SIZING 5 5
I f
1
---
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
AP
THROUGH VALVES AND
FIlTINGS
Date
TEPlDPlEXPlSUA
3.2. taLr-t
aF
A
T-l-#
:?/as
ra--~*~
S. \I.
-C
'44
Revision : 0
1
%\-
.
s,
$9
~ D H
LI-I
Y'&,= r ,
I
:A,
5
K-~'CI
- $1
-K '
Pogo No :
10,~.
-
*
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
A
Revirion :
o
Page No :.
P THROUGB VALVES AND FITTINGS
TEPIDPIEXPISUR
Date
:2/B5
1 0 .I 7
.
v
3.4
trc 5,ts,
3-lr.4
Q15,
zy2 -L
p
Q
Q,
5 4
vaunl
Cr.*)
a
a)Lku.\
3-lc.2 -
5. =
V.,%.
>S.
br-h
sp++b-a
- '-'. 5.
x . ~ + ( ~ * ~ - 2 ( , . ~ ) - , . b , , ~ ( ~ )
z . l - ( r - sa),
1
.
-
TOTAL
Revmian : 0
PROCESS ENGINEERING DESIGN MANUAL
A P mrnUM
VALVES AND
F l g a No :
PI'ITlNGS
f EP/DPf EXPfSUR
: 2/85
Data
10. 10 4,
3.4 3
-
v.
+--?$ 5.
L+ .&\.
),c
J '.
5,
&=***k
O C ~ C C ~a -. l ,(
= kt
[, *($
- 2,
A --I
M.72
f b
-
K
b)
--
*($r]
~ t r . . ~ h +bic*.h
K
.-
R . [O.%
-
.
5 V.
+
2)
+* 4
~ * q * '
j v.
oql, ( I - 4,
16f
-3
2/,
I 4'. 1 C.
4'
:
0 4
h.
5 & 0.0 v. 5 Ye
)or$
TOTAL .
Revision :
PROCESS E N G I N E E R I N G DESIGN MANUAL
0
P 4 t No :
A ? THROUGH VhLVfS AND FITTING5
Dart
TEPlDPlEXPlSUR
;2/85
Resistance Coefficient. K The rtsisrrnte coclicicn ncrlculatrd by thr formub:
K= r
D
L
V a l m of 1ht Irktion fmor, 1, b r valiovr pipe sizes are lined in rablt 1.17. W l u n for LtD and C. k r Wy ~ n t valwr d were taltulared from thearetical s~nldcratiom.Vllvcl of C. for panialty open u a k u were rnripolalrd from in1 rnultJ lor rtprcrenlrtwe sizrr of brll v a k . Chrn 1 * 18 provides graphic reprcsrntation of vahn pahion *nus the percent of full O w n ires.
Table 1-47
FricIlon Factor Ill
Table 1.3 Calculated Values of t/D for Full Opening Cameron Ball Valves In Full Open Position
m ] T l -.-
.-
~
ro
dm
1.1 8,
I . 8.
I
I .
SC rn
7-
I.I I-
-
'I1 .-1 *#
.. ir
am 5-
in I*
.*
1 11
1.1
IY
1r
1 rn
m
1 Is
I Y Im
--
10.19
.
-
- -.- -- -..
TOTAL
A P THROUGH
v~LVESA m FI'ITINCS
a
TEPIDPIEXPISUA
: 2/85
t
Table 1-5 Calculated Values of L/D for Reduced Opening Cameron Ball Valves in Full Open Position
-
---.... _ --.
mw.
un.
--r
1.7
-
4 9
..1
1.1
m..
3Z.m
*I
aI 'I II5 111
I1
a. 1,s
11 1
11 1
111
11 1
ISP 11 1
I,.
nnm
111 LI
11
, I . "
P*
muu - ~ m4-=d -1
. --41111a -- , i t1 *' nb g:
u.n
I.rlI
11 1
11 1 111
ma
w v u .
-
HI+I
a a l p ~ -
m e w .
F 111m
-1011 --.-m
dI
nI
tl
rnl
n.
LI
1%
111
m*
*!I
I.
UI
*I 3.e
Ita
111
a>*
"'
1,.
11 1
it.
aI
*a
#'*
2 2 19
I. I
11 I
k* 1.1
111
74.n
P. IH
1.,
111 13'
111
I, I m.
I1 7
111 1Y 111 11' 111
In* 111
I.1
H I
I-
nn
1.1
Table 1-6
Calculated Values of L/D for
Venturi Openin Cameron Ball Valves in Full pen Position
8
-,-.
,
A
.
n.
91
Pago NO :
~ * v i ~ i o: n
~ D O C E SE~N C I ~ ~ E R ~ DESIGN NO MANUAL
.
10.20
-
I. . . I I
CONTROL VALVE SIZING
10.21
TEPIDPIEXPISUR
1. APPLICABILITY Tht purpose of this chapter is t o give some formulae to estimate the size and the number of control valves installed for one given service, and to estimate the capability o f the control valves i n case of revamping. The final sizing should be done by instrument people.
2. CONTROL VALVES CHARACTERISTICS Them are determined principally by the design of the valve trim. The three fundamental characteristics available are quick opening, linear, and equal percentage. 2.1.
QUICK OPENING
As the name implies, this type provides a large opening as the plug is first lifted from the scat with lesser flow increase as the stem opens further. The most common application i f for simple on-off control with no throttling of flow required. 2.2.
LINEAR Linear trim provides equal increaws i n stern travel. Thus the flow rate is linear with plug position throughout i t s travel.
2.3
EQUAL PERCENTAGE Provides equal percentage increases i n rate of flow for equal increments of stem travd. The characteristics provide a very small opening for plug travel near the Seat and very l a r ~ e increase toward the fully open position. As a result, a wide rangeability of flow rate b achieved.
3. CONTROL VALVE RANGEABILITY For an estimation only it is common practice t o select a valve i n which the valve opening
. .
at maximum flow is smaller than or equal to 9 1 per cent. For normal flow the valve opening should be at least 60 per cent while for minimum flow, il applicable, the opening should be larger than 10 per cent. If the inlnimurn flow is clor
.
the n
'o or smaller than 10 per cent, a smaller valve should be installed i n parallel with n valve.
For a flow rate the valve opening depends on the valve characteristics and i t is given by vendor i n their catalcgue.
4. FORMULAE
The valve area is characterized by the coeificient Cv (except lor FISHER which use Cg for the gas (see hereafter). The Cv coefficient is the number 01 U.S. gallons of water flowing during one minute through a restriction and the pressure drop through this restriction is 1 PSI. The following formulae are slmpllfied and to be used only far an estimation of the Cv. Some corrections may be necessary for the installation of reducers around the control valve. I f so, the Iormulae given by manufacturcrs i n their catalogues w i l l be used for a better Cv calculatlon.
/ 7/
-
TOTAL
2/85
Drte:
4.1.
Page No. :
CONTROL VALVE SIZING
TEPlDPlEXPlSUR
I
0
Rcvir~on:
10.22
LIQUID
A
1 1 I
- Sub critlcal flow
8
- Critical flow
P v < P Z a n d P I - P 2 < ~ f 2A P S I P I - P ~ > C ~ ~ ~ P S
I
v
. ..Q j PI - PZ
= I
=
CI
I 1
c
v
.
JEZ ~ Ps
critical flow coefficient (given by manufacturers and depends on the
type of valve and the action of valve by increase of variable) cf Pv
=
P1 P2
:
fluid vapor pressure in bar g. upstream pressure in bar g.
=
downstream pressure in bar g.
A pi
= PI
I
- (0.96 - 0.28 @ ) Pv PC
or to simplify, i f Pv < 0,s PI,
4.2.
<
-
APS
PI
- Pv
PC
=
Q
=
fluid critical pressure in bar f b w rate in m31h at upstream conditions
sg
=
specific gravity at flowing temp. (water = 1 a t 15.C)
GAS AND STEAM
I I I I
- Sub critical How PI - P2 < 0.3 cf2 PI A
I
8
- Critical flow
PI
- PI ) 0.5 ~
f P2I
1
I
,--=A 295
Cv
=
-1
GAS
-
(PI P2)(PI + PZ)
I 1 =-,
I
I I
47.2 W
1
JIPI-P~)
I I
( P ~ + Prg ~I
Q 257 Cf PI
C V = 54.5 W
ct PI
G
W = mass flowrate in t h
172
-
TOTAL
Revision:
0
Page No. :
CONlROL VALVE SIZING
TEPIPPIEXPISUR
Date:
2185
10.23
SATURATED STEAM
I Cv
I cv=- 83.7
72.4 W J(PI ~ 2 (PL 1 + ~2)'
r
-
I I I
W
Cf P I
SUPER HEATED STEAM C v = 72.4 (I
t
0.00126
I
I Cv = 83.7 (1 + 0.00126 Tos) W I Cf PI I
Tw)W
PI - P2)(P1 + PZ)'
Cg, PI, P2, Q =me definition and unit as 5 4.1.
G
= relative density (air
T
=
Z
= upstream compressibility factor
W
= =
Tos
1.0)
upstream gas temperature OK = 273
+ 'C
s t e a m weight in tlh s t e a m superheat in 'C
43. T W O PHASE FLOW For sizing, maximum
A
P
-
PI
- P2 = 0.5 ~ 1 P2I
- Without liquid vaporization
&=
I 1 B With liquid vaporization
1
-
1 cv
51.8 W
q-)
I
.
36.6 W
Cg, P I , P2 same definition and unit as 5 9.1. W =
t o t a l fluid flow. in t/h
dl =
upstream mixture density in kg/m3 d=
W x 103 WII dl1
-t-
Wlv dlv
Wll = upstream liquid dl1 = upstream liquid 1 = upstream vapor d l v = upstream vapor
172
flow in kg/h density in kg/m3 flow in kglh density in kg/m3
i
~ O T 11 A p m.ouci.
Rkvilion : 0
v,uvis
rrmNcr
d2 = downstream rnjxturr density in kg/m3 d2
=
W x 103 W21 w2v -+d2 1 d2v
W21
r
downstream liquid flow in kglh
d21
t
downstream liquid density in kg/m3
W2v t d2v
4.4.
=
downstream vapor flow in kg/h down~trcamvapor density in kg/m3
FISHER FORMULAE For gar 'FLSHER" use Cg instead of Cv
C1 = valve coefficient (given by catalogue)
-c ]
W
Cg = 0.4583
dplsin
3
dag.
W =
gas flow rate in kglh
d = gas density at upstream tanditions in kg/m3 PI : upstream pressure in bar (a1 P2 = downstream ptessurt in bar (a)
5.0
REFERENCES AND USEFUL LITERATURE
-
-
Vendors documentations
CPSA chapter 2
rPage
No. :
TOTAL
PROCESS ENGlNEERlNC DESIGN MANUAL
tEPlDPlEXPBUR
Revision :
Datw
-
/,-=
: 2/85
Plgr No :
-
-
TOTAL
Page No. :
Revision : 0
PIPELINES
. 7EPlDP/EXPISCIR
Oate:
AP
and A T calculations will may be necessary however to make an
For both feasibility and preprojcct studies, long pipeline normally be performed using PETITE or RESEAU. I t
11.1
2/85
estimate by hand. Details are glvtn below on how l o proceed on this.
I
2. PIPELINE PRESSURE DROP FORMULAE
2.1.
GAS TRANSMISSION
there exist many methods of calculating arc :
hP
for gas transmission lines. Some of these
American Gas Association Formula
Wcymouth
Panhandle 'A' and '8'
Darcy
Colebrook Below is given the Panhandle 'A' for use : r 11.1539
Where
Pi
s
P;i
=
C
=
Ts ps T
= :
L rn
=
q d Z E
r:
=
=
= =
Upstream pressure bar (a1 Downstream pressure bar (a) Specific gravity of gas K (273 K or 298 K) Base temperature Base pressure bara(l.01325 bar) Gas flowing temp K Pipeline length krn Flowrate at Ts, Ps bast m3/d (at Ts, Ps) PIPELINE DIAMETER crn Average gas compressibility Efficiency (0.92 for a clean line)
The formula does not fake into account the pipeline profile which, i f significant, can be added t o the A P calculatcd if required.
I
22.
LlQUlD FLOW IN PIPELINES
Use Darcy equation :
M
= Mass flow
kdh
F
p
=
kg/m3
E
D
= lim id
AP
z
Density
pressure drop
crn barlkrn
= '=
Moody friction factor
Absolute roughness (KC page
= viscosity
em
10.8 and 10.9) CP
.
-
1
TOTAL
Reuis~an:
Page No.:
PlPELlNES
2/83
Date:
TEPIOPlEXP~SUR
Re
0
= 35.368 x M
F = 6@lRe F
x 0
i
-----a*---
1
( 7 i ~ e I . 9+ (0.27 E/D) 0
=
2000
=[(31~d12 + i/(A+B) 3/21 1112
Ln
with : A - 2.457
<
for Re
I
11.2
for
Re > 2000
l6
(37530/~e)16
BE C A R E F U L when using friction factor charts as confusion arises
between MOODY F and FANNING F' : 2.3.
F' = 1/4 F
HORlZONTAL
T W O PHASE
Estimating 2-phase flow
A
P by hand for long pipelines
is not recommended, a8
the flow characreristics and equilibrium wUI alter along its length. However an estimate of
A P can
be hand calculated providing the phase regime is fairly
stable.
Given below is a calculation method based an LOCKHEAKT-MARTINELLI-
BAKER method. This method can be used for both longpipelines (stable regime) or process lines.
METHOD
A P2 PHASE
-
A P HORIZ
+
APVERT
1
Evaluate flow regime and adjust Pipeline @ if required
2..
. a ~ c u ~ a t eA
P ~
3. calculate &pr 4. Calculate ( ~ P ~ / P P ~ I ~ ~ ~ 5. Calculate
AP
2 PHASE
factor....
:P H
6. Calculate ApVert factor (vertical section of pipe)
For convenience pipe ids are in crn viscosity is in cp.
/7f
-
-
-
11.4
1 1 1 1 1 I
(W
Vs=
I 1 I II
+ m) W1
=(&)f
I I 6. CALCULATE LOADlNG FACTOR WS
I I
WS
I I
-
I I
I 1 II x = C.\\S
I
I I I 1 1 I
I
I
1 I
1
I
II
I I I I I I I 1
I 1 I I
1
I
1 1 I
I
I I V3 = average velocity I
VS = !-!. 0 3 ;n/s
I ws=7?123 1
W i x 0.205 A
r
I I
I I
5. CALCULATE X RATIO
x
I I 1
1 1 I
4. AVERAGE VELOCITY
1
7. CALCULATE PH FACTOR FOR HORIZONTAL FLOW L
(
TYPE OF FLOW I
I I
1 I I I
I
I I 1 II [
I I 1
I
I
W..S€D
..I
Rt
[..UP
•
I I
i
BUCBLE
*X
Oltl.
wbl
ANNULAR
FLOW TYPE = b;si'f52rb
b
e
. m
-
.1.*1.*
b.&-&Wd 4 3
Q
LI,.,~"
~4 1
#]I
mu.
1-3I
*'' I
-- -
I
1 I I
D+S5J
Ey+- - I
WAVE
I
fS
I
PLUG
HI.=.&
~h
WG
]A?,
II
-
A
- -
-
rk Fn * 0 . 2 1 1 1
- -
-
hhs
-
-
FLOW f YPE =
7
A PZH =
A ..
=S.t54
rn
I 1
m ~ ~ p w~ h~ ~1. >
8 . -CALL . 'LATE ~n FACTOR FOR VERTICAL SECTION
i1
Fw
-
I x I I
SECTKIN
I
I I I I I I I I I
I
. . X
V i r m h D i n cm
ra.9 "'/a (x) I I R N P . ' ~ ~ XD in D i s p r r d 1l@r
APH,.
a19
t.510
to 1-1 PH r m .
Horizontal
:
Vertical
:
TOTAL
1-r 8 1 \.St0
A PZH =bpGx PHZ
A PZ,, = ~ P xGP
&P = (ApZHx L +APzv x h)/1000 =
=
H =~
1%3 4 0
o.ri>
bar/km
I
I I
bar
1
PROCESS CACCULATlON SHEET
OAT^
TWO PHASE PIPELINES P CALCULATION
ITEM :
Ilao T I T L ~. rzniirr i
JOB NO
I
barlkm I
/SO
TIC~W?T)tC'€lP~SUR
c nx
PH z pH,=
I I I I I I I 1 I I I I I I I
I I I
9. CALCULATE TOTAL TWO PHASEAP
m@/ TOTAL IV
WAVE
3-793
bar/km
YLRTICAL
I
1 I I
I 1
I STRATIFIED I
,
I
I
I I I I
I.Pf8
=
PH
I I
Sheet 2 of 2
NO. :
Itv
TOTAL
Revision :
0
Pmgt No. :
PIPELINES
TEP/DPIEXP/SUR
Dare :
2/85
I I.5
3. TEMPERATURE PROFILE For detailed and accurate AT and hP calculations in 2 phase lines buried, subsea or in air the program PEPITE should be used. The hand calculation method presented on pages Il+6, 11.7 is accurate t o wllhln 10 96 for both gas and liquid lines. The procedure is easily adapted t o a small pragrammablo calculator and increases in reliability the greater the number of segments used. The fold #ingshould be remembered when designing pipelines,
.
For long pipelines assuming isothermal flow can result in overdesign in pipeline sire and
A P.
.
If the plpeline is constant with regard t o material, insulation and burial depth along its route a fixed thermal conductivity (k)can be assumed.
.
For gas pipelines the internal film rcsistivity is negligible - Ignore it.
.
For all steel pipelines the resistivity of the metat 1s also negligible.
. .
Small plpelines 1< 20") have a large heat flow compared to the specific heat of the flowing medium. Consequently the gas w i l l reach ~roundtseatemp in a relatively short length. For large pipelines the converse is true and a long distance is required t o reach ambient. For oil and small gas pipelines the asymptotic temperature Ta is that of the surrounding medium. For large diameter gas tines, Ta d e p n d s largely on the JwlrThompson effect.
The attached calculation sheet can be used for hot lines in cold surroundings or vice verm
For subsea pipelines, epoxy wrapped, concrete coated resting on the bed an overall heat transier caeff of U = 10 I S k c a l / h m 2 * ~is a good estimate for calculation purposes.
-
/r1
+
-
?.
11.6 Coverinn Mcdjurn :
%,?.
b
y
DATA -
AY
0
h PI
P2
AP TI J
)
Tg
Total pipeline length No of segments L e n ~ t hper segment Total elevation change Pipeline diameter Pipeline diameter Burial depth to c e n t r e
rn
= 2aa.o
m
=
ins rn
= 3= 0.16~
m
=
=&
-+ m
losoa
= a 1-a
-
GAS FLOW
I.tl
bar
=
OC
= A?
Valumetrlc flow Molecular mass M Mass flowrate Cp Speciiic heat
10
FLUID JOULE THOMSON COEFFICIENT = (set fig. I , page 11.8)
I I
-
5
I
= tkT/ln[n + (x2
I x I s 1
- l)f)
I
.at flow ratio per unit a
1
1
I
II I
I I
I
( a
c
=rrHti ~ ~ - 1
1 I 1
I I Ta=-hI°C I I I
T2 I
4. Calculate downstream temp
T2 =(Tl
I
I
- ~a)c-aL+ T a
I 1 Repeat steps 3 + b for each segment I See s h e e t 2 for stepwise spreadsheet I
m&u TOTAL m z 3 sun
I T2 =bl.kqC I
I I
kcal/kg*C* 0.6
o.ooao5)
:o-L<'~lbrr
I I I
NOTES
I
1
k
kcalhm~ I
I
1.99 0.022 0.508
I 1 1 I I I
0.30 1.49
1 1 I
I
I I I I I I
I I
f I I L is segment length I j = 426.5 & I kcal I
I I I
I I I 1
1
I
I
I I I I
I I
I I I
1
I
1 t?2 PROCESS CBlCUlATlON SHEET
BURIED PIPELINE AT CALCULATION
1
I Sheet 1 of 2
ITEM Ho.
T€PrmP*oIPEX@
CHK
m3/d (std)s ?d 0-e = tq kg/h = wcabS
:3.33 Soil = 5 keal/hm°C 1 Air I Water I Sand dry I Sand wet
I
I @@ I 1 a = r/MCp (liquid or gas1 I I 1 3. Calculate Asymptotic temperatureTa 1 1 Ta=Tg-(JbP+Aylj~p)/al
x
I I I
VALUE
I
1 1
1 1 2. Calculate .
rc *F/IOOOpsi (
s I I
I I I
07
Volumetric flown3/h = Density (av) k8/m3 = M Mass tlow kg/h Cp Specific heat kcallkg * C =
bara = L o bara = l a
Inlet pressure Exit pressure Total plpeline Initial Temperature
I
Temperature * C = \O Therm. cond. kcal/hmnC = 1 . Lq
LIQUID FLOW
I I STEP t I I 1. Calculate heat transfer Iactor 1 1 x = 2h/D
I 1 I I
k
-+ TI,?.
L
-
C
L
q
OCTE
108 TITLE
tsAdl€
100 Mo
REV
-
.
11.7
AT.
ITERATIVE CALCULATION LOG FOR A BURIED PlPELlNE
I
I
SEGMENT N*
I I
I I LENGTH I I I I
I
I
I I
1
1
I
2
I ,*eo, I
3
I
I
I
I I I I
I
I 1 1 I I
5
I
8
1 I I I
9
I
I
a
,..a
41.0
I I 1
I I
I
7
1 I 1
I
I
I
1 I I
I
I I
I +QT£.
)
b r
wrfc
a
c
t
..In1.1.c\*i
PC I I I ~ ~ C. hIs0 t u v P L t O \ * ~ ~ 3 .*,I uc~.o,. . hu
*td
I 3 ~ 16 3 0
I
I
-
I
I
I
I
I
I
I I I I 1
I I
I I
I I 1 I 1 1
I I I
I
1
1
1 1 I
I
I I I I I I I I I I I I I I ! I 1 I
1 1
I I I I I I 1 1 I 1
1 1 I I
I
I
ou
1
1
1 I
Cp -1
PP L q . 4
I I
I
I I
I I
wnrd
I I
I I I I I I 1 1 I
I I I t 1 I 1
I
I
I I
I I I 1 1 1 I
I
I
I
I I
I
I
I
I
I
1
I I I I I 1 1
I
I
I
I I
I
I I I I 1
1 I
J
.
I I 1 1 I 1
I
1
I I I I I I 1 I
1
IAI.L II -
1 1 I
I I I
I I
I 1
I
I I
I
I I I
I
I
I I I I I
I
PZ
A
I0r r
I I
I
I I I I
I I
I I
I
I
I I I 1 I
10
1 I I I I I I I
I I I 1
1 I I I
~
13s
~3
I
1
b
1
1 I I I
I
I 1 I I I PI I T I I Ta I T2 I I I I 1 I I
1 I bar a l ' C I 'C I ' C I b a r a l I 1 I I 1
-+ m
I I
m
I
4
ELEVATION
J
I
I I I
I t
I I I I
I
I I I I
I I
kl
LWU&JC
4
4
j.L~liv~
l r
&
1
<>
PROCESS CALCULATION SHEET
BURIED PIPELINE AT CALCULATION
CHK
oa~t
ITEM
uo
flP'OOP'D~?'ta~~sun
II
Sheet 2 of 2
I roo
TITLE
t s ~ ~ t * i L
JOBwo
I
ntv
I
d
r
Revirion : 0
TOTAL
Page NO. :
PIPELINES Date :
2/85
11.8
4. LITERATURE AND USEFUL INFORMATIONS
9.1.
LUDWIG YOL I chapter 2
4.2.
CAMPBEL VOL I chapter 12
4.3.
KATZ, HANDBOOK OF GAS ENGINEERING chapter 7
4.4.
CRANE MANUAL
4.5.
"Equations predict buried pipeline temperatures" GiKinp, 043 March 16, 1981
8.6.
"Two phase
Soil
hP computedM
1.19
Wet soil 4 9 Ground -> air 2.98 G r w n d --> water 29.8 Steel 38.7 Epoxy coating
0.67
Caai tar
0.22
Hydrocarbon Processin)! April 1984
R. Soliman
concrete
0.65
sand(dry1
0.30
sand (wet)
1.C9
Air
0.022
Water
0.5 10
-
1.19
'5 1
ri 2
loule-Thornson coefficient' r
m.*--
Specific heatso \
f
*
'*-.Htlwa--
4
I
0 PI
ra
Pr ~.mol*l.rollml.IDP2.OPI
-c
*
DI
-
rn
b)lm.ut411nIJPIm *
I
-
TOTAL
PROCESS EHCINEERlNC DESIGN MANUAL
TCPIDPIEXPISUR
R.risim :
bat*
4
12, PACKAGE
UNITS
: 885
P q r No :
-
-
TOTAL .
Revision : 0
Pagt No
Date : 2/85
12.1
DEHYDRATION
TEPIDPIEXPISUR
I. APPLICABILITY For many studies undertaken there wifl be a requirement i o r 8 gas or liquid dehydration unit i n ardcr to reduce the water content of the export phase to acceptable limits for pipeline transportation. Generally this design will be undrrtaken by a vendor sperialist. However the engineer should be aware 01 some o f the options available for dehydration schemes, some of
the dos and donts of design and also how t o undertake the basis slzlng of the most common unit (TEG). The majority of this section i s concerned with gas dehydration using tri-ethytene glycol contact, this being the most widely used. 2. GENERAL DEHYDRATION NOTES
(English units ate used throughout this section for convenience)
, Gas is normally dehydrated to 6 to LO lb af H20 per MMSCF in order to prevent hydrate formation in gas tranrmlssian lines, and reduce corrosion. Unless the gas is dehydrated liquid water may accumulate a t low polnts and reduce the flow capacity of the line. Methods of dehydration i n usage arc : I. Adsorption 2.
Absorption
(Alumina, silica gel, male sieve) (di- or tri-ethylene glycol)
3. Direct cooling
4. Compression followed by cooling 5. Chemical reaction (for method injection see 4.0) The last three methods have minor usage and are discussed elsewhere in literature.
.
A sumr,
y of the advantages and disadvantages
of various absorption liquids i s given in
Table 1. Tri-ethylene glycol is the preferred (mast widely used) absorption liquid. Example flawsheets of di- and tri-ethylene glycol arc given in Fig. 1 & 2.
.
In order to limit the overhead glycol losses a max practical operating temp of 38
*C(100
'PI is used. A maximum of 50 'C (50 @ F )i s recommended t o prevent problems due t o t h t glycol viscosity.
.
Glycol losses arc usually i n the order to 0.012 gaIfMMCF (0.0016
r n 3 / ~ ~ r n 3due ) to
vaporisation and loss in the overheads. Total lossea due to leakage, vaporisation, mlubility run around 0.025 gallMMCF (0.0033 r n 3 1 ~ ~ r n ~ ) .
.
Concentrations o f TEG upto 99.1 % can be acheived without the use of stripping gas. For higher purities gas w i l l be required.
if?
'
TOTAL
Page No, :
Date: 2/85
12.2
DEHYDRATION
~EPJDPIEXPISUR
.
Revision : 0
Glycol foams in the presence of light hydrocarbons. This can be minimised b y goad
feed
prescrubbing and addition of anti-foam agents.
.
Actual gas e x i t dew points are usually 10-15 ' f (5.5
-8
'C) above the theoretical
equilibrum dew point. Take this into account when setting the specification.
.
The number of trays (or packing height) is usually small I 4 trays) an excess of either is always provided i n the design. Recommended efficiencies are 25 % l o r bubble caps 33 113 % for valve trays. Use 24" tray spacing*
, Regenerator temperatures should not be above 400 'F (204 in order to prevent
#CC)at atmospheric pressure
-
glycol degredatjon. L i m i t heat flux to 5000 7000 BTUlhft2, aim tor
-
6000. Provide a t least ZOO0 BTUlgal pump capacity.
.
To prevent hydrocarbon condensation i n the glycol feed maintain at 10-15
.
'F (5.5
- 8 ' C ) abave the gas exit.
Regenerator s t i l l column should run at
220
the inlet temperature
'f (104 'C)a t top to prevent loss 01 glycol
but maximise water rejection.
.
Glycol clrculation rates should be between 2-4 gall/lb t i 2 0 removed (3 i s a good number).
3.
PRELIMINARY SIZING CALCULATLONS An exact sizing of a TEG unit will normally be performed by the vendor on request. The CFP lnhwse program "GLYCOL" also exists Ior estimating vessel sizes, circulation rates
and utility consumptions. These arc based on data from the B5+0 design guide. The following hand method can be used however t o estimate the required size :
1. Determine water content 01 inlet gas t o contactor a! required temp and pressure Fig. 7 Ibs/MM5CF, k g / ~ ~ r n 3 . 2.
Calculate total water mass in feed gar to contactor
3. Repea: nlcuiation lor exit gas using required exit dew point (add 10 "F contingency). Calcula. dew point depression 'F, 'C.
b. Calculate amount of water to be removed in contactor. 5. Use 3 galls f E G / l b H Z 0 evaluate glycol circulation rate.
6. Use Fig. 3 to determine required TEG concentration. % Use Fig. 0 t o determine required stripping gaa rate 7. Use 2000 BTUlgall TEG circulated to determine rcboiler capacity.
188'
Rewislon : 0
TOTAL
Page No. :
DEHYDRATION pate:
TEPIDPIEXPISUR
2/85
12.3
8. Use Fig. 6 t o determine number of trays required in contactor and Fig. 5 to determine contactor diameter.
9. Evaluate contactor height (set section I vessels) include integral KO pot in base of tower. Hence estimate weight of contactor. A more detailed sizing method can be found in
CAMPBELL VOL 11.
4. METHANOL IN3ECTION (HYDRATE INHIBITION)
In order to prevent hydrate formation in gar transmission lines the product is normally dehydrated in s TEG or mole sieve unit as defined in previous sections. On some occasions however (wellhead to plant) this is not possible due to the location of the source. If the minimum pipeline temperature is below the hydrate point the inhibition of water i s required. This is acheived by infection of inhibitors to depress the hydrate and freezing points.
.
. .
Common inhibitors are methanol, DEG, TEG. R ~ C Q V ofC ~inhibitors ~ a t the receiving plant ir normal, t h e liquid being then recycled. Econamics of methanol recovery are not favourable. Methanol i s adequate for any temperature. DEG not good below Limitations. Above 10 ' C better as lower vaporisation losses.
-
10 *C due to viscosity
Predict injection r a t e for hydrate depression as follows :
W =
W =
d M 100 Ki+dM
TO uw
v e equation
:
weight % inhibitor
= 'C hydrate depression M = Mol w t of Inhibitor
d
Kt =
.
-
1297 for ,Me OH 2220 for DEC, TEG
1. Predict hydrate formation temp at max. press in line TI 2 Estimate rnin flowing temperature in line T2 3. d r T I - T 2
The amount of inhibitor injected must be sufficient to depress the hydrate point as
calculated above and also provide !or vapour and liquid phase losses due to vaporiwrtion + dissolving. Adjust injection rate accordingly. For glycoI use 0.0035 r n 3 / ~ r n 3 (0.23 I ~ ~ M M S C Fvaporisation. ), For methanol use vapour pressure charts (CAMPBELL pp 159).
/ST
w
TOTAL
Rtvision :
0
Pmgs No. :
DEHYDRATION
TEPtDPlEXP/SUR
2/85
Date:
12.4
5 SOLID BED DEHYDRATION Solid bed dehydration is used when lower residual water concentrations arc tcqulrcd than the over achieved by glycol units. This is generally around the
- 40
' C mark or 1 ppm
residual water. Solid bed dehydration can be used l o r less stringent design requirements
TEG.
providing the cost is competitive when cotnpared to NOTE5 :
. .
LNG facilities always used molecular sieve dehydration t o acheive I pprn H20 or less. Available dessicant medium :
k~HZ0/100 kg bed
.
Bauxite
4-6
Alumina
4 -7
Gels
7 -9
Molecular Sieve
9-12
Beds can be severely degredated
cheapest
most expensive
by heavy oils, arnines, glycols corrosion inhibitors,
salts and Ilquids. i t i s essential t o have a good feed filter or scrubber prior t o entering the dessicant bed. ,
Bed life is usually 2-4 years depending on contamination.
-
Gas flow through the bed is generally downwards. Regeneration gas flows upwards.
This
ensures the water is stripped from the media without having to pass a l l the way t h r ~ l g h the bed. Figures 8 and 9 show a typical molecular sieve arrangement. Regeneration temperature is usually 175 " C
-
230 OC. Too high temp destroys the
media, too low results i n poor regeneration. Table I gives a summary
of operating and regeneration practices.
6. USEFUL REFERENCES AND LITERATURE 6.1.
~AMPBELLVOLIICHAPTERS~~AND~S
6.2.
HANDBOOK OF
6.3.
PERRY
6.4.
GAS DEHYDRATION
N A T U R A L GAS ENGINEERING, KATZ, Chapter "Fire tuning existing fleld installations"
D. CRAMER 63.
"Cutting glycol costs I"
- World O i l - Jan 1981
C. SIMMONS 0
+ C3
-
Sept 2 1 1981 Sept 28 19111
"Cutting glycol costs 11" 6.6.
16
"Correlation eases absorber-equilibrum dehy4ratian"W. DEHR 0 + 93NOV 7 1983
1Yo
line
cales
for
TEG
natural
gas
--
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Revirion : 0
/
Fagr N o :
DEHYDIUTION
TEPIDPIEXPISUR
Date vrn
CCYT
n
avca
12,5
: 2/05
WIMT
no. g no- *tar b h i a h y l w m glyml ddtydrerian plant i C o m M omd lwrmrw.
.
s r m u ~ ?a wm*cu IAD D r s w w w m r LtWlD
C.IC1-
MVMffiU
Chlor14.
L L ~ L I P cU.111.
U#i c.pst1ty
1.1
b . = . = . . . I . . I.*.
UI.~
k t b71rmlit14 l l m i l f kr
10-xr p*.c.nr
MU
00-11 ?.rr*.r
WC Umt-r
t-v..
wht I=l.mm.L..
.I
-tw
L o n - i m ~ cI11wL..
1.1
pu~%fi..
I . .1 .
a . ow.lln.
Di.lh,L-.
Clw-1
Lubl. SI
..lIdih
is c o 5 ~ 1 r . c d
wlrcm. IC.bI. L. p.m.-.
d .UIlrrs .I u-1 e+.r*tw ta?-mtw-. ant-
.rl
cq
I.
mwr brr-.r* Can? w n uii I
I
b*. n m l U i I ~ im .m.emcr.s*4 1 1 m t h . Bnmbb Is V.UY* 01 o r i t u . EW1.1c q a t w r u l 0p.r.t1.# i"~.t.*..... I I B h I ? hY11.rm.lc m a i l l r.ll.rmt.4 c- I t y r C"t
.
t.pemair= 1 .lY1 1 ..
Y ~-.rej.l
11.1..
-1".
D.h~dt.t..
bullltl.~I i c b e l l , Cerrmd.m ~1rrrrsl~~lc.ll~ la" I . . pll. I.p.I..II hlr*mn rdlU.'lsru 11.=1piI.Imm
.,...
1.-Y'C
e*. .IS .lalr-*arol~.
Ol?col r4doc.e
TABLE 1
DIYWUI*DU
nu, lyhlvp l ~ l l
3-10 l m r = * m *
- urarrrm rxwwr
UI"th.
C.*q l.t -11 llmh i.r v1.c 1.~~10111
sarrl n . r mlrmel.
Ciur.r
I..
rk..
r l t b rrhthrl...
L 1 d z . d 1.r i r ~ r t i s a puxpom*m l
I.
mnmr l.bllr.mim. r r himh rq.a.*.rlam chp.r*tur~. me.4.1 rmrra.1r 1 . prmblu. D.I pist d.pr.111m 1. 1hLt.l a.1 1.~. t h e lie t=bt h r l w 117~m1.
Calr, e m # w u t r l h l m r i l h t r l m t b l n a t11101. n t . Ia -1 r t r n t s a l n l r r r ir & l o t w o 4 m#.U?.
.,...,
i in I... th.. t s i m * w ~ - s mimm~ namb i m i r v l *em& k. ,.Id
.I,b
li'h l m i 1 h 1 a w l w i b i t m so- r-mi., t-d*=, is ~ t u =a . -1 Itmhr L l l t a c ~ t bIlqrli.. ~ bf ~ m l m m*IWL mu*= -ltll* b1 1 4 d d .
!
!
I
TOTAL
PROCE5S ENGINEERING DESIGN M A N U A l
Rtvision : 0
Plgb No :
DEHYDRATION Date
TEPIDPIEXP/SUR
: 2/85
12.0
a f 10unt 0 I I A Y D O R I*CI(INC RrOUIRIO TOR
I
--
-.-
II~Y~.
.
..
7 ../.
rant
unm err w m . *C ca.rm< or w m.m * r
I q4
s t u r - l -9.
OLlCOt D E H I O M T O R S
1
TOTAL
PROCESS ENGINEERING DESlON MANUAL
DEHYDRATION
I
rm Y
r
12.9
-
maw
rmwr
m m
1.r h e 1 1 1 . 1
1
I,**,warn
mllrnm
n.p
iIPi
I
I
mlo~vllt
m~*rlr..
, ~ M M
n.~.rm
!w*n mn
tu r w r * M r Sornmm-W r ~-WIII*LIC.*I. rmrlu(Wmmm
rrmln
n r m r n
!u#lanl,
r.ll"lm~*
{*I
o w
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: U
: 2/85
Date
~ E P ~ D P'{SLIR ~E
I
Pngo t4a
Revision :
d w l h * l * l W y h
Y h""lhl
I* M.
I
11111.11
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w
1111 r r m n n - a e q Y l l , r * h C
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hkd.. r l h ~
,
wdlh
hm Drrrhadam L CFIW LV ~l#lt(wlt lhPm*l
/ a-tm >I m l l r m . 11.
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fnml
,
ct
,
n(dl.m
I0
hlb*
llm*
R
h l m I I C ~~ k k
:
Y I W W W-a ~ Lmwlm ilmln<18
I
n(tlN
I WIHVIII
.nh
!m l l b h t
*- > I 8 ;I*IttLI. 't
1 ELM
ulw ca.nvn*h I. 1tmr8 IJI hwq I* rlrhrtrlhallr 1Irn.IICmlm"L .(
*a i r m , w IW*
I,1lblUI*lMl*
HI1d nnrmm i m l l , I..,."i.lmy
I
I
ft4r)U
3
Basic Charmtteriattc~Of Kolecular Sieve*.
om*
SAI
IECICLEO QbI CObPIlEiSDI
F,Cdkc q
I C Y t Y N K OllO.lY
O? YOLCCULLfi l l l V l fiV10.p11m
/# r
*
.
TOTAL
RevisiMl:
0
PageNo.:
GAS SWEETENINC
TEPtDPtEXPISUR
Date :
2/85
12.10
1. APPLICABILITY Generally natural gas, or associated gas contain acid components, mainly carbon dioxide :en sulfide (COS), carbon disulflde (CS2) and mercaptans.
(C02)hyi
To obtaln a commercial product, gaseous or liquefied, the gas needs to bc treated t o eliminate these sour components for safety or process reasons. An other aspect of gas sweetening is linked with the development of the C02 injection to improve oil recovery. In this case C01 is extracted by a selective process. This section details different methods available for gas sweetening and lists their advantages and disadvantages. Guidelines are glven on which system to select lor specific services. A detailed sizing method is beyond the sccpt of this section, but can be found in the
referenced literature is required.
2. UNIT The specification of treated gas can be given in grains/lOO SCF for H2s or sulfur content
1 gralnllOO SCF r 16 ppm volume 3. GAS S WEETENINC PROCESSES
Various prwrcsscs a r e available :
-
3.1.
chemical absorption
-
solid bed adsorption
phy slcal absorption cryogenic fractionation chemical conversion using catalyst the absorption process b the most utilised
CHEMICAL ABSORPTION In this type of process, the chemical solvent absorbes t h e acid components present in the feed gas by chemical reaction and releases them by heating at low pressure. T.he main chemical solvents a r e :
-
-f h t Alkanolamines
. . . -
.
Aqueous ?6 normally used -
cwt)
MEA (Monoethanolamine)
DEA ~Diethonolomlnc) DCA [R)(Diglycolamine), {FLUOR ECONAMlNE) MDEA (Methyldiethanolamine) DlPA (Diisopropanolamlne), (AD]?)
or alkaline salt solutions as potassium carbonate KzCOj
146
15-20 20-35 up to 65 15-30 30-50 25-40
.
-
TOTAL
nevirion : 0
page Ida. :
GAS SWEETENING
TEPIOPIEKPISUR
act*
!
2/15
12.11
Alkanolamincs cannot be used undiluted because :
.
I
. lo
-c t o solid s t a t e a t ambient conditions
gtability et high temperature (heating is needed to extract the absorbed acid
gases) wlth generation of highly corrosive products by decomposition. Table 1 shows the advantages and disadvantages ol these p r o c t s ~ s .
3.1.1.
MEA PROCESS ( x e figure 1) MEA solution was the first solvent used and is still widely used. Generally a
I5 % weight solutjon is utilized. a) A d v a n t a ~ e s
-
high reactivity
- good chemical stability
-
low solvent cost
-
publicly available (no licendng fees)
b) Disadvantaftcs
- irreversible degradation into corrmlon products by sulfur components such as COS, C52 - trreversible degradation lor t h e salvent by oxygen (Direct contact with -
air must be avoided) ineffectiveness for removing mercaptans
- high utility requirements - high vaporisation losses - need of reclaimcr t o purify the circulating solution - no selectivity far absorption between H z 5 C02 - foaming problem and
C)
Fields of utilization
- general use
: MEA can be utilized for gases conraining from 60 ppm to
I5 % volume acid gases without COS, CS2, mercaptans and with acid gas partial pressure up to 100 PSlA currently maximum capaclty for a MEA unit is around 250 ~ 1 0 SCFD. 6 3.1.2. DEA PROCESS
The second most wldely used gas treating process with a tcndancy t o replace the MEA process and some improved processes. Flow diagram very similar t o MEA process without rcclaimer.
14 -7
TOTAL
Rrvlrion :
0
Page NO, :
GAS SWEETENING
- TIPIDPIEXPISUA
Date : 2/15
12.12
a) Advanta~cs
-
-
no degradation by COS and CS2 (hydrolysed into C02/H25} a significant amount af the light metcaptans present on the feed gas is absorbed a good chcmlcal stability a very low absorption of hydracarbons
publicly availabIe
-
no need for a reclaimer reduced vaporisatian losses
b) Disadranta~es
-
lower reactivity compared to MEA and thus higher circulation rates
lor the conventional system (Not applicable to SNEA-DEA process)
-
-
C)
an irreversible degradation of the salvent by oxygen and HCN hlgher utilities rtquirelnents no selectivity l o r absorption between H2S and C02 foaming problems
Fields of utiiization The DEA process i s used t o treat gases containing H25, COZ and also
COS, CS2, RSH (up to a total acid gas content of 20 % volume)
Hz5 content of the treated gas lower than the normal specification
requirements 14 ppm volume) can be achcived. The CO2 content of the treated gas can be as low as to I00 ppm volume. Performance of the
process depends on the C02/bi~Sratio in the feed gas.
dl Improved DrDceSSeS I. Split flow (see figure 2 ) For sour gases w i t h high acid gas content (above 25 % mole), DEA
flow rate can be reduced. Investment cost increases significantly (more equipment, complex columns, increased regenerator height). 2. SNEA
- DEA process.
SNEA company has developed a pracess using a hlgher concentration of DEA (above 30 % wclght). The process licensor claims to give In one step, for gases containing 0 to 35 % of Hz5 and 0 to 35 % of COz, a treated gas matching the most stringent H ~ spe~iiication s (4 pprn by volume).
1qr
TOTAL
0
Page No. :
2/~5
12.13
Revision :
GAS SWEETENING 0ate :
TEPIDPIEXPISU~
3.1.3.DIGLYCOLAMINE
(DCA) PROCE55 (FLUOR ECONAMINE)
The DGA process has a limited number of units compared w i t h MEA and
DEA.
Although in the public domajne, the process was developed by FLUOR and is refered t o as the FLUOR ECONAMINE process advantages and disadvantages to compare with MEA arc :
a) Advantages
-
low solutlon circulation rate due to the concentration (same absorption
capacity as MEA)
-
low utilities consumption
- very low pour point (-b0.F)
- Plants in cold climate areas
b) Disadvantages
- needs cooling of the solution during the absorption phase -
-
high solubility hydrocarbons and aromatics are dissolved high solvent cost.
c) Criteria of selection
Like MEA, DCA reacts both w i t h C02 and CS2 and a reclaimer is required. The process i s applicable to gases with acid gas content from 1.5 to 30 % volume and CO~/HZSratios between 300/1 and O.lf1 a t operating pressures above 15 PSIC. 3.1.4. DIPA
PROCESS
This process has been developed by SHELL under the ADIP trademark name. It is characterized by the selective absorption of H2 S in presence of
Cot-
3.1.5. MDEA PROCESS As with DIPA, MDEA is characterized by its selectivity for H2S i n presence
of C 0 2 . MDEA processes arc proposed by process liccnaors :
-
-
SNEA (Dl UNlON CARBlDE : UCARSOL
lr Y
Reviston : 0
TOTAL
Paga No. :
GAS SWEETENING
TEPIDPIEXPISUII
-
Date:
2/81
12.1b
3.l.b.HOT POTASSIUM C A R B O N A T E PROCESS (see figure 31 A n activator specific t o each process licensor is added t o increase the reactivity o f the ~ l l u t i o n
- BENFIELD (amin@m d other activators) -
-
CATACARB (aminc and other activators) GIAMMARCO-VETROCOKE (arsenic and others activators)
The main characteristic of the process is that the absorber and the regenerator operate a t the same temperature (1 101115'C)
a) Advantages
-
no degradation by COS and Cs2 which are hydrolysed
- no need for a reclaimer
goodthemical stability
-
no reaction with alr
low hydrocrarbon absorption
-
low heat requirements (isothermal)
selective C 0 2 absorption (GIAMMARCO)
bJDisadvantages
-
-
licensing fees required
high water content of treated gas
- no mcrcaptan absorption
low reactivity with M2S
c) Fields of utilization Applicable mainly on gas with high C02 content. Low H2S absorption makes it difficult t o achieve specification of 4 ppm voiume.
Generally a two stage process w l l l be used
-
K2C03 for C02 removal
This dual system (amine
-
/ K2CO3)
arnine l o r H2S removal
can
be
in
some instances more
attractive cost wise than an amine process 3.1.7.
CONSTRUCTION MATERlALS
Carbon steel generally utilized in the chernical absorption units. Regenerator can have a strainloss steel cladding and trays. Rtboller tubes can be stainless, but s t i l l subject t o corrosion. Monel is an alternative by costly, copper alloys shall bc avoided. h
2 00
TOTAL
Revis8on : 0
Page No,,
GAS SWEETENING
TEPIDPIEXPISUR
Date :
2/85
12.15
Generally solutions treating gas with high C02iH25 ratio will be rnorc corrosive. When the C02/H2S ratio is high, 3tainless steel w i l l be preferred far the following
equipment : amlnelamine exchanger
tubes,
expansion
value
internals, regenerator trays and rtbailer tubes. 3.2.
PHYSICAL ABSORPTION In
i
type of process, the solvent extracts the acid components by simple physical
cofltc t and releases them by simple expansion at low pressure.
High pressure and low temperature favour the physical absorption. Table 2 l i s t s the advantages and disadvantages of physlcal solvents. These processes are applicable especially in the case of high acid gas partial pressure (above 5 bars also). Not suitable l o r sweetening at low or medium pressure (10 bars abs) gases containing large amount of heavy hydrocarbons. Can be considered for a selective absorption. The main processes a r t : 3.2.1.
WATER WASH Can be used as primary treatment. For absorbers water wash can be achieved by addition of trays
in the top section.
Because of Its low efficiency, water wash should be used mainly on gases with
a large amount of H2S. Corrosion problems for this process should be considered carefully. 3.2.2.
SELEXOL PROCESS (see figure 4)
-
developed by
NORTON CHEMICAL PROCESS can
be applied to gases
with large acid gas content.
-
has been applied for sweetening of gases containing up t o 65 % of C02 and 9 % of H2S a t pressure ranging from 25 t o 100 bars abs. treated gas specification can reach 0,02 % C02 and 1 ppm W2S. When used to absorb selectively H2S or C02 it can also dehydrate.
-
other sulfur compounds (COS, mercaptans) are also eliminated.
do 1
TOTAL
R r v i s i ~ n: 0
Prge NO. :
Date : 2/83
12.16
GAS SWEETENING
TEPIDPAXPISUII
3 . 2 3 FLUOR SOLVENT
- developed by FLUOR, propylene carbonate is used as t h e solvent
-
primarly intended for t h e removal of C 0 2 from gas containing up t o $0 % volume residual CO2 content arwnd 1 % volumc in treated gas.
-
C02 solubility is higher than t h a t obtained with MEA o r potassium
carbonate.
- c a n bc used
to treat gas containing Hz5 and C02. H2S content would
require a iinlshing t r e a t m e n t douwstrcam t o obtain 6 pprn of H25. COS and rnercaptans a l s o absorbed.
3.2.4
requires an extensive use €rotating equipment.
PURISOL PROCESS
- proposed by LURGI uses n-methyl-2-pyr-rolidone as solvent - ss t h e scrlubility of Hz5 is higher COZ can be c~nsidertda s a rclective than
precess t o r e m o v e H2S even in case of low H2SICQ2 ratio. 3.2.5.
RECTISOL PROCESS
- developed by LURttl, uses a refrigerated solution of methanol as solvent. High s e l c c t i v i t ~lor C 0 2 , primarly used on synthesis gas o r on p r e c w l t d gas (cooling by an external refrigerant c y c l e for example).
- major disadvantage of t h e process, when not integrated in a plant already equipped with refrigeration cycles, needs refrigeration a n d methanol injection.
3.2.6.
ESTASOLVAN
Developed by F. UHDE GMBH uses trl-n-butylphosphate as solvent. Selective process for H2S extraction. li C02 specifications on the t r e a t e d gas ate stringent, additional unit downstream will be required.
3.3.
PHYSIC0 3.3.1.
- CHEMICAL PROCESSES
SULFINOL this process has been developed by SHELL
- involver a physical solvent (rulfolant) and a chemically reactive agent [DIPA alkanolarnine) in aqueoLls solution.
Revision :
*
PrgeHo. :
GAS SWEETENING TEP/DPiEXPISUR .+&
------
Date :
------r*-rrrrr.....-.--
2/85
-..,.- -.
A
12.17 -.--.--
Sulfolane permits deep absorption of C 0 2 and H Z ~Arnir~e . facilitates the
-
extraction of the acld gascs from solvent during repcncration performances for selective and non selective kt25 absorption depends on operating conditions process also permits extraction of mercaptans and other sulfur cornpounds (C05). As tor physlcal absorption, absorption of heavy hydrocarbons
occurs (mainly aromatics). Does not d9hydratc the treated ias. Compared t o smine processes, SULFINOL shows a low foaming tendency
3.4.
SULFINOL solution freezes at about -2.C.
SOLID BED PROCESS
3.4
h4OLECULAR SIEVES
-
not widely used for gas sweetening can be used as a finishing treatment to remove rnercaptans absorption in molecular sieves is particularly well adapted for LPG as finishing treatment to obtain the sulfui content specifications of propane and butane
-
3.3.2.
good absorption capacity for Hz5 low for C 0 2 . They retrlove water preferentially sieve l i f e is reduced for gases with high
C02 and Hz5 content
IRON SPONGE PROCESS
-
-
-
could be also classified as absorption process or as a conversion process (Hz5 is converted to sulfur)
mainly applied t o gas with low H2S content discontinuous process, iron oxide has to be regenerated or replaced. Spontaneous combustion of the fouled product occurs w i t h air.
4
CRITERIA FOR SELECTION OF ABSORPTION PROCESSES
-
there is no multipurpose process for gas sweetening, each case
is specific and shall be
studied accordingly
-
final selection is done on the basis of ccor~ornicalcriteria from short l i s t of prwesses which seem appropriate to satisfy the treated gas specifications
d
--
c.2
-
-
-
TOTAL
Revision :
0
Psge NO. :
GAS SWEETENING
TEPIDPIEXPISUR
Date:
2/89
lLll
k
-
chemical processes are characttrizcd by their ability to absorb acid gases w i t h a Low
-
influence of the gas pressure. They require a large heat quantity for regeneralion physical processes performances are more dependent on gas pressure. A t high pressure with high acid gas partial pressure, the absorption is better than l o r
-
chemical processes
selection criteria listed herebelow can be used for preselection of sweetening processes but shall not be considered as definitive.
4.1.
C02 ABSORPTION (NO HtS 1N THE GAS) (we figure 5)
4.2.
SIMULTANEOUS ABSORPTlON OF CO2 AND H2S (see flgure 6)
Q.3.
H2S ABSORPTION (NOC02 I N THE GAS) (see figure 7)
This is not e frequent situation with natural gases. 4.b.
Hi
ELECTIVE ABSORPTION (H25AND C02 IN THE GAS) (see figure 8 )
Physical solvents are particularly welt adapted in this case. Among the chemical proccsscs, only MDEA and OlPA seem t o be adapted for this
service.
5
REFERENCES AND USEFUL LITERATURE (1)
Natural gas production transrnlssion and processing
F.W. COLE, D.L. KATZ, L.S. REID, C.H. HlNTON (2)
Gas
conditioning
and processing [volume 5)
gas
and
liquid sweetening
by
R ~ B E R TN. MADDOX edited by JOHN M. CAMPBELL.
40'1
i
i
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Revision : 0
GAS SWEETENING
Data
TEPIDPIEXPISUR
FIGURE 1 YE). P R O C E I I
?Lor
DILGRIY
.. 2/85
Page NO 12.10
TOTAL
PROCESS ENGINEER~NG DESIGN MANUAL GAS SWEETENING
ntvllloll :
Oat
T EPIDP16XPISVR
: 2/85
Pnye No :
12.20
h
TABLE
4
AOYANThGCS CNn W l A P V h H f A G t 5 OF AnwPP7KYI PUC€€S5Ef . . I CHEMICAL J O L Y L H ~
xIt#nl i . c m n e ~ tel i h r q w . r L n y p r t s r w e
~ r r n r v It ~ Lpnw!lw
i
l o a m 6 9 when ihr $alutom t i ~ ~ l l ~ l ~ d l h ~ o r f f ~ r b o n l . . ~ s w " d e d 5011d11
RiL
m rh*
v t r y slicnt ~ b g o r p t i o n01 h r w y hldroc~rbonb~a,8blv w r ~ c n 80l !he feed a l l
C o r r ~ m n mproblems r e s v l t i n ~1r.m ~elulbono.~allmbn l c m 1 1 ~ 1w l l h ,if) a irom mlvrlon ~lp*rhc.ain~hlrmng rtFtnrr*loen.
r l a r r -1 i h r I*W~%ICJ availnbb ir the mhblic o o m l m Irm trrcnMn# I t r r )
Pure
..I+,tequmrrd to dilvlr !he mlv-nl
.lcmd # a r l t o l ~ = n rt ~ u i l i b r i 4 ~.1n . IltlC~aIw.
Hilh
*.re,
.~.ll.blr
in the
H~.tin@ r m u r t d lor wlrefil 1101aEe.
i l ~ 4 ~ 0 ~cog1 b l 01 t mlrmls
TABLE 2 PHYSICAL D V '
.
SDLVLNT~
tGEI
L o w e r u r l y tequtrrment? !or
@~SADVANTAGLI
.
te#emwariam
I
. Ler
I
.
r m r r r r m l e n t of thv
!remt*d
8,s
V o healin# required lor w l r e n t ,Iarqr
c m l m l 01 l h r ~ r e a l t d 11s
n l l h i m l t b i l i l y .s a d d 81s ~ r t i a l prr~~url
.
4bim~1ia.sI h r a w hlrdrcc.~lrbom lram the 1e.d
8Ij
. Highcssr 01 lhe %ol-*nn
--
-
TOTAL
Page No
Revision : 0
PROCESS ENGINEERING DESIGN MANUAL GAS SWEETENING
12.21
: 2/85
Datr
TEPIDPIEXPlSUR
I
.el0 *.I
mamum ue"YYL.IoI
1011
8 . ~ ~ OCI 1
.,u
nut" IOI
*
.11*..1n
IlllL".!
~ 1 0N1I U V ~
IWI C I S
I
11EA"
M O T C A l l B O N L T € PROCESS
FIGURE 3
-
n2$ 6
RESIDUE G A S
AIR
COMPRESSOR 4 HEATER 4
FUEL STRIPPER
aBS0RBER
-
'ICET G A S
COMPRESSOR
SOLYEWT VENT M
O
L PROCESS FLOW FOR HlGW GOl AND MIOM HIE
FIGURE 4
PIR
-
.
.-
TOTAL TEPIDPIEXPISLIR
PROCESS ENGINEEllNG DESIGN MANUAL
Revision : W
W\S SWEETENING
Dale
: 2/85
TOTAL TEPIDPIEXPISUR P
PROCESS ENGlNEERfNG DESIGN MANUAL
Revi*ion :
o
Psgc No
GAS SWEETENING
Dale
: 2/85
12.23
:
Revision : 0
TOTAL
Page No. :
REFRIGERATION Date:
TEPiDPlEXPISUR
2/85
12.24
I . APPLICABILITY For both fea5ibility and pre-project studies, the engineer will be required to select a process scheme k c . : choice between coid frac and refrigeration system) t o estimate the power, utilities, weight af this package,
2.
DESCRIPTION
The description is based on simple cycle. A refrigeration cycle is based on the exchange between a hot source and
s cold source. The
cold source is a refrigerant, the air or rhe
water, the hot source is the gas to be refrigerated. (see figs 1, LA) Figure 1 shows such a cycle where : tl
:
Is refrigerating stream temperature
t2 P~ P2
: :
is condensed refrigerating srream temperature is vapor pressure of the refrigerating stream a t t l
r
is vapw pressure of the refrigerating stream at t2
Pd
:
compressor discharge pressure
td
:
Tl/T2
:
Compressor discharge temperature initial and final temperature of the hot source initial and final temperature of the coid source
TRlITR2 :
On the figure I A , i t is easy to explain the cycle on a pressure enthalpy diagram
A 91
:
is the duty of the process to be refrigerated
A Q2
:
is the duty of the condenser
A Q2 3- MODIFICATIONS
Q1
:
HP HP i s the power oi the compressor +
- ECONOMISER
During the. discharge of the cryogenrc refrigerant, a mixed phase is generated (vapor and liquid). Only the liquid phase participates i n the coding duty. The vapor phase being compressed from low pressure t o the high pressure without participation a t the refrigerated duty. I t is possible to remove a part of this vapor phase by addition of an intermediate pressure stage removing the vapor from the low pressure stage compressor which i s called
economiser (see figures 2 and 2A). An economiser is widely used in the industry.
a ia
-.
Revision : 0
TOTAL
REFRICERAT [ON
TEPIDPIEXPISUR
Date:
.
4.
Page No. :
2/85
12.2s
SELECTION OF THE REFRIGERANT Depends on the required final temperature of the hat source and the disponlbility of the
country where the units are installed. Tables 1 shows the performances of different refrigerants in various conditions. it
is recommcndtd that the compressor suction pressure be maintained abovt atmospheric
pressure. 5. CHOICE OF DIFFERENT PARAMETERS
5.1.
REFRIGERATlNC STREAM TEMPERATIJRE t l AND COMPRESSOR SUCTION PRESSURE P2
tl
to be
3 t o 6*C lower than the final temperature of the hot source 12.
With the selected refrigerant and t l read on the MOLLIER diagram of the selected
refrigerant the vapor pressure.
1.2.
CONDENSED REFRIGERATING STREAM TEMPERATURE t 2 AND COMPRESSOR
DISCHARGE PRESSURE Pd In first, estimation take t2 t 2 to be checked later If it
:
TRl
(initial temperature af cold swrce) + I 5 or 2 0 ' ~ .
Is compatible with the cold source flowratc
and the pinch
of the condenser [pinch are shell and tube g 3 note 2) which should be 3'c minimum. With t2 determine PZ which is the vapor pressure of the refrigerant a t t2 (read MOLLIER diagram). Cornpressar discharge pressure = Pd
: P2
+
P through the
condenser.
5.3.
PRESSURE I N THE ECONOMISER
P,
This pressure w i l l be finalized with the compressor manufacture but for an estimation take
p,
.
!
=
Pi
dI/
TOTAL TEPIDPIEXP~SUR
1
6.
7-----r Revision : 0
REFRICERATION
,
Oate :
Page No. :
-
12.26
2/g5
CALCULATION N T H ECONOMBER (a figure 2A) Step 1 Deterrnlne refrigerant circulation through the evaporator = rn2
W vapor at evaporator inlet
% liquid a t evaporator inlet
=
=
/
.
Hz
-
H3
'42
-
'45
HZ
x 100
- '43
Step 2 Determine vapor refrigerant circulation rate through the economiser = mj % vapor a t econo~niserinlet =
% liquid a t econorniser inlet =
m1=
H4
-
H4
-
HI
H4
-
H5
"I
H5
% vapor at econorniser inlet
m2
x 100
H5
% liquid a t econorniser inlet
=
m2
Step 3 Dctermine refrigerant circutation through the condenser rn=
Step 4
ml
>
HQ
=
-
-
H5 HI
m
rn2
Duty of condenser
A Q ~= Step
+
HI
x
rn
(Hd
-
HI)
Calculate the compressor discharge temperature and power (see compressor chapter).
Step 6 Check the pinch in the condenser and the cold source flowrate (if not acceptable select a new 12 and Pd and repeat the ca1culation). Step 7 Size drums evaporator and condenser (see vessels and shell and tube exchanger chapter 5).
TOTAL
Revision :
Page No. :
0
REFRIGERATION
t€PlDPlEXP/SUR
Date:
2/81
-
12.27
7. SELECTION OF MATERIAL The material selection t o be made carefully. We recommend t o take the temperature corresponding a t the vapor pressure at the atmosphere pressure (1.e. : for propane it 1s recommended to select the law temperature killed carbon steel).
.
MULTISTAGE CYCLE
If we look at the enthalpic curves of the exchanger (precess refrigerant) with or withwt economiser, it i s obvlous t o see that the area between the process stream and the refrigerant stream is proportional t o the compressor work (in a first approximation). It is possible to reduce this a r t a by addition of several pressure levels between the discharge
and the
5'
regulation)
'ion of the compressor. However, there is more equlp~nent(drums, exchangers,
d the compressor
is more complicated.
The number of pressure levels is an economical problem but the maximum i s 3 or 4 selections of these pressures: the pressure ratio between each pressure
Is for a
first
estimation.
7
=ne
n PI P2
= number of cornpresser
suction
= first compressor suction pressure condenser pressure
9. REFERENCES AND USEFUL LITERATURE 9.1.
Gas conditionning and processing volume 2 by Dr. John M. CAMPBELL
9.2.
Applied process design l o r chemical and pctrxhemical plants volume 3 by Ernest
LUDWIG
9.3.
Chemical Engineers Handbook by Robert
21% L
H. PERRYICECIL M. CHILTON
E.
-__-..-.
,
TOTAL,
PROCESS ENGINEERING DESIGN MANUAL
Revision : 0
REFSICATION
Date
TEPlDPIEXPISUR REFRIGERATION CYCLE WITH
ECONOMISER FIGURE 2
EVAPORATOR
ACCUMULATOR FIGURE 2A
: 2/85
b g e No
12.29
-
m
I*
oC
Frean12
Amnia
rcfrSgcntlon
Brrke hovscpol*r pr ton of rtfrlgerbtlm
I
~ i l w a t ~r t ton of r e f rtgcrrtta
s
Pmpylme 1.21 Propane . 1.30
W n i a h p y l a n e 5.59 5-57 to pure Frcon12 6 .
Propylac 7.49 Propane 7.47 F r e m l 2 8.09
2.91
Jamnia
0 D.YOI 0.614 0.363
5.986 1.11 0.868 0.491 -
0.716 1.13 1.2 0.641 -
0.958 1.79 1.41 0.827
1.26 2.21 1.1 1 1.63 2.69 2.16 ,
cOHPARISON OF COmON REFRICEWTS
2.095 3.31 2.63 1.64 2-02
3.M
2-65 4.00
3.27 3.72
3.33
3.22 2.95 2.89 3.23
3.87 4.33
4 3.96
0.206 0.889 0.925 2.2
2.79 2.62 2.56 2.83 1-80
1.75 1.73 1.4
1.60
1.51
1.54
1.55
2.32 2.47
2-67 2 6 2.01 1.99 2.L3
2.15
2.69
2.09
2.08 2.06 2.03 2.14
2.41
2.80
3.23 3.10 3.03 3.31
3.74 3.61 3;43 3.19 2.41 2.3L 2.26 2.47
0.197 0.798 0.807 1.96
0.200 0.199 0.830 0.812 0.853 0.830 2.05 2.00
0.202 0.848 0.875 2.11
0.204
O.871 0.898 2.16
1.33 1.30 1.31 1.37
1.78 7 4 1.75 1.83
0,767
0.780 0.789 1.91
1.12 1.09 1.11 1.16
5
1.46 1.49
1.50
0.776 1.87
0.195
0.196
5.30
5.01 4.92
6.72 6.60 1.11
1.17 1.21 2.8
3-70 3.97 3.86 7
4.24 1.45 4.S 4.66
3.27 3.50 3 . 3.57
4.60 4.78
5.85 5.46
4.38 4.71
2.54
1.11
1.07
0.219
6.25
4.96
0.221 1.10 1.15 2.63
5.32 5.18
5.68 5.96
2.7
0.223 1.13 1.19
3.13 3.66 3.59 3.61 2.48 2.73 2.68 2.74
2.84 3.09 3.03 3.12
2.U
0,215 1.41 1-04
1.81 4.11 4.06 4.18
0.217 1.03 1.07 2.47
0.835 0.830 0.800 0.W8
2.18 2.41 2.37 2.39
3.20
3-18
2.08 2.1D 2.07
1.89
2.78
3.23
1.63 1.80 1.81 1.80
1.42 1.51 1.54 1.54
2.03 2.07 0
1.90
2.54
2.79 2.81
2.92
2.19 2.41 2.43 2.41
0.211 0.210 0.203 0.957 0.234 0.912 0.980 0.953 0.925 2.15 2.27 2.21
0.940 0.895 0.925 0.970
0.464 0.498
0.591 0.633 0.753 0.791
1.32
1.22 1.33 1.32
1-77
1.12 1.11
1.03 1.16
1.38 1.55 1.50 1.49
1.63 1.78 1.77
2.10
0,206 0.875 O.BB0 2.05 0.207 0.894 0.903
0.110
-1.02
0.952 L,10 1.03
0.835 1.96
0.BU
0.204
0.366
0.342
0.362
0.360
0.925
0.761
0.977 0.821 0.933 0.788
0.865
1.24
1.25
1.16 1.31
2.01
0.205 0.857 0.857
0.483
0.483
0.W 0.485 0.49 0.490
0.699 0.694 1.10 0.647 0.622 0.668 0.623 0.619 0.716
1.41
9.03 7.58 4.99
0.648
0.112 0.7OB 1.73
0.768
0.726
1.03 1.00 1.01 1.05
1.26 1.20 1.24 1.24
7.79 6.485 4.23
6.15
0.191 0.191 0.190
3.56
5.51
5.03 6.62
0.721 6
2.97
5.68 4.64
4.11
0.193 0.192 0.153 0.139 0.756 0.739 1.81 1.79
3.31 4-82 3.86 2.46
0.213 0.980 1.01 2.33
Cmdcnaed Liquid T e m ~ r r t u r c52'~; Condenser Pressure *n U r s : L R o n i g 20.8B; R o p y l m a 21.64; Propane 17.92: F r m 12 12.68
tgm refrigerant per alnute prr tan of
3.73 3.72 4.25
h w n e Freos12
Propylmt
LRmnl*
5.10
refrigeration
Xlloultr pcr tom of
4-98
1.98
Propane
Freon12
0.913 0.958 2.28 4.47 4.3'1
Ammia Prapy3ent 5.M)
Brake hwsrpo*s* p t i tcn of refrigcrbtfon
0.655 0.513 0.271
1
W c n r c d l i q u i d T a O c r r t u r t 35%; Condmser Proswe In B*rs i9mPnir 35.58; R o p y l w 14.61; Propme 12.20; Frwn 12 8.48
0.38t5 0.198
0.4%
krsnlr R . o p y l e ~ 0.939 RDWIIC 0.990 FreolLZ 2.35
h n l a Pmpyl*lc Proplna Freon12
kqn refrigerant p t t minute p a r tan of r efrlgcratian
-
I n hrs
P~CISUN
Evamratw
Tap.
Table
0
.
..
3
..
4
0
z!
R Z
'"
m
m
9 '2
Z
z
n2
m
C)
0
v
n
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Revision : O
REFRIGERATION
Dart
TEPIDPIEXPlSUR
Refriv*ranl Wvlblr
(kR1 mlprutionl
Vapor C 1.013 lrrr
P ~ p eM a :
-1'~
I
-22
r-113
F-111
:2/85
12.31
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Revision :
-
TEPIDPIEXPISUR
13.
Omre
Page No :
: 2/85
UTILITIES
21 q
-
. Revision : O
TOTAL
Papt No. :
UTILITIES
Date : 2/85
TEP/DP/EXPl5UR
13.1
-
1. APPLlCABlLITY For both feasibility and pre-praject studies the engineer will be required to make an estimate of utility requirements both in consumptions and equiptnent required. This section details e few gutdelints and notes on the following utilities :
WATER TREATMENT UTlLlTY AND INSTRUMENT AIR INERT GAS GENERATOR5 WATER SYSTEMS FUELS 2. WATER TREATMENT
T h e following details the common used effluent water treatment equipment given in order of
effluent quality :
API gravity settler
.
Usually the first line of d e a n up. Simply a settling tank with a top skimmer to remove any floating oil or debris and a bottom skimmer to remove sludge.
,
. .
Effluent quality around 150 microns globules and 150 ppm oil. Large bulky items, cannot be used offshore, Either circular or rectangular in design.
Simple, cheap very common in onshore use.
Tilted Plate Separator (TPS), Corrugated Plate Interceptor (CPJ)
. . .
. .
Widely used both offshore and onshore. Uses plate packs, usually at 45* mounted in a tank and relies on gravity settling between ail + water within the spaces between the plates. €[flu
quality dawn to 60 micron oil globules and >0-200 ppm.
Can have problems with high solids content
it upstream settling tank i s not installed.
TPS units are usually used as the first treatment stage offshore.
Flotation units
.
Uses induced or dissolved air flotation t o remove any residual solids/oil in the cjlluent. Works in reverse to a gravity settler (small air bubbles trap debris and float to top of tank).
22 >
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UTILITIES
TEPtDPlEXPl5UR
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Effluent quality better than 40 ppm. Vendors usually guarantee
13.2
< 30 pprn.
Can be used both offshore and onshore. Usually instalIcd downs~reamof a T PS unit or API separator.
Filtration (Use for Water injection systems only)
.
~ i l t r a t i o nunits either uses media beds [sand, anthracite, garnet, walnut shells) to achieve water quality or filters (fibre sccks, mesh, stainless steel cage).
.
IJrwlly not required for effluent water treatment unless very ldw residual solids content eniorced by lacal effluent standards.
.
More commonly used for water re-injection where high quality, low solids level is required. Can achieve 1-2 ppm in certaln beds, 10-15 ppm is more common. Units arc generally cornpacl but heavy due to media bed weight.
.
Good pre-filtration is required to prevent fouling up of main bed units.
Effluent standards
Listed below are maximum residual oil content in effluent water for dumping t o sea :
NORTH SEA
40 PPm
INDONESIA t MIDDLE EAST CHINA
30 pprn 20 PPm
5 pprn (European standard)
LOCAL ESTUARY (river)
Process drains, produced water, deck (site) drains [see figure 1)
.
Produced watcr may need degassing before treatment. If the amount of dissolved gas is small it may be possible to handle it i n the TPS unit.
Deck
or
site drains normally iluw to a separate sump tank before Qe-oiling. If the deck
drainage i s small or produced watcr itow is small, both streams can be combined through one TPS unit.
.
Process d r a l n ~are normally manually initiated and pass directly to the return oil slop tank. These drains are generally watcr free. Always try
3
use gravity iced between units. Pumping can cause e m u l s i o ~and make
oil-water stparatian harder. Similarly avoid fast flowing lines and turbulent pipe arrangements.
22
TOTP I
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UT1LITIE.S
Date:
TEPIDQIEXPISU.
2h5
13.3
3- UTILITY AND INSTRUMENT AIR (see ligutc 2) C O m p r e ~ f e dair is used on plants lor instrument control, turbine a n d engine strtt-up sod utility services t g : pneumatic tools, cleaning, etc.
:
For turbinelcngine start-up 17 -25 bar supply will be required.
. .
For general instrument and utility air, compressor discharge around 9 bar is adequate. Consumption :use 0.6 scfrn 0.017 rn3lrni1-1)for each air pilot (- valve) 0.8 s c f m (0.022 m3/min) lor valve pasitioner (instrument air) generally 1 m31h per valve unit will do as first estimate. Add 25% to comprcswr capacity for design.
.
Utility a i r : consumption is intermittent and difficult t o estimate a t early project stages. Add 75-100 t c f m (130-170 m3/hJ t o compressor capacity for initial estimate.
.
. .
All plants should have 100% instrument air standby capacity. Utility and instrument air c a n be supplied from same compreswr or separate ones depending on capacity requirement. Instrument air must be dried befare use. Dew point of air b dependant on minimum air t e m p e r a t u r e in location of unit. Generally dcssicant bed driers arc used giving dew points
as low as -60°C.
.
Size air r t c c i v e r s t o give 10-15 minutes of instrument air assuming t h e compressor goes down. Pressure in the instrument air receiver should not f a l l below SO psig (I.>bar g) during this period.
.
For long air transmission headers in cold climates intermediate KO p u t s may be required.
.
An e s t i m a t e of compressor and dryer weights and power a r e given in figure 3.
4. lNERT GAS GENERATORS (N2,CO2) Inert gas i s required in all plants for purging and incrting of equipment. For small requirements Nz bottles c a n be used in racks. This hawever is not feasible for large units and so gas generators must be supplied. The main types a1 generator in use are :
- cryngeni,~distillalion of air - oxygen absorbtian on sieve
-
.
gas combustion
For nlrrging purposes estimate capacity based on 3 times the volume of the largest vcsscl to
bt
lrgtd in one hour.
-
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.
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TOTAL
UTltlTlES
TEPlOPlEXPlSUR
.
Date: 2/85
Cryogenic
13.4
"stillation is used only for large volume requjrtments, $pecifically LNG
plants. Not
.
Page NO. :
ed offshore.
Gas combustion produces a N2, C 0 2 mixture for inerting and purging purposes. Not used
much these days except for onshore large volumes.
.
Pressure swing absorbtion is the must common used method for
N2 generation. Skid
mounted units are sometimes supplied with dedicated air compressor, or can use existing plant air compressor for supply. Air consumption is 4-5 times inert gas production rate, residual 0 2 i n gas is 1-2%-3%.
.
Details and weights of common units are given i n figures 4 and 5.
5. WATER SYSTEMS
Seawater
.
Used for coaling purposes both onshore and offshore.
Can also be used as wash water,
sanitation water and feed to potable water units.
.
Seawater is also used for fire water systems but is usually a separate system. The seawater cooling circuit is normally connected to the fire water ring lor emergency supply only.
.
Always coarse filter the seawater before circulating to the plant. This removes any
debris or rnatine life.
.
Treat with chlorine at I - 2 ppm concentration
- maintain a residual CL- level i n the
water exit a t 0.3-0.5 ppm.
.
S e a w t e r exit temperatures t o outfall canals or drain caissons shouId not be above 40'C
to prevent corrosion.
.
Once thrwgh water systems are preferred for small, cooling duties with only 3-4 exchangers. For large duties and number of units where the cost of corrosion proofing i s prohibitive conslder using a closed loop cooling medium system. Cornmon used i s
- 25% TEG
.
in water.
For cooling medium/~awater exchangers consider using titanium or similar plate exchangers. These are especially ideal offshore due l o reduced weight and space requirements.
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UTILITIES Date: 2/85
TEPtOPIIXPISUR
13.5
Potable water
.
Depending on location of plant potable water can be made i n sttu or supplied by tanker lor storage, or taken ditccily from a mains supply.
-
For onshore plants most common method of water supply is evaporative distillation. Problem with these units is size and weight are high and residual
T D5
(Total Oissolved
Solids) is 5-10 pprn. This results 1s a bland distilled water which is not pleasant t o drink. ,
Increasingly popular now arc Reverse Osmosis units (R01 which art lighter and need less maintenance than cvaporativt units. Water quality is 400->OD TD5 (World Health Organization TDS for drinking water i s 500-1000) operating costs of RO unit5 i s 1.5 times that of evaporative distillation.
.
Power consumptions : for a 100 gph (0.38 m3ihl unit. Evaporative Distillation unit Reverse Osmosis Vapor Compression unit
.
IEO) 3.5 kW (XO) I kW (VC)t5
kW
Most common unit ofishorc a t present is the VC unit which i s very reliable and easy t o
operate. Unit operates a t 100.C and is more susceptible t o corrosion.
. .
RO units are relatively new, operate at ambient temperature and has lew mechanical parts lor servicing. Average membrane life is 3 years. Consumption : estimate on 50-60 gallons per day per man (0.2 m 3 ) Storage
: allow 10-15 days for oiishorc units
I0 days for onshore remote artas
.
Potable water can be dosed with hypochlorite a t 0.4-0.5
ppm to inhibit bacterial growth.
U1astt water and sewage
.
Before discharging to rivet, sea, or underground sewage + waste water must be treated t o meet local health regulations prevalent in the area.
.
Limlts are imposed on BOD (Biological Oxygen Demand), COD (Chemical Oxygen Dcrnl-d), coliiorm bacteria count and 75s. Examp
Limits are r
<
bacteria
T DS
200 per 100 ml 150ppm
BOD
CL' residual
22 3
< >
100 mgll 0.5 mg/l
<
1O , mg/l
-
d
Revision : 0
TOTAL TEPlDPlLXP/SlJII
.
Page NO. :
UTILITIES
,
D a t t : 2/85
13.6
Sewage is treated by physical attrition, airation and chlorine dosing to 30-41 ppm raw sewage.
.
Provide 15-20 hr retention time for enzymic action to reduce 3 0 0 .
.
Allow 30-50 gall/day per person (0.15 m3) for sev;age, shower, laundry and kitchen wastes. Use upper limit for hot unsociable climates.
6. FUELS
Diesel . Used
for emergency generators, pump motors and air compressors, cranes, and alternative fuel lor turbines,
.
For emergency equipment pravide individual day tanks sized on providing fuel for 2@hr operation.
.
Main diesel tank [for fecd to day tanks) should hold 10-12 days supply. This is dependant
an location of plant and normal supply periods.
.
Diesel should be filtered t o
* 5 Microns.
Can be centrifuged to remove residual water
and smaller particles. This is especially recommended offshore where longer storage times, supply boat debris, seawater contact and poor supply quality can lead t o operation problems.
.
For storage use atmospheric venting tanks with vacuum-PSV pedestrals, platform legs or inter-deck space for of lshort storage.
vent. Use crane
Gas -
.
.
Fuel gas is supplied as normal fuel to generators, turbines and any gas driven motors.
Always pass FG through a scrubber before use. Filter gas supply to turbines 10 10 microns (generally turbine manulacturcr will s t a t e quality required and may InClude his own filters)
+
- do not rely on this and provide separate treatment anyway.
Maintain FG temperature at least 15'C above dew point. Minimum temperature of gas to be 5'C.
.
Common supply pressures a r t 15-20 bar fsome jet engines need 35 bar).
Size fuel g a suppiy on maximum design duty of all users operating. Allow + 10% margin.
-
FC used for flare purge and pilots, ctc., does not need t o be filtered to 10 microns
- use
gas strai, ' off scrubber overheads.
&k if
-
Ldyoul plan
I a i mn*rrsur PAhcdr 3 num,r
4 Adwbrr 5 Pmduo buLv wsul 6
sblrrrt
-
-
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
TEPIDPAXPISUR
Dote
22
L
R#rlrion :
I
P q e No :
: 2/85
---
TOTAL
Revision :
0
Peg@ NO. :
2/g5
14.1
COMPUTER PROGRAMS Date :
TEPIDPRXPISUR
. AMINES : Sizing of gas sweetening unit. FUNCTION This program provides capability for the calculstion of gas sweetening p r c c e s r s using s single aminc (MEA at DEA). It also determines the main equipment characteristics of the unit for preliminary studies.
OUTPUTS Contactor bottom temperature Amine Howrate Exchanger amine/amine area Contactor diameter (3.5. CONNORS formula) and number of trays Stripper reflux drum : height and diameter Reflux ~ w f f p:power Amine pump :power
RANGE OF APPLlCATlON The temperature of the rich arnine entering into the stripper is 190 f.
The bottom temperature of the stripper is 240 F. The default pressure of the reflux drum is 20 psia. Steam saturated temperature i s supposed t o be 250 F. 2. BRILL 1 and I1 : Pressure drop profile in gas and liquid pipes FUNCTION
BRILL 1
The program predicts pressure gradients and liquid holdup occuring during the simultanews
flow of gas and liquid i n pipes; BRILL I1
This program is specially assigned t o calculate the transpdrt capacity in the case of a mixture of t w o gases.
RANGE OF APPLICATION These programs were written for the
FRIGG pipetine.
However, the)' can be used for other
lines, sptciaHy far gas w i t h condensate.
REMARKS The line can be level or not.
The r i s e r s are calculated. BRILL 1 takes into account the line temperature profile.
i
TOTAL
Revision : 0
COMPUTER PROCRAMS Date : 2/85
TEPIDPIEXPISUR
1
Page No. :
14.2
3. FLASH : Equilibrium ~ a l ~ u l a t i a r . PROCESSING The program is based around the
Peng Robinson equation
of state and the API (modified
Lee-Kessler) corr+sponding states method for thermal properties.
REMARK This program is not as robust as large commercially available batch simulators such as PROCESS, but it is very quick, cheap and easy to use.
L%nswersare instantaneous.
The program is self documented.
1-
C O M W L Y : Multi-stage compression unit
FUNCTION This program simulates a multi-stage polytropic compression unit.
PROCESSING CPSA method.
RANGE OR APPLICATION The transformation i s assumed to be polytropic,
The number of stages is fired Qr calculated (for a compression rate). It is possible t o input non-standard components. The KATZ table glving Z (Pr, Tr) is included in the program.
I
5
GLYCOL :Sizing of gar dehydrating unit
FUNCTlON This program simulates a gas dehydrating unit using tri-ethylene glycol. PROCESSING
The gas is countercurrent dehydrated in the absorber using a triethylene glycol solution which is then regenerated by stripping in a packed column. RANGE OF APPLICATION Gas input pressure into the absorber must be between 200 and 2000 PSIA.
Gas input temperature into the absorber must be between 40 and 160 F. Gas dewpoint temperature must be >
- OD F.
. Revision : 0
TOTAL
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COMPUTER PROGRAMS
TEP!DPIEXP/SUR
Date : 2/85
14.9
6. GULF : Sizing of petroleum ptatlorms
FClNCTlON Estimates and simulates pttroleum platforms. For preliminary studies, it calculates :
.
. .
size and weight of equipment5 [ p r ~ e s utilities, s drilling quarters)
size and weight of structure and substructure cost of the construction
PROCESSlNG
The equation of state used is a modified version of SOAVE REDLICH KWOWG. REMARK Oil flowrate can vary trom 3000 to 300 000 BOPD. The program i s specially adapted for compact platforms [drilling, quarters, production) but can also be used for production platform only. The accu
y
-
of the weight and cost estimations is respectively about + 15 % and + 20 %.
7. HANLEY : Density, thermal conductivity and viscosity calculations
FUNCTION This program uses the HANLEY equation t o calculate density, thermal conductivity and viscosity of hydrocarbons and hydracarbon mixtures.
INPUTS
The program w i l l handle a 20 component mixture. Library data is available for C1 thru' Cl7' Nitrogen, Carbon Dioxide, Hydrogen Sulphide and Water. Pseudo components can be dcflned
-
in the input file r if they are used, thermal conductivity will not be calculated. A datafile i s required. For each pseudo component, the following properties are needed.
. . .
critical pressure, atm critical volurnt, ~ r n 3 / ~ - r n o l e critical temperature, Kelvin
. .
.
Acentric factor Molecular weight Normal Boiling Point, Kelvin.
This empirical equation is believed t o be the best correlation currently available for
estimating liquid and vapour densities a t pressures above LOO aim. Vapour densities calculated using this method a r t believed to accurate up t o 680 atm. The viscosity correlation is very accurate !or the vapwr phase, but not as reliable for
liquids. The best available method is probably the Chung-Lee-Starting equation, with an average deviation 01 24 %.
The thermal conductivity correlation is included for completeness, but i t s accuracy has not been assessed.
2 p s
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TOTAL
COMPUTER PROGRAMS
Tf PlOPlEXPlSUR
8 . L l B P R 0 0 :Fluid
Page NO. :
0ate :
14.4
2/85
physical properties calculations
GENERAL
The LIBPROD iibrary encloses
FORTRAN subroutines for calculating various properties.
FUNCTION Subrwtine ASTM
:
stock tank oil viscosity at a certain temperature by the ASTM
correlation. Subroutine CALBO :
Oil Formation Volume Factor by the STANDING correlation.
Subroutine CALFRI :
Friction Factor by the MOODY diagram
Subroutine CALSIG : Subroutine CHEW :
Gas-oil surface tension by the BAKER and SWERDLOFF correlation 01 viscosity by the CHEW and CONNALY correlation
Subroutine LEE :
Gas viscosity by the
Subrwtine RSOUPB:
Solution Gas Oil ratio by the STANDINC A N D LASATER correlation Gas compressibility factor by the STANDING and KATZ correlation
Subroutine ZED :
LEE-ET-AL correlation
9. MASBAL :Creation of mass a n energy balances resulting from PROCESS program. FUNCTION The "MASBAL" program generates mass and energy balance tables, in conjunction with the
SSI program, according t o the user's specifications. The program uses %heoutput of SSI program and generates mass and energy balance tables which can readily go into a report.
PROCESSING The tables can be generated either in Metric or in English dimensional units system as i t
.
may be the case in the 551 program. The clasaificatlon of components defined in the 551 program can be reduced for mass and energy balance tables (components up to C20 for SSI program can be classified up to C[o+ in mass balanccl. Printout of cnthalpy is optional.
The stream composition can be expressed in the four different ways : rnolal flow rate, molal percentage, mass flow rate, mass percentage. Each table contains 8 streams maximum.
P 3d >
-
-
..
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Revision : 0 COMPUTER PROGRAMS Dale:
TEPIOPfEXPfSU4
I
Page NO. :
2f>
14.5
LO. MONOAGA : Pressure drop profile in dry gas pipes
I
FUNCTION Calculation of pressure lossscs for steady flow in dry gas pipes. PROCESSING MONOAGA uses the A G A method which is based on the general equation for compressible
fluid in pipes, whatever their profile may be.
OUTPUTS Any af the lollowing five variables can be calculattd :
.
flowrate
.
length inlet pressure
.
.
.
outlet pressure inside diameter
RANGE OF APPLICATION This program can also be used to predict the behaviour of gas with very low condensate contents (less than 50 crn3/~rn)). The profile of the ground can be f l a t or otherwise.
The tern--raturt profile can be fixed.
I
1l.F'EPITE : Pressure drop and temperature profiles in gas and liquid pipes
FUNCTION This program calculates the profile of pressure, temperature and hold-up liquid along pipes carrying single or two-phase fluids. PROCESSING
This program user the most efficient correlations which exist at the present time for single or two-phase flow, whether the ground be flat or otherwise.
Pressure losses for two-phase flow are based on the research work carried out in BOUSSENS. The calculations methods used are commented in the note "Two-phase flow in pipelines" written by Mr LAGIERE, and included in the 1982 Surface Seminar.
OUTPUTS The program can determine, at any point of a pipeline, the pressure, the temperature, the flow pattern, the liquid content and the other hydrodynamic characteristics.
..
T
TOTAL
Revision:
Page NO. :
COMPUTER PROGRAMS Date : 2/85
TEPIDPIEXPISUII
14.6
R A N G E OF APPLICATION The many tests run under various conditions show that PEPITE is definitely better than
other models. The good results arc obtained by PEPlTE 80 t o 90 % of the time, whereas traditional models only provide acccptablc results 50 % of the time.
The least effective results obtained by PEPITE are those for steep uphill slopes. This drawback is on the point oi being solved. On a whole, the accuracy of the calculations i s in lint with that of the accuracy of the measurements themselves. REMARKS In addition to pressure and temperature calculations the PEPITE program will define the flow pattern. The user can do ten dif ierent calculations with a single run. The results can be either summarized or detailed, on request. Either starting on finishing conditions can be given as inputs lor the PEPlTE program.
12. PETREL :Pressure drop profile in gas and liquid pipes FUNCTION Calculation of the pressure losses and liquid content of the pipes, for condensate gar, oil and gas, oil gas and water flows in horizontal, slight slope pipes.
INPUTS Temperature profile o r average temperature. Physical properties af the fluid. Line profile. Some physical opertles can be predicted with correlations included in the program. PROCES51NG
The PETREL program offers several caiculations methods corresponding to different fields of application. Methods available in PETREL include : DUKLER, HUGHhlARK, EATON, BONNECAZE and FLANIGAN.
OUTPUTS Anyone of the following parameters can be calculated : inlet pressure line length outlet pressure
. .
.
RANGE OF APPLlCATION This program does not calculate risers. The calculation of liquid contents is doubtful in the case of condensates gases.
.
a3't
-
TOTAL
Revision : 0
page NO. :
COMPUTER PROGRAMS 0ate:
TEPlOPlEXPlSUR
2/85
-
14.7
I
13. RESEAU : Combination of PROCESS and PEPITE programs
I
GENERAL
This program i s the combination of the PEPITE and PROCESS programs.
FUNCTION This program calculates pressure drop and temperature profiles using the results of the proctss program. PROCESSING Fluid physical properties needed in the PEPITE program are interpolated into tables generated by
PROCESS program.
INPUTS
Input data is composed with : Process input data Unit called "US 14" (name, inlet and outlet stream numbers)
1
Options of the calculation Pipeline ~haracteristics RANGE OF APPLICATION Pressure must be included between 1 and 7 250 PSIA Temperature must be included between - 200 and + 200 'C Only tv-nty "US 14" r a n be calculated per run.
The PRC
'SS options r OUTDIMENSION, SCALE and SEQUENCE cannot be used.
The PROCcSS option "CALCULATION TRANSPORT
= 2" is compulsory.
lib. THERM :Pressure drop in liquid piper
FUNCf ION The TERM program computes heat and pressure loss calculations in liquid pipelines f o r Newtonian or non-Newtonian flow. It can
alsa predict the restarting pressure after a shut d ~ w n .
I t also allows pump calibration.
Revision:
TOTAL
0
Page No. :
COMPUTER PROGRAMS
TEPIDP!€XPISUR
Date:
2/65
14.8
INPUTS
Physical properties of liquid :
, viscosity versus temperature (for Newtonian flow)
. . . . .
viscosity versus temperature a t dltferent shear rates (for non-Newtonian flow) ylcld strength versus temperature density versus temperature
specific heat versus temperature thermal conductivity versus temperature. Some of the above properties can be predicted, but it is preferable to obtain viscosity and yield strength of liquid from laboratory measurements. OUTPUTS
Three artput formats may be selected by the user "finite clement length" "percent length increment"
. . .
:
"preselected finite element length"
In the third case, the program also computes the restart pressure as a function a1 time after shut down.
15. UPFLARE :Flare calculations
FUNCTION Radiation level calculations for an oriented pipeflare or
a Coanda flare tip.
INPUTS Boom and tip characteristics.
Gas characteristics (flowrate, gross heating value) Climatic conditions (wind, sun) Calcvlatim
ions
PROCESSING The calculatjon methods a r e API RP 521 or KALDAIR.
OUTPUTS Flame profile
Radiation levels a t given points or isopleihs {lines ol constant flux).
REMARKS The method used [API RP 521) has been extended to three dimensions and any flare tip orientation.
a ro C
-.
.-
-
l
-
TQTAL
PROCESS ENGINEERING QESIGN MANUAL
TEPIDP/EXP/SUR
Rarision :
Dmtr
"..
Z YI
: 2/83
Pbg?
Ma :
-
Revision :
TOTAL
0
Page No. :
DATA SECTION
T EP!DPlfXPlsi!R
Date:
2/85
15.1
-
PAGE
2 3-9
General data Converslon tables
I0
PSEUDO CRITICAL5 AND OIL PROPERTIES
11-14 15 16
Figs. 1-3 9
5 17 18
6
7 8
19
20 Z1
10 11
22 23
12
24
13
25 26 27 28 29
30 31 32 33
18
19 20 21 22
23 24 36 37 38
25
39
26 27
40 4I 42
28 29
k3
30 31
32 44 45 16
47
48
DENSITY -density of petrolturn fractions VS T Relative density of petroleum fractions VS MABP
VlSCOSITY Viscosities of hydrocarbon gases V i s c ~ i t i e sof hydrocarbon liquids ASTM viscosity chart
VAPOUR PRESSURES 14 15 16 17
3Cr 35
Phy slcal properties of hydrocarbons Camprtssibility factors of natural gas Pseudo critical pressure VS. MW Critical constants for gases and fluids Critical temperature VS. normal boiling point Characterised boiling points d petroleum Fractions Molecular mass, BP, and.denslties of fractions
33
31 35 36
Low temperature vapour pressures High temperature vapour pressures True vapour pressures of petroleum products and oil Hydrate formation pressures SPECIFIC HEATS Specific heats of hydrbcarbon vapours at 1 AT M Heat capacity correction factors Specific heat capacity ratios a t IA T M Specific heat capacity of hydrocarbon liquids THERMAL CONDUCTlVlTY Thermal conductivtty of natural gases Thermal conductivity ratio for gases Thermal conductivity of hydrxarbon liquids LATENT HEATS OF VAPORISATION Latent heats af various liquids Latent heats o f hydrocarbons Heat of combusion of liquld petroleum fractions
SURFACE TENSIONS - MlSCELLANEOU5 Surface tensions of hydrocarbons Dew points of natural gases Solubility of natural gas in water and brine Sobbility of methane in water Solubility of natural gas in water Solubility of water in hydrocarbons Temperature drops for expanding gas Temperature drops for expanding gas Physical properties of gas treating chemicals Physical properties of water Physical properties of air
2 93 7
I
-
4
TOTAL .
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GENERAL DATA
TEPIDPIEXP/SUR
&,,*
Ravision :
~ R O C ENGINEERING E ~ DESIGN MANUAL
IOU rn44eJ-d
.
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=
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TOTAL
PROCESS ENG~NEERINGDESIGN MANUAL DATA SECTION
TEPIDPIEXPISUR
2
1
cenrimitn
I . ~ ~ D D ~ rE ~ Z
Data
2
Page NO : 5
15
-4
AREA
I
LENGTH
I
1 , M Y ) o O O L ~ Z 1 . O m W E W 1.6d0000EtiO
mitre
Revisien : o
3.937wO€+01
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VELOCITY
TEPlDPlEXPlSUR
DATA SECTION
DENSITY
5.)8? 037 t -04
TOTAL
PROCESS ENGINEERING OESlGN MANUAL DATA SECTION
TEPIDPIEXPISUR
.
Pan* No
I5
: 2/65
Date
VISCOSITY (Kinematic)
n i t r m ad Wr
u d *
mnu'nokwr
I r t
pw wand
,quan feet @r bru*
1
I
1
munr.
Revision : 0
-7
-
1
I
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1.076 3ni E+OI
3.835 091) E fbr
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3.11 75 008.5 -02
9.290 304 E-02
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?.6806*0 €4
2.W1180 €+Of
3.117)78E-M
,
I
TOTAL
PROCESS ENGlNEERlNG DESIGN MANUAL DATA SECTION
TEPIDPIEXPISUR
Revision : 0 Dale
: 2/85
5PEClFIC HEAT CAPACITY
THERMAL CONDUCTIVlTY Cr*IDUCIIY,Il
I*€sY'Om
rwr-.'c
WIC.~
m , m, ,-4
muw
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ha.**,. 4-4t.kir
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1
1101rn 1-01
I H I 1I1I41
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HEAT TRANSFER COEFFICIENT
FORCE
Paw No : 15
-8
--
7
TOTAL T EPlOPJEXPlSUR
I
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
Revision : o
Date
; 2/85
Pagr ffo :
15
HEAT CAPACIT Y/ENTROPY €NICI#IEt
carrcilt
~UERMIW%
JIK
1
LWIK
I
POWERlHEAT FLOW RATE
ktd'~
9
TOTAL .
Revision :
,
TwtnP/Ewnutt
0
Page No. :
1/15
15.10
DATA SECTION
'
:
PSEUDO-CRITICAL5 AND OfL PROPERTIES
.
Deflnitionr :
True vapour pressure
-
I
actual vapwr pressure of a crude oil a t the actual
temperature of the fluld.
Reid vapour p r c w e temperature of I00
r
- reference vapour
*F (used as a basis for
Mom average bo-
pint :
-
pressure of an oil at a controlled
product specification).
equal to t h t Sum of the mole fractlcm of tach
component x i t s atmospheric boiling point
Volume average b o U i ~point r VABP :
OR.
- average temperature at whlch the ASTM
10 %,30 %,50 % , T O 96 and 90 % volumes boil. VABP. T I 0 % + 730 % + TJO % + T7O % + T90 %
5 M e a n averrEe bailing polnt :MABP I
- the slope of the AST M distillation curve i s used
to c a r r u t the VABP t o give MABP. See
Fig. 7
-
Cubic average boULng point z CABP : another corrected form of VABP. llOP K or WATSON CHARACTERISATION FACTOR
KS~!!!!
i g at 60/60 CABP in ' R
Sg
Thfs lssued as a characterisation factor when defining crude oUs. I t is required for variws other data evaluations.
dS3
-
TOTAL TEPIDPIEXPISUA b
1
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
Pagm N o .
Dare
: 2/05
15
-11
7
TOTAL TEPIDPIEXPISUR
I
PROCESS ENGINEERING DESIGN MANUAL
Revision : 0
I
DAth SECTION I
Dam
PHYSICAL CONSTANTS OF HYOROCARBONS(27)
: 2/85
PW No : 15
- 12
.
-
7
TOTAL
PROCESS ENGINEERING DESIGN MANUAL DATA
TEP/DP/EXP/SUR I
5a NUII NO
-
-.-
Revision : 0
SECTION
Date
Pagr
: 2/85
15
10.
1
12.
I l ~
H U I ~ WIW. 15 *c'
i
13
;
Flarnnyb~la~v
ASTM
tumuls. "01 % ~nb+r rniw!u<~
hrmw
DCI~W
I
1
cmwum
-
-
37.691 33938 I wrnmr 68.032 51.58bh 1s 4 5 b 1 Elham 60.395 86,453 93972 Y 1 . W 25 39Ib 3 Prmw 4 n.Eulwt 112.391 121.>19 49.158" 247ll)L l12'.0Jl 121.4X 49.DUb 27621. ' 5 lr~qrl1n . ' I=,= 149664 . 8 . ~ 7 PIw a nPtnlarr 7 lwpntm# 13,0114 149.31S 48.570 90333 137 465 I 4 L 7 S . 8 4 2 f h 281L064 I Nmantrnr 1Sr.402 l 7 t . W ' 4.W 32091 9 n.Mbrw 10 2 ~ l l l v l ~ n l w lbr076 171.22P 46313 9 1 7 4 2 11 3Umhrlmnlbm 1 w . 1 ~1 7 1 . ~ 1 #.m 3 31 512 1 7 6 1 1 I 2 keoh*=m 161 0% 171.170 40.1W B 1st 13 2.3.Dm~thvibutalu 14 n4ilotrn 1m.m ~ 0 6 4 3 1 48.101 m a s 190,099 205.132 4E.m) l 2 l O O 15 Z*Hlthwlhm.M IW,243 m . 2 7 6 u . 0 ~ 2 3 3 2 4 ~ 16 3.M.lhvihr.*~ 35m6 17 1Eihvlmn1mr 1555327 205.3S -.rot 1896XI KY.m 479b4 I@~ ~ ~ l m l h u l p . n t b n I n 2,44vnr1n*lpn1an IBP.W3 20..d% 1B.W 32501 4 1 33. I 20 3.30imlhrlo.nnn I I W W 71Y.722 47Sa2 33319 f l Triolm 318174 2132M 47PtB 33166 22 nOtlmm 215,191 2 3 1 7 m 47la32 33 312 23 Diirobrl~b 315.732 232.644 A7.843 PlZPD 4 Ismclan 342.389 =;.I= 47.7B3 M 4 5 25 *-NDIW 2 8 9 ~47.8'10 ~ ~ %PBS 21 n-D.onn 131.114 tW.KP 41955 35225 z7 Cvf~oafiram ?I W t n v l h ~ l ~ m n ~ r r *1S6.757 IM.033 46.8Z3 JJ 270 S497 46.1580% 167.29 C~rcbhesaw 1E1,%7 1 9 4 . I M 46.5n J5Wt 3 wm,lc,ck,n.bm 50.10Q 55.042 31 C l h r r lflhvbml 07.11G 11.402 n P ~ o D . ~ i.rr-l..wl l 0 7 . 4 n 114.991 .80814 Zn9leh 33 18ul.N I~UWIHI 107.191 114.701 47.027h P ~ S L 34 ri1.2.0urw 1 W M 7 114.473 4 7 M a " 19 lMh 35 t~.ru.1.€lucmr 106.755 114.211 4 7 . 7 W =feen 3 ltarrrr ~ 133465 lumo 47.71~) m 37 I*UIUUM 101.118 1a.755 4Y .W* 31 21011 JI l I . & r w m r * 29242h 101,017 1 0 7 5 8 41.P I . Z h w i ~ 1273m iIY.141 aL4m 31 62d 40 IVCPYP70 53cw 41 Aolvllr* rY,OSS 139691 4t.843 3642 Bvru*rr 159531 107.MO a2450 DOOO 43 Tolunr lE%,s% lV4.DS 43.014 37478 44 Ethvlhnr.rr 165.002 194.407 42WO 37 935 15 a.Xvl*rr 1%5,0;10 194.415 42.M1 37 245 40 m.xrl47 #.XvIer* lll5,OSO 191.445 4 2 W l 37 131 1@0,?PO 1 8 7 . W 42.213 3 8 4 8 4s Slyrru 443.410 375Q1 211.324 1 ) 2 r # imp.opv~brny*ru 3 Z W . 2 2 . a I 8 067 . 28 ? Za CIu.1hVl.lcYW2 W.WS OQ.107 23513 51 Elh*l .*&I 11.9% ll.SS 52 Clrmmmwmm& 0 0 53 Clrbon d i o d e 21.912 23.791 Y n v ~ , w wit* 55 Sullur dm141 1 p . m ~ 10.1ai 54 4vmonib I 7 Air 12.a1 10.230 5d Mvdl-n ;
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I.-
W m ~rthrn.bln
n.1. Rl)n arbuli.l.4 t4h"r". iZLl Lmru. S . ~rmmarun,. n,.4. web. li Y Fd. " M r ~ h r r * lmlw m.wm-I l b d , m a ~ ~ T . b k . d ~FLv!dK..u-l": hr P.r~.nwm Fb-: hid.1971 rr.1 Anrml, S. trm.lruna. n. de h l . c. H..Ed.. ttlnurn.ln-l +h.*dyn.mm Tab*. of Ih. F1.Y % . ~ - h h y * n . . lm": bl.rrr.nb Landam. 1974 L.Call.rhn.3. S.J. rhrl.Cham.M.ml. l*ll.t U. *I l r - r . 1311~ n l ~ n A. # ~rurk.W. M ,~ r n n ~ m nUg ., Edr -NI 1~urn.1T l u r d nmmr f.b*rdrh. ) 7 d %iulrn-~~,~I.Wa P.M.: D I M . lt7k "H.l,u., L""rn.li.~*iTk"lr I S 1 *,,,"I.,$.. dr hw. K Y,.
lm H.r.
t
s.
d . . . ~ tab*,
.IA. n u ,suu-r..
?....nu h n : 0.M.
r ..CrbLII
11
f 1-
un
r.eIw. ..
nu- -..1w-
wc
r.lw~wr.ptyrruvn~ Th.~.rublll,f~d,*r".
..d ir
~u.1." z # p I7
1 lk 5.mo,0 +4 a. *ul su nlv,.e w .r i.Yl~UuWr.vl T~..*L~~*.~..I.I.YULI."O)~ TI. .Co& d . " .I.. *..I ,r #7 .#.
-
*
.+ xr
wr
l'b4.u i.r. V ( J . c l # u V V k u b d m..l 1 r r " k".,.", I. h &I(., r.. -.l.k.d t." uw -.&vwvw mJ.r k m t r a c n t .n w rein .~rr nu. -.n r r k u d Col&. nol-... ..nuom d C L I * . Th. I d L I 1-. r*. U.lll 1.dq.DAO.I Lua re .mar a n d n r d h u .-.nu1 -...r.. unu .II.MYI L.b- lb'C.I* v.lu"#twmamG~M 8
...ad,
"
FHI 3 U..Z "c."%.d...-'....
r.,"
. .
.rCUL"md,UI
I6 T h b w . r
belr
lr
"Q
*#.awe
.f*.I,."4
-,
.r uv o%a.lr,
."r.r.r,.r.d
.I n n k . h
u h y f h )Y mUn4.d .UV mL 18% .C ** cr...u. *Ire , " I . . . . . u . . m u dl rt Ibl.8-b %?I mL.1 F r a r r d r*.n l h h . l r u CdiaOkSIPlr. wnrhnvnmrru c.n.%s,wha. I ..,I - h +; + IIW,) .COIGI>. I-
)I
)U
-<
-
T EPlDPlEXPISUR
DATA
Ps.ud.
SecrIm critical ptrrnurr
Dale FIB. 4
: 2/85
15
- 16
TOTAL TEP/DP/EXP/SUR
PROCESS ENGINEERING DESIGN MANUAL DATh
SECTION
Ctirical Irrnpmralur*S N o m d boitinp point. *C
Revision : 0
brtr
: 2/05
P b y NO:
15
- 13
-
TOTAL
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
TEPIDPIEXPISUR
as-u
o Y smna IP t-
Revision : 0 Oat,
: 2/05
PIOI No :
IS
- 18
.C.hlara mr-M
cular mass, botllng d relative densltles
100
200
4 00
300
Mean awlaye boililly fminl. O
C
26 I
-
TOTAL
0
Revision :
page NO. :
DATA SECTION
TEPIOPIEXPISUII
Data :
2/85
15.15 M
DENSITY
VAPOUR DENSITY
Yapour densities or molar volumes can be caiculated from the equation :
Specific gravity of a gas
a
MWalr = 28.967
r
LIQUID DENSITY
The density of a multi component mixture can be calculated utng the summation af the component densities :
Wl= mass component = density component
P'
liquid densities for hydrocarbon mixtures can be estimated using. Figures 10, 1 1 in this section.
-
262
.
--
-
-
TOTAL
-PROCESS ENGlNeCRlNG DESIGN MANUAL DATA
TEPIDPIEXPISUR
SECllON
Pw Na :
Revision : 0
Date
; 2/85
15
F16. 18 kppeomimate t c t t i v n density of pelrslrum frotiionr
I.mp.l.l"l*
-.---
.~
----
26 3
.L
-20
TOTAL
Reuision :
0
Page NO. :
DATA SECTION Date :
TEPlDPlLXPlSUU
2/85
1S.U
VISCOSITY
UNm : Dynamic vlscoslty
r
I centipooc
=
0.01 dyne.rlcrn2 e
=
0.01 ern2/s
Kinematic viscosity : 1 centistake
Other quoted units for kinematic viscosity arc
Saybolt universal Saybolt fur01
r
0.000672 1bfft.s
Dynar&icv:yit
y
i
Redwood
Engler
conversion charts are sited in literature
VAPOUR VISCOSITY
. Use .
figure 12 in this section or
Calcolatt using :
i) r m =
Zp- 1:
fl
~~6
mlxturt viscosity
P= y; = component viscosity nw: = component mol.wt
ii)
3:
rn = A exp l0f)
Az
0-
(q.4 * *.Ql w) -r!.r (CW 4 14 n.ru,,-r) \a4
-
9tc +
3 .
0.01
MU
= component mo1.frac accuracy 2 5 %
T in
L o L T L kCo
@F
7-
C = ?.A )7J.
P'sRT
PL !oo.o
0.1 b
I A . ~L
P
R = L65.P
a+'
pr:%
LIQUID VUCOSlTY
. .
.
Use Figurt 13 in this stetion or :-
Calculate using :
1)
/-'a
[-
(y
The viscosity of crude oils with an API
> 30
hf
X; =
component m o l . f r ~ c
(sg = 0.88) can be estimated using :
-
logy- a (0.035HAPI) .C I a
centipoise
I
where
3%
54 71 88 104
.
1 1 1 1 ]
2.05
1.113 1.55 1.30 1.08
Corrcldtiolrs for tiquid vi~cosltypusscsa u general rclidbillty or
- 15 t
%
[ TOTAL 1 TEPIDPICXPISUR
I
I
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
Revision : D Date
: 2/85
VISCOSITY OF NATURAL GASES
Papa No :
15
- 23
.?LC
I
TEPIDPIEXPISUR
DATA SECTION I
Date
: 2/85
TOTAL TEPIPPIEXP/SUR
PROCESS ENGINEEAINO DESIGN MANUAL DATh S E C T I N
rcmpcrature 'F
QSTR VISCOSfTV CHWlT
96'6
Rsrisbn ; 0
Datr
: 2/65
P.01 No :
15
35
( TOTAL 1 TEP/DP/EXP/SUR I
PROCESS ENGINEERING DESIGN MANUAL DATA
SECTION
I
Revision : Date
O
: 2/85
FIG. 14
I1 15-26 I
TOTAL
P R O C E U E N G I N E E R I N G D E S I G N MANUAL DATA
TEPIDPIEXPISUR
SECTION
Ptrml~rlblmmzprnrlbn of 4 0.7 rtlrtivr density
Revision : 0
Date
: 2/85
Plpr
I5
NO :
- 29
~ P e r m l ~ ~ li~panrlon blr O l I 0.8 rrlatlvb dmnrlly
Prrmlrrlblr mapanrlon of r 0.6 rmlrtlrt density
a
I
10
II
T n n w r a i u r 'C
n
w
FIG.
17
rn
2 D M 3W04000 6W3 I D 0 Flnbl vrmssurn. hPb (ab.1
MmO
HYDRATE FORMATION
2TJ
-
TOTAL
0
Revision :
Pap.
:
DATA SECTION
TLPtDPlEXPlSUR
Date :
2/85
SPEClFlC HEATS
(HEAT CAPACITY)
1 BTUllb .F
BTU/lb O F kJ/kg *C
UNITS :
I BTU1lb.F
=
4.19 k3lkg -C
= 1callg.C
VAPOUR MiXTURES
.
Use figs 18, 19 in this section
.
Cp* Is a fuctlan of ternper*tlue and can be calculated ualng r Cp*
s
A + BT + C T ~
where A, 0, C are constants dependant on system composition
and T h In * R [K) Values of A, 0, C are cited In Kern, or Perry.
.
Cp* can be corrected for preswre if Pr and Tr are known uslng Figure
.
K = ratio of specific heats
8
this should also be ~ M r K t e d for pressure If required.
LIQUID MIXTURES
, Use Figure 21
in this section or :
, Calculate using Cpl Cpl
NO.
= =
- 1.34 G + T (0.00620 - 0.002349) 0.68 - 0.31 G + T (0.00082 - 0.0003 191 2.96
G
=
liquid specific gravity
(accuracy t 5 %)
1 rt3
k3)kG * C (T in 'C)
BTUllb
O F
(Tin *F)
CAMPBELL
15.30
TOTAL
PROCESS ENGlNEERlND DESIGN MANUAL
T EPIPPIEXP/SUR
DATA SECTION
Revision : o
Dae
Pagm No :
: 2/85
FIG. 18 SPECIFIC HEAT OF HYDROCARBON YAPOURS AT 1 ATM (NOTE UNITS ARE BTU/LB/*F)
TOTAL TEPlDPIEXPlSUR
PROCESS ENGINEERING DESIGN MANUAL
phra SECTSON
Rnision : 0
Dale
: 2/05
PW ND:
15
-32
8
Ut4~~D 4 0l l % b V . ~
a01
02
FIB.
0 6 01 ID
01 a4
P # # * c *~r e > w * , 4
=
8
19 HEAT CAPACITY CORRECTION FACTORS (NOTE UNITS ARE BTU/LB
M O L E / * F ) (8t attnospheric prtswre)
2 ?S
--
Revisiorr :
0
pagt N@r:
2/85
I>.%
DATA SECTION Date :
TEPIDPIEXPtSUR
THERMAL CONDUCT1VITy
BTU/lb *F
UNITS :
VAPOUR MIXTURES
.
Use figs 22,23 in this section
.
Low pressure thermal conductivities of pure gases and vapours can be estimated
ushg
:
k=
r(=r
I-Af
accuracy 2 8 %
k
-
y Cp -
B1Wh.ft.F
lblh-ft BTUIJb 'F
llp~as
. .
Usc fig 24 In this section or : Liquid hydrocarbon mixtures can b t estimated uslng :
a = WE' [ I =g
-
accuracy + 12 %
- on003 (r- 32)] k
rg
- BTU/h.ftaF
- specific
gravity
7 -OF
< > -93 32 < > 392 .78
mLl!3S
.
See Perry of Kern for details of metals, earths and building materials.
277 --!
1
mTnk TEP/DPIEXP/SUR
F I O C E S ENGINEERING DESIGN MANUAL DATA SECTIQN
vision : 0
Orte
: 2/85
Pagr No :
15 -35
lhcrrnol ronductiwity r o r i o lor goran
t.1m.d
f HERMAL CONDUCTiVlTIES OF HYDROCARBON L I Q U ~ D S Ft6. 24
r*..nr..?a
Revision :
0
Page NO. :
DATA SEtTtON
-
TEPIDPIEXPrSUR
Oatr :
2/85
15.36
LATENT HEAT OF VAPORISATION
UNITS s
BTUflb
1 BTUllb = 0.5556 kcallkg
kcallkg
. .
Use figures r 25, 26
Estimate using Trwtons rule :
A-2 l - ~ hcallgma~c accuracy 2 20 %
.
Tb s boiling point *K
For relief valve calculations use 50 BtU/lb If actual Lt.ht i s not known.
, Detailed estimation methods in Perry :pp 238
2 74
TOTAL TEPIOPIEXPISUR
,
PROCESS ENGINEERIN5 OESIGN MANUAL DATA SECTION
Revison : 0
a
: 2/85
Page NO:
15
-33
E3 PRECISION : 10%
L
LATENT HEATS OF V A P O R I Z A T I O H O F VAAlOUS LlbUlDS
FIG.
a 2 &-0
-
>
TOTAL
PROCESS ENGINEERING DESIGN MANUAL DATA SECTION
TEPIDPIEXPISUR
CPl
W2
QO4 Q05 03
0.2
0.4 C5 PRESSURE
!
Revision : - 0 :, Oatr
1
: 2/85
P w No :
15 -38
2
- ATM
LATENT HEAT OF VAPOURlSAflON OF
HYDROCARBONS
F I ~ .26
-
.2g
TOTAL TEPIDPIEXPISUR
PROCESS ENGIIIEEIING DESIGN MWWLL
DATA ACTTON
Date
: 2/85
Pago No :
(5
-39
5 K)/WmF . '
1.10
Rmwuan : 0
.no
7
TOTAL
Revision :
0
DATA SECTION
TEP!DPIEXPISUR
Date :
2/85
SURFACE TENSIONS
.I dyntlcrn = 10-3 ~ l m
Dymfcrn
UMTS :
N/m
. .
For surface tenslons of paraffins use fig. 28 To estimate surface tensions for hydrocarkn Iiquida/gas
a-.
'[nu . "-PI
use
4
(2.A
w r c e r baker
accuracy :2
=
1U %
18.07 + 2.996 M W for paraffins with M W < 100 = 278 + 2-55 (MW 100) for paraffins wiik MV > 100
P
c
Parachor
PI
r
liquid density iblft3
-
pv = . vapour density lb/ft3
.
papa NO. :
For oilagar mixtures can also use 0 . .
-..a*?
T
=
temperature in O F
P
=
pressure in psia
7
-
0.
zc1
A?L)
-
Lrp
source B e g s ' + Brill
2
r3
(- 6 . 0 . 0 ) 7)
U.40
.
PROCESS ENGlNEERlNG DESIGN MANUAL
.
TEPIDPIEXPISUR
DATA SECTION
Revision : 0
ma
:Z/ES
Pw No : IS
-41
TOTAL TEPIDPIEXPISUR
7
PROCESS ENGlNEERlNG DESIGN MANUAL
RarNon :. o
DATA SECfTQN
-
Ontc
: 2/85
Paw No :
15
- 44
FI6. 55 solubllny of watar In hydroearbonr
Z? 7 --
"
U
g a
I.
0
o
-.
0
-
.-C . .-> d
2 3
z
2 z CI
0
3 .
.
.
I
a v
-
\n'
* 2 .. 0
.-
8
z
-.
0
4
s- E3 . - 2
Y1 LU
.z 0
2
W
8 W
0
0
K
Q
. a
.
.
;S
E
Il ~Utt'l
.
r 1.9
3.m id1IWI XOOLeL.'o 3.051 +.'I LWI rclj
.%oc %OOI~SLS
1COl
.
3.0~~ C O L .
>.I'1F
2-02 0 co WC.IOI
WL'I rpc I 616 ~5
I'd
1st
LII-
ut-
X S L P B'S
J'S2
J.E I L W L
3 . c ~ IWIO '
3.s~
3 . CC
, -CU011 WZ
*
r ,*.mq,.r(y.wg 3 .I-.*-
.
3.M 1+'I
eUI'O
CLZ'O 13.01-*$1 Dl?'& LIIL'O WI
OIL
OS~C
1.um3 . Lral
mlna
rW IOEG H O ~ H ~
.-~-wrs
'
-
'Ulrrr LC1 LOLI'I
3.001 1LI'O 3.a * F L L O as'? >.st- Q 8'01
--
rm
~
aW ~ D
**I C.IO&
>.(rl COI'I
W'l L'TMI
--
C~P-
ZH ~
WZ4I c
--4r,lrtUYl
. ~~
LH r&r I
...&?LC
>WIUOI WICIOI
1Ll.t
0.r t P*ZL Cl? rbez
.-
-
U C r I
CC I
90
a WI
.~.
PPI bCEr' I
LC1 US?'&
LUl-
a . 7 ~ 1r w ml-
.
Lumlvwm
. . Crl
u?~'L
.~ . .
911
Pltrl
).0Ci4.0Z
r s W~E.IOI*QM
5sll.l
1.~511
""4.""
....
..fDdy...
-4!-wA
-
.*+V*U
qqq4
#.W4 :#,OH
%WPUW
""
bD . r,n
........ .................
'"'
a,(3..~q)R~'Ir!aod*r
*lmWdmrP
I*
qulq*
w d
I rn-4
.4,!W*
IIUWIO
.
' I V ! ~"!ZBU~
'e*rwdwrl 'mci#*q lonvr~
'Mu.? 3.Ot
.ryml.r
i . 4 ~
IW-SL
rayW e W
I-
..................................3 .................................. s~n w w ow113 w ww a1fll .....3-02 lwh..r~'llr '&u!3.r~~ q!ds "".."".."""
lq('9nlndl
).QLIS.Ol ...................... 1UIQ ........................ x ...................... 1 q m ) o& -nu........................... 3. .............
g.--4
".."."........................
lu(md
3. CIOL1 ......................... ....norn,rp,**W
"
~
puy~
P l~
......................,..*Y
''N
................................. & . Z %>'# ......................*.+-.-. 3.M "
'"...'...'.h-8. r q I- Btrrr
'Irpodw rv*v em05 -&!'.P mAwpu
..............lrDvr
@r
'wed
WWma
'mm8orrdur*l
EWIQ~
'3.04 a h u - a ................................. 3. ............................... 119e) *ry '-a44 .................................... P W J 3. Oqzbud ...................... 3. '119.1 9'101 **!@a ........................
m-'-'"m-"'-
LWO l*t)r.pa~~r ".. .........3.a. h 9 . q b li.n4J/rq IC'C .. ..m.-..o.,wuh......... 3.0~t3.w ...............................
ru~r~
1wtv
KI.HtMn
ELldl
ELC
c111
WQL
.
roi VOdl
W.I9
'W,,,4)CW
.IV+ Odyq l* 'mrpu! v*pwr)*a
>.'303 ...................3.w 'w
"... ."" ".." ",. ........................-" ........................
Cb
LSV'L
3.ua
W m --All ILI 9111'1
. nuauw 3.a IWC
Luo!wr
.
1111 101 LSPI ISrL
zl.voL
HrlO,H'J~H
'
su
l-40 *-I1wm tll
.I.-
CCSl'l
r
~.OL*CIOI CWIIad-
3 . 0 8 19tE'C
-1 C ' I O I @VEm '.'(@90) %34e
.I3 U'd &W9 MC'O
#to1
SEE
-I
LIS'Z bOCfOE)4&4Vt
OSC
6PC ? I'SOI
PEL'O lWL
SUll
Y I E'LOL d O I E W I C . t O l
w o
WC':
~ ~ ~ e 4 .3.08 o I L'SP WFLOI **I? ~ir~ot+o ~ 9 r 1 . LIC'O >.PS' I .)6tL'Q W.2 ~C~I'I
cr II or CMC
EvKlLLC Lac L C ~ ~ I 11'osl H ~ I O W ~ ,,qD.H'3)O" ~
>.St& >-PC 3.w
-
mdl(PlraI
-
'
WOwh-4~ W o -WIW
.
Z??
a??z
OCf l'l *111 CiE
SMS
zue
r'zz
,",,,,.n(Xrn)
---
'
CLLC
out
21-.
b1'911
. w tv
,,qmrj0
p s ~ 121 1i'SOt
(nm.odwoa.O)
4IZ
4++,r( , , , 6 ~)n
CI'CCI ,,,,t(tncm) I
..*-
.IPY.(UYIw I
O
..IYUIwII
3mQC1U I ' C ' IdC.2 3.0ClSP 1WQ 2150'1 3mOC.4bb ?.Ptl&IEOI MI . to1
V
qmlul*yr k l l r n a r ~l o 6 (m rmlr*dord 10-
i
!
.
.
DATA StmlON
PHYSlCAL PROPERTIES QF WATER
,
Il-mkn..
m.4
r+ T l l C
tim
4 wmr a d Skim.
.ruan.J('W
,
,
,
PROCESS ENGINEERING DESIGN MANUAL
'
~ e v i s i o h: 0
----
I
btntm a1 a b n r m & r l . ~u rn Iunetimo Fw tk d 1h ~IM, U.''In~#rm.LiomJ Cljef.J .T&-," vd. 8. M;' b Tim 011 snd 2-34.
I..
' h p k d h r E ~ b ,sc td,h n $1 ~m. hm W' lo 1Yn.L. 1 h. IW b.n. h V-mn. L.r,~cL&r. ad bbwd 5bmpkr*t*l m n n d rm id ira c a m . - WF. W. and ?.E-SSf tnr TI a m . 1C1. rru -n -I-. Irwl- d PF.IM
IWC,
nt K l '
I t .
.
n a XI Im
1
. P q b No :
PHYSICAL PROPERTIES OF AIR
P
Revision : 0
Page No. :
PROCESS CALCULATION SHEETS TEPlOPfEXPfSUR
Date :
EQUIPMENT CALCULATION SHEETS
AIR COOLER
SHELL AND TUBE EXCHANGER
PUMP CENTRIFUGAL OR AXIAL COMPRESSOR RECIPROCATING COMPRESSOR
TRAYED COLUMN VERTICAL LIQUID GAS SEPARATOR
HORIZONTAL TWO PHASE SEPARATOR ' HORIZONT A 1 3-PHASE SEPARATOR
PIPELINE TWO
PLPELlNE
PHASEAP CALCULATlON
AT CALCULATION
2/85
16.0
OPERATING CONDlTlONS AND NATURE OF FLUID I Duty
.IQ= I
Fluid inlet temperatwe Fjuid outlet temperature Fluid inlet pressure Air arnbiant temperature Overall heat transfer coeff. l ~ e Table e 2 and/or a t t a e a
IT1 ITZ=
1
kcrl/h I aC 1
-
'C
-
*C
*C I FLUID AT^ = T l T 2 IF= bar abs 1 Itl= I 'C I INLET ATL TI t l = I'U = i kcal/h m2 *C I
I I
-
work sheet)
I
(Based on bare tube area)
1
NOT@
STEP 1.Optimum number of tube rows for U selected 2. R = At air/ t m 3. T1 TZ/TI tl 4.Y =At air/Tl t l . 5. Atair s Y x (TI tl) 6. Exit air temp t2 =&air + tl 7. Average differential temp. At, = dtalr
-
-
-
!N=
I
I
(N~VC
N* 4)
lR=
1 I
I
(curve
N* b)
1
*c I I *C I
IY= I
-
I I t2 m I I 1 km* 1 T . 1 . I 8. Bare tube surface A r LA= 1 Ux tm I I 9. Bare tube areatrow Fa=AIN I Fa = 1 LO. Tube length IL- I 1 1 . Tubeslrow TR = FdLlt0.08 ! TR 1 12. Cooler width W=TRxO.O635 1 W 1 13. Total fan power =Fa*0.795 1 Fp I 19. Number of tam I NF I IS. Fan diameter I FD I 16. Powcrfian Fp/NF I PF I 17. Estimated weight 1-M I 4.88 (36.4X9.35 NIxWxL 1 1 IAtair
-92
*C
I 1
'C
1 I I
rn2
(curve Na 5)
I m2 I m
5
1 3, 4 , 5 , 6 , 7.5 or 9 m are common I (I" OD tubing)
rn 1
kW I
t
max. fan dlam = 4.6 m
kW
1 1.
kg
I
m
(including rnotars)
I
Notes : Curves numbers refer to Process Dedgn Manual Chap. 4.
246
EZU 4223
PROCESS ~ ~ L C U U ~ SHEET O N
TOTAL
ITEM:
AIR COOLER
T€*mO?QIC E X P I U I
sv
1
r nr
- DATE
I
101
~mt
b.! 1406 he..
I
urvl/
. 1,
LIQUID COOLING LIQUID VISCOSLTY AT
s
T2
+
2
GLOBAL HEAT TRANSFER COEFFICIENT :U = (Read curve n* 1)
2. GAS COOLlNG
MOLECULAR MASS :Mw'=
GLOBAL HEAT TRANSFER COEFFICLENT (Read curve n4 2)
:U =
3. TOTAL CONDENSATION
Tl-T2
=
*C kcallh rn2 ' C
GLOBAL HEAT TRANSFER COEFFICIENT :U = (Read curve n* 3) Ir.
PARTIAL CONDENSATION WITHOUT LIQUID AT INLET
4.1.
WGl
-
outkt gas flowrate WG2
-
inlet gas f lowrate
outlet liq flowrate
Tl
s
VL2
- T2
C
GAS MOLECULAR WEIGHT AT
y,
HEAT TRANSFER COEFF. Uc
=
kcauk rn2 *C
(Read curve n* 3) kcal/h m2 'C
:
HEAT TRANSFER COEFF. Ug (Read curve no 2)
GLO~AL HEAT TRANSFER COEFF. kcallh rn2 *C
SELECTED GLOBhL HEAT TRANSFER COEFP. t
=
u
Curves refer to PDM Chptr. 4.
a4 7
L
m
TOTAL
-r
TEI1WP:DV:E X W U *
I*
cnu
1
PROCESS CALCULATION ,SHEET
AIR COLERS
HEAT TRANSFER COEfflClENT OATS I ( 101ilnt
ITIW :
w.. 101No
I
ntv
1 ;
2
WITH LlQUlD AT INLET'
inlet liquid flow rate
WLl
-
kglh
outlet liquid flow rate
Wtt
-
kgfh
LlQUlD MOLECULAR WEIGHT AT T1
+
f2 =
7
LIQUID SPECIFIC HEAT AT
QL
-
t
v
T1 + r2 CP1= --?-
) x CPI x [Tl
- T2)
=
outlet gas flow rate WGZ
-
GAS MOLECULAR MIGHT AT-
=
'
inlet gas flow rate WG1
GAS SPECIFIC HEAT AT
kcal/h
kglh R%h
T 2 CPg =
kcallkg ' C
2
= f W C l +2WC2) x CP& x (TI - TZ)
QG
kcallkg f C
=
kcallh
CONDENSATION HEAT Pc=Q-QL-% LIQUID VlSCOSlTY
kcal/h cpg
AT 71 T2 +
2
LIQUlD HEAT TRANSFER COEFF. (Read curve n92)
Ur =
kcalfh rn2 *C
GAS HEAT TRANSFER COEFF.
U8
kcalfh m2 *C
Uc =
kcal/h rn2 *C
. (Read curve n* 2)
CONDENSATION HEAT TRANSFER COEFF. (Read curve n. 3) GLOBAL HEAT TRANSFER COEFF.
U=
A
$+F+$
SELECTED GLOBAL HEAT fRANSFER COEFF. r -
&y TE?~OCV~PIZ~?ISU(I
6
*
I
CHI
OATE
.
U =
kcallh m2 'C
=
kcal/h m2 *C
U pq Y
PROCESS CALCULATION SHEET
AIR CoOLeRS HEAT TRANSFER COEFFICIENT
4
1 lO# T111f
nzM: ~o
.
100 ho
I
I
l t ~
-
1 I
! ITEM: I
I I I
I
Q
DUTY
II
I I I I I I I I
I T2-tl
I
Inlet remperature TI Outlet temperature T2
COLD FLUID 1n:et temperature tl I Outlet temperature t 2
I I LMTD from formula(l) I
I I I I I I I I I I
.
I
I I I
I I
t2-tl
-
I I 1
TI tl TI-T2
1 1 1 1 I 1
p=t2-tl
rl-tl R=Tl-T2
m
I I
keal/h
NUMSER OF SHELLS F = LMTD correction I factor (3)
I I I I
NOTES : II I I I I Indicate temperature I I I
1
I 1
'C 1 ' C . 1
I
'C 'C
-c
1 1 I I1
1 1 I II
'C
I
I I I
I 'C
I
'C
I
*C
1
I I
I I I I I I I I
I I
-
rn2
1
I
Shell
I
-
I I
I
I I I
I
1
I
I 1
I I
I 1 1
2
I I
1
II
I I I I
I I I I
I I I
I I 3
f I
I 1 I
4
I
I I
I
I
Including fouIing
1 I I I
I
I
I 1
1 U.LMTD ORR I I ESTIMATED TUBE LENGTH FTlrn) 1 ESTIMATED SHELL DlAM I inr(mm)'l I I I I I ESTIMATED WElGHTBundlc 1 - tonnes I
1
I I
I
I
I I I I I I
.c
1 Fig. 2 I ' L 1 I CORRECTED LMTD CORR. I I I I HEAT TRANSFER COEFF. U I kcallh 1 TABLE 3 P a ~ e4-10 I m2'C
I I HEAT TRANSFER AREA I 1 A'.+.
+! I
VALUE
I
I
I HOT FLUID
I I I I I
I
I I
factor
'
I I I I I
I
I
I I I I
1 tonnc~ 1 1 tonne* 1 1 I
1
t 1 1
I 1 I
1 I I
247
i!i&
PROCESS CALCULATION SHEET ITEM:
StPIDD?'D~P~ X P ~ S U U
av {
t
cnx
I
SHELL AND TUBE HEAT EXCHANGER
oat€
JOB nnr
N,
ror NO
.
I
REV
I
-
lndicstc pressure, elevations and system sketch
PUMP TYPE r Speed t
FLUID PUMPED r Liquid : Pumping temperature T r Vapor pressure at T I Density at P, T I Specific gravity at P, T r
'
I
.
SUCTION PRESSURE
Min. Origin Pressures + Static head at LLL = (m x sg x 0.0981) A P suction line
-
-
baral m bar t bar1
2
1 Othu I '
l
+ vapwr pressure correction . m 1
I
TOTAL AVAILABLE NPSH
m
MAXIMUM.SUCTION PRESSURE Vessel
I II
Statlc head at HLL
%
I
. 1
bara bar
bar
bar br bar bar
1
DlFFERENTlAL PRESSURE
1I
1 I
1 I I 1
I
1
r ---
I
..*---
*I
300 PROCESS CALCULATION SHEET
I
CHI
.
1
I I I
I 1 (2)
1
I
,
I
'
I 1 (31 I 1 1 141 I !((I
I 1 I I
-
.
-
ITEM :
PUMP
TECWoPXWP'tI(P I V
I
P ~ W L RREQUIREMENTS
I * .
TOTAL
11 1
I
I Estimated weight
Em7 sun
I
I I bara I bara I I bar I m I
I 4Fig3for 1,)
-1
I I I
1
Design operating load i411qmkWI
I
net bar.
I
I
I I Brake Horse- ower = (l)x(2) kW I MAXIMUM DISCHARGE PRESSURE !I+ 7si. . I P1 1 bard I Estimated mator size kW 1 Max. suction pressure Normal pump AP x 120 % bar1 I I I
I I 1 1
bar I
PRESS bara
1
net bara
II
*
TOT MSWARCE
Suction pressure
~ b d ]
m3/h
I
1 Discharge pressure I I pump 'A P 'I
bar 1
cP
I I
bara I
PSV setting
m3/h
Delivery pressure
m 1 m
Design margin : Design llow at P,T (1) :
I Static head f d P control valve(s) I A P txchan cds) I A P orific 51 1 AP 1 OP lint 105s
I
Line loss
(reL
I I DISCHARGE PRESSURE I
1 I
I I PUMP SUCTION PRESSURE 1 I NET POSlTlVE SUCTION HEAD 1 Static head at LLL
..
Viscosity at P, T Specif ic.gravity Normal flow Q at P,T :
*C
bara kglm3
OAT€
10.
rant
He.
I 0 0 lro
1
rtv
I
r 1
OpER4TING CONDITIONS SUCTION PRESSURE PI = DISCHARGE PRESSURE P2 =
bar a bar a
TI =
SUCTION TEMP*
'C
i
SUCTION f LOW ACTUAI. VOL FLOW
PRESSURE RAT10 P2/Pl
W + V =
*K
MW
kgir m lh
GAS DENSITY AT
a
SUCTION =
kg/rn3
NOTES
STEP
PC
1. GAS PROPERTIES 2. POLYTROPlC EFFICIENCY
3. AVERAGE 8 = MCplMCp-1.99
=
9~
=
SEE FIG. 2
8
=
ESTIMATE T2
3
4. DISCHARGE TEMP ~2 = ~ l ( a )
5. DETERMINE Z AYC
~2
SUCT
2 1
DlSCH AVG
bar a
Tc
'K
K
t
C
=
REPEAT STEP 3-4 IF ~2 IS DIFFERENT FROM ONE USED IN STEP 3
=
Z2
=
Z
r
6. CALCULATE GAS HORSEPOWER G H P = Z X R X W ~ ~ X ( T ~ - T~ If )j p
k
R = 8.314 kJlkgMOLE .*C
kW
tHP<800 kW 8 0 0 < < 10 MW > I D MW
M W x 3600x(X- 1). 7. CALC SHAFT HORSEPOWER PS = GHP x (1 +
FIlOO) x I /. ,q
PS
8 r ESTIMATE DRIVER POWER
ELECTRJC MOTOR PS x K PO PO GAS TURBINE PS x (1.14 + K)
=
- --
kW kW
k
=
F
'Im
5.0
0.96
3.)
0.97
.
0.98
1.0
K = 1.15 K s 0.02 TO 0.04 WITH GEARBOX
9. ESTIMATED PACKAGE WEIGHT
COMPRESSOR-DRIVER-LUBE
NOTES I
M
=
--
kg
(SEE FIG 4 )
- . 301
&2.Lb
TOTAL
ED3
1IPIPW~lhlXI~IUR -(.CUK
j
PROCESS C&LCUCATION SHEf T
CENTRIFUGAL OR AXIAL COMPRESSOR DATE
f JODrrne
lllY :
wo. : 10s mu
1
UIV
1
-
t OPERATING CONDITIONS
SUCTION PRESSURE P1 = DlSCHARGE PRESSURE P2 =
TI
SUCTION TEMP.
V
PRESSURE RATIO P21PI =
bar a C
o
MW
K
=
W
SUCTION FLOW ACTUAL VOL FLOW
bar r
,
z
kgjh m /h
c
GAS DENSITY AT SUCTION =
STEP
NOTES TC =
1. GAS PROPERTIES
PC =
-
2. AVERAGE 8 = MCplMCp 1.99
*K
bar r
II =
.
3. CALCULATE DISCHARGE TEMP Tlx
l-2.
(E)Y
T2
= m
5. DETERMINE t AVG
kdm3
SUCT
Z2
AVG
Z
Repeat 2
- 3 if T2 differs
from that used In STEP 2 ".
*
Zl
DlSCH
'K *C
=
= 7
6. DETERMINE OVERALL EFFICIEN&
'le
s n FQ 3
'lg =
7. CALCULATE GAS HORSEPOWER CHP =
Z x R x W * 11 x ( T 2 - T I ) M W x 3600 x i 1 1)
-
8. CALCULATE SHAFT HORSEPOWER
GHP=
kW
PS =
kV
R = 8.314 kJ/kgmoldC
PS+ GHPlf x v g
f = 0.96 t o 0.97
9. CALCULATE DRIVER POWER Electrical Motor
Po = 1.15 x PS.
Po =
kW
30 2
PROCESS aLcumnoN SWEEI
lmm
TOTAL
ITEM :
EEu
RECLPROCATING COMPRESSOR
TICmwmMXCnVn
mv
cut
O~TI
JOBnnr :
:. IOWUO.
:
IIV
1
TRAY CALCULAnON SHEET
Name :
Columm item :
Number a! passes r
Tray number : to =
.*c
PQ =
bar .a
1. VAWUR.AND LIQUID T O TRAY
I HYDROCARBON :I I .LIQUID I I VAPOUR 1
I TOTAL
-I
I
I
1
I
1
1
I I
I
I
I -1 I
I ! I
I
1
I
I
7 -
-
'I
I
I
I I
' 1
I ---
I
Compressibility factor Z
Kcduccd Pressure Pr
Reduced temperature Tr
From charts Figure 1,2 or 3 page 15-15
?pour actual rate
I ~'
--
Cv=k&= Dv h.
.$W
I 'IEP'DWrDlP'tlCSUR my
OLTt
CUE ,
.
&
m3h
309. PROCESS ULCULATION SHEET
Sheet 1 of 4
ITEM:
TRAY COLUMNS
!
1 Ion tlm,.
WO. :
.
.
10s no
r
REV
I
2. LlQUlD FROM TRAY to =
D15
.C
'
Use figure 10 page 15-20
kg/m3
Liquid flowrats =
DL a t to r
kg/m3
k&
3. DOWNCOMER DESIGN YELOClTY YD bg
TS : = DL-O":
m m T R A Y SPACING" kdm3
m3/h/rnZ From figure 2 Page 3.10 v D dsgo = from table 1 Page 3.9 System factor Kl rn31hlrn2 . VD dsg = VD dsgo x Kl = 4.
V A P ~ U CAPACITY R F A f f O R CAF
.
TS:
mrn CAF 0 = from (Fig.3) on page 3.10 from (Table 1) page 3.9 .System factor KZ = .. C A F = CAF , x K 2 , = 5.
VhPOUR E F F E m V E LOAD V Load
6. APPROXIMATE COLUMN DIAMETER DT =
D m ,
30Y PROCESS CALCULATION SHEET
TOTAL
Em3
TtP'DDCPC.TXP~SUR
rn f r m Vlg.4) page 3.1 1
Sheet Z of 4
REM:
TRAY COLUMNS
*o. ;
1
riv,:,
COLUMN HEIGHT ESTIMATION
I
I
_
1 "a
I
a. HI : See design details on vertical vapour-liquid separators. Minimum distance for H1 will be one tray spacing. Minimum distance between
inlet nozzle and top tray 300 mm.
HZ :trayspacing x (number of actual trays - 1) No actual trays = theorctjcal traysltrray efficiency
= 50%
for tray efficiency see section 22. page 3.3. Assume
Actwl trays a
Note.: ifthe column diameter changes over the length, the transition piece will be h*
~
= @0l
- (2)
long and t i 2 r i l l increase by this amount Selected H2
I
*-
..
TO~AL
,
PRQCE%$ CALCULAnON SHEET . , .. IttM.
TI~AYCOLUMP~S T CP.~bP#Pl@*txt~SUt B
cur
1
'
.
DATE
I
...
!I O B T I ~ L ~,
5
mm
Sheet 3 of 4
no..
1 ror no
I
ttu
I
..
c.
..
H3 r H3 s h l + h2 hl = tray spacingx 2 =
.
mm
h2 = h6 + h7 + h8 (see vertical separator sizing) h6 = hold up time
..
.
For
production flowing to I
.
anothci column
. . . .
. t
r
2
storage
10 5
a furnace
another unSt . reboller/heat exchanger
h6 =
15 rnh
rnm
h7 =
5
rnm
+h2='
Hf = h l + h2 r
mm
h8 :
rnm
.
mm
. TOTAL COLUMN HEIGHT
. rnrn
Selected H3 =
e
HI + H2 + H3 =
mm
~.
p
6.
PRDCESS CALCULATION SHEET ~ h & t4 of
TOTAL
1EPrDDP:DIPJELHSUI
I
C ~ Y
.
~ E M :
Bf.1 81
4
PATI
/
TRAY COLUMNS
ma:
IoRTITLt :
lOrnN0..
.
]
REV
i
:
CALCULATlON SHEET FOR VERTICAL TWO PHASE SEPARATOR
EOUIPMENT N* Operating data :
,
'
Pressure (operating]
bara
r
Temperature (operating) Gas MW Gas flow rate Gas density (f,P) Actual volume flow Qg
'C
=
Mesh pad
Yes No
: :
--
.
Liquid flow rate Liquid density (T,P) Actual volume flow Particle size
kg/h a kdm3 = m3/s
. .
.
Liquid description :
=
=
kg/h kg/m3
=
m3Irnln r microns =
Estimate Vs using Fisure 1 and 100 micron curve If P < 50 bar and )J < 0.01 use Fig. 1 and f 50 microki f > 0.01 use calculation for Vs ~f ~ > ' 1 0 b a r o r
1. Vapour-liquid settling velocity :from Fig l/calculated
Vs a
c =
'
vs =
m/r
m/s
Delete as applicable maximum velocity
2. Derating % = 85
-
Vm
=
m/s
= Calculated drum fi =
Drum flow area
3. Actual volumetric gas flow
m3/1
m2
mm
mm
SELECTED DIAMETER = 4. Required liquid hold-up timer
h5 : HLA
- HLL
h7 : LLL
-
5. Mesh pad:
LLA Yes/no
r
min
=
m3
=
mifi
=
rn3
thickness -s .
mm
. m
mm
rnm ,
Em2
&jetY;[
PROCESS aLCULATION SHEET
I
E ~ C A vAwuR-Wu1o L SEPARATOR
I .-.CII.
30? .
ItTM. YO
Sheet 1 of 2
6. Hci~h:calculation
=
mm
1
U
h4
-
mm mm
h3 :
=
mm mm
h5
-
-
.-
=
mm mm
-
mm
rnm
300 mm for side LC
=
rnm
h6 + h7 + h8
F
mm
TOTAL VESSEL HT TAN#AN
=
-
For "drymvessel
-
A.
'
s
.WLL
LtL
=
mm
h8 :
.I:
-
5
h7t
N
h6
50 % of @ or 600 mm
From step 4 or 350 mrn FromstepIorlSOmrn 150 mm for bottom LC
h6 r
% I
4:
bl
=
With mesh :hl + h2 + h3 No mesh 2 hl + h2 + h3 8 60 % d or 800 h9 : 400 mm + dl2 r d = inlet not2 P hS : From step 4 or 200 mm
I+
L
t 5 % of 0 or 400 mm [Use mad h2 : mesh pad
hl :
TL
ua
I d
mm
t
7. Wall thickness
. .
P= c=
DESIGN PRESSURE CORROSION ALLOWANCE
mm
Max stress : 5 = 1220 bar CS
LO00 bar CS Joint efficiency (.a51
mm
Diameter D =
hrg
t
S=
= Z X SPXx ED- I ~ Z +P C
E=
-
tmin = Df800 + C
mrn
8. Veswl weinht (Flg. 6) t=
mm
L=
m
Dr
m
shell \eight = Head weight = (t x 201
b
ks
dx
TOTAL WEIGHT =
h 30 S T
1OTAL
m.
VER'llCAL YAPOUR-LlQUID SEPARATOR
IEC'DDC'D(PIEXMUR I
I
1
I
----
-
"., . -
.
Sheet 2 of 2
PROCESS CALCUUnON SHEET ntw :
-
. .-.. "
I
..
I4
~ of
CALCULATION SHEET FOR HOMZONTAL 2 PHASE SEPARATOR TANnAN fL' )
t
.
:; .@ 0
HLL
0=
LLL
ht
. h2;
3
EQUIPMENT N * : DESCRIPTION r
Head type cllipticallhcmispherlcal Indicate on sketch if 2emlstcr mesh required +
* Delete as applicable Operating data r Operating pressure bara Opcrating temperature ' C = Gas molecular weight
x
Gas mass flow rate k d h
=
Q g actual val f b w
m3/5
= =
Gas vlseodity
CP
=
Gasdensity
T, P
kg/m3
Liquid nature : Liquid flowrate Liquid density T,P Q1 actual vol flow partide size
I. Vapour-liquid settling velocity : from Fig. I/calculated C
kg/h kg/m3
Vs =
*
=
m3/min = microns = mls
=
* Delete as appliabIe
-
2. Max. vabour'velofity
Vm=VsxfxL
LID 3 3. Actual vapwr volumetrlc flow Qg =
m3/s
mlr
Vmr
b
*" = %=
m2
30 7 PROCESSCALCULATION SHEET
Em3
-
&?P)
CALCULATION FOR HORlZONTAt
2 PHASE SEPARATOR
IEPIOOP UIPIE~PLSUR
BY
C ~ K
DATE
IOD TlTLl
.
Sheet 1 of 3
ITEM : WO.
:
JO@ no
RlV
4. Nozzle sizlng Ivelocity limits (rnfs) = Inlet r 7-13, Gas outlet :15-30, liquid outlet 1-3 i
lnlcr flow =
;
Actual vel =
n
Nozzle ID =
m3/s
mlr
(+ 10 96)
!J2 : Gas outlet = Li@d outlet =
m3/s Nozzle ID = m3fs Nozzle ID = w
n
Actual vcl
mls
a
Actual vel =
mla
5. Drum sizing For trid I t,,
= 4 min
voL
required r b x Ql =,
I TRHL Selected h/D Vapwr area Av % Total area (Fig. 3) Total area At Liquid arcs Al
a
Calculated drum # Selected drum 0
m2
m2 m2
mm 0
-
mm
LID (3 4) Flowpath length
L
rnrn
Tan/Tan length
L1
mm
HLL hclght Volume at HLL
mrn m3
LLL height
mm
Volume a t LLL Surge volume (HLL
- LLL)
Calculated treS
m3 d min
I
I
I 1 1 1 1 I I i 1 1
I
I I I 1 I I I I I I
I I I I I I I
.
I I I I
I I I
I I I I
1
1 1 1 . 1 1 1 I 1 I 1
I I I I
I I ,1
1 , I I I I I 1 1 , I I
1
II -
t
I
I L
I
I
I I
I
I 1
I I
1
I
mm
r
m m tanltm
d
T m / t a n l e n g t h L 1 = L + If x l l + 14 g2 (ignore this correction if D < 1.2 m and use L for volume calcs. For trial 1- use &d ignore heads).
b)
If VOL HLL is less than rquired surge i n c r e a ~D, L or h/D or reduce inspection).
I
1
1 I SELECTED DRUM t DUMeTER
I
'
I I I
I
I
1
.
I
I I I I I I I
I
I I I
I I 1 I I
I
1 I I
I 3
I I I
I
1
1
NOTES r
m3
L
trcs (by
3 l0
FvZa
&qJJ
PROCE5S LnLCULLITlON SHEET
CALCULATION FOR H O R I Z m M
2 PHASE SEPARATOR
TE~QOP*RV XP'~IUI
BY
cnr
D L ~ E
101 TITLE.
sheet 2 of 3
nt~: 116.: IOI YO
.
I
REV
'1
I
L
6
Wall thickness
. +
DESIGN PRESSURE CORROSION ALLOWANCE
P=
barg Max stress
C=
mm
CS = 1220 bar
SS = 1000 bar
5=
Joint efficiency E =
=
p-
PxD
+C
mm
5
8. Vessel Vfei~htFig. 6)
L=
rnm m
Shell weight = Head weight =
D=
rn
It x $r 20)
t=
kg kg
k*'
TOTAL WEIGHT =
.3 PROCESS CALCULATION SHEET
L q T J -'
TOTAL
CALCULATION FOR HORIZONTAL
E a 3
TIPIDDPOIP IXPISUR
BY
CWK
A
T
I
2 PHASE SEPARATOR
] 101TIT11
Sheet 1 of 3
"EM :
Ha' 101No
1
mtv
-
-
II;
f ANITAN LENGTH L' FLOW PATH LENOTH L
-
1
Or
t
TO
.
Amend rkateh if boot requited instead of bfflr .indicate on sketch
HLL
if mesh r.quir+d
.Heads :2 :1 slliptical /hemisphsricaf
EaUlPEMENT No : DESCRIPTION :
1 0. Operating data i Operating pressure a = Opcratlng temperature 'C =
-flowrate
PC Ql I."
GAS MW
= kgfm3 =
Mass
kglh F Density T,P kg/rn3 Vol flow T,P m3/rnin =
CONDENSATE Flowratc
=
Viscosity
cp
Flowrate Density T,P VoI flow T,P Viscosity
kglh
kg/h
Dtnslty T,P Qg Vol flow
m3/h
P
Particle size
WATER CUT
--
PW Qw
microns=
P "'
r
I. Vapour-liquid settling vclwitr: from Fig. Ilcelculatcd C
*
Vs =
-
kg/m3 =
m3/rnin = ep =
ds
,
5
Delete as applicable 2. Maximum vapour velocity
YmrVsxOd5xL
b
LID = 3
3. Liquid-liquid settling
Ut = 0 . 5 1 ~ 8 [ ~ ~ - f ~rndrnin ]
Oil in water
U+il=
mmlmin
Utwater =
mmlmin
)c. I J =~ 0.1 101[-.]
Water in oil
rnrnlrnh
re
31s PROCESS C&LCUCATION SHEET
TOTAL
m
CALCULATION FOR HoRIZONT&
T~F,DOF.~)I~~~P'SUR
-
67
I CHK 1
OAT€
I
3 PHASE SEPARATOR 101 TITLE
-
Sheet 1 0 i 4
1 7 ~ : NO.: to6 lto
.
ltlv
rr. Nozzle sizing r velocity limits (mi$)= Inlet ! 7-13, Gas outlet 11-30, Liquid outlet 1.3
m3/s :.
nozzle 10
actual vel m/s
1. Inlet flow I (+ 10 %I 2. GM outlet I 3. HC outlet r 4. Water outlet r 5. V e s x l sizIng For t r i d 1 use
tresoil
[HLL-LLL) = 4 min
OIL SECTION
I TRIAL Selected h/D Calculated (Qg/Vm) Av as % AT (Fig. 3) Total area Liquid area
Av
At A!
-
Calculated @ Selected I
m2
Flowpath length
L
TanlT an length
L'
HLL height Volume at HLL LLL height Volume at LLL Surge volume {HLL
h1
LID U 5)
h2
- Ltt]
Calculated t,,
m2 m2 mm
I 1
mm mm
mm m3 mm
m3
m3
I I
I I 1 I
tan-tan length Lo=
I I I I I I 1 I 1 I I
I I I I I 1 1 I
I I
1 I I I I
3
1
1 I I I I
I L + Ij x
1
I 1
1
I I I
I I .I 1 I I I
-
+ 02) mrn Ignore if
.
I
1 I I
1 I I I I
I I
I I
I I I
I 1 I I
I
I I I
I
I I I I I I
I
I I I
I I 1
I -1
I a)
I * I 1 1 1 I I I
1
min
Notes or comments r
1
I mm
D
I
I
I
I I I
I
I I t I
I
I
1
I
I
I
D < 1.2 rn
-
- $3
ky>m
Ff OTAL Jrn
T~PDDHQ~FTXPSUR
.i.w
I
I
ewe
I
PROCESS ULCULATION SHEET
CALCULATION FOR HORIZONTAL 3 PHASE SEPARATOR 1 inn rlrm
'TtM:
Sheet 2 of 4 .--
no : IMw e
I
UIV
1
WATER SECTION
Trial 1
= 213 x L r
8
rnrn [rwndcd)
11 Rl AL 4 1 I m3lmin I I I I I
Total liquid vol f lowrate Qw
+
QI
I
8
Baffle distance Liquid area at HLL Horizontal vcl at HLL Ut water b t e p 3) Vertical fall from HLL =BxUt/Vi HLL vertical fall
A1
m2
V1
rnrnlmin mrnlmin
-
i
i
I
i
I
I I
mrn
mm
vz
rnmfrnin
mrnlmin .
mm
hS selected LIL level
mm
h6 selected outlet height
mm
ql water vol at H E (upto baffle)
m3
LlL (upto baffle)
m3
q3 water voi at NIL (upto baffle)
VOI
i
mrn
Horizontal vel at LLL Ut oil (step 3) Vertical rise within dist B * 0 X UtfV2, = mex. outlet height
q surge =
I
rnZ rnrnlmin mmlmin
A1 VZ
Check oil rise r
94 water voI at outlet (
I
mm
Selected baffle height . h3 Selected HIL level . h4 (adjust h3 and B if necessary)
q2 water vol at
I
mrn
Liquid area at LLL Horizontal v t l at LLL Ut water (step 3) Vertical fail from LLL = B x UtlV2
'
I
rnm
I'
-
(ql q21
. ,
i
3
I
rn3
'i
m3
i
I
I I I
min min
swge time q surge/Qw
residence time q3qb/Qw
calculated oU residence time (upto baffle) Vol (NLL NIL)/Ql min
-
I I J
I
I
I
I I
1 1
I
I
I
1 I
I
1
I
'
I I I I 1
34-
Em3 TOTAL
PROCESS CACCUUTlON SHEET
nEm '
CALCULAf ON FOR HORIZONTAL 3 PHASE SEPARATOR
TE?.WC OR,I X M U I m
a
I
I 4""
?ST, r
Sheet 3 of 4
..
ne.: +
I
~
L
Y
~
I
nru 1
6. Wall thickness
. .
DESIGN PRESSURE CORROSlON ALLOWANCE
P=
k g
C=
mr(r
Max stress
CS = 1220 bar 55 = 1000 bar
s= Joint efficiency t
=
PxD
+C
73izlm,
=
E=
mm,
8. Vessel weight (Fig. 61 t
=
Shell weight = Head weight (t x D\ 20)
mm
L*
m
I3 =
m
kg
k!!
1OTAL MIGHT =
tfg
..
-31 5 <
i f
PROCESSaLcuanoH SHEET CALCULATION FOR HOWOmhL "'M-
3 PHASE SEPARATOR
tf P DDPRIP'EXPISUI UT
cnr
01Tf
101t a t .
Sheet 4 of 4
wa: 10s Nn
MV
-
OPERATING DATh
-
GAS FLOWRATE DENSITY
Wg
VISCOSITY
Yg
kglh = kg/m3 = .. cp
Dg
*C
=
PIPELINEDIAMETER D cm LNTERNAL AREA A m2
=
f
k&
DENSITY
VISCOSITY
W1 01 Vl
SURF TEN
st dynestcrn
FLOWRATE
-
FLOWING TEMP
LiQUiD kg/m3 =
cp
m = m =
PIPELI~SE
LENGTH L Vertical change Ah
s
STEP
Wg
Bx + 210.3
I
I I BY r 1
I
I
dmxvel
r
~1213
11
.
2. CALCULATE Apgas
I
I Re = I I
35.368 x W E Vg x D
I Friction factor ( ~ o o d y ) I I ~ P =G 6.254 x f x,wg2 I
D
I
gxD
3. CALCULATE ApLlQ
1 Re = 31.368 x W1 Vlx D I I
I
I A P L 36.254 x f x ~ 1 I Dl x D> I
'
I I
I I I Rex' ! I
I I I I I 1 1 I I
I
I F
I
ldPG I
.-
a
bsrlkrn
r - r n
%LF~DPd'TilP.T XP.%UR CCtK
1-JL
Ohti
1
()osntir ~ * * f i r c ~
40.7
I
I
scr
rf
10-9
I t
I
I
1 I I
I
I I I I
I
1
I I
bar/km
1 II I II I 1
I I I
J I -1 I
pAOCESS a L C U t 4 T I O N SHEET
TWO PHASE PlPELwE P CALCULAnON
CC
1 I
I I I Re= I l f = I I A P= ~ 1
rcr
I
I
z z v --
f TOTAL
i
1
1 I
3 16
-
?
I
I I
=
I
11
I
I
I '-I1
REGIME FROM BAKER CHART
1
I
1
ma*
I
1
=
st I
7.087 x W
I
I
I
1. DETERMINE FLOW REGIME
I I
-
NOTES I -
-
1
= =
Sheet
' ' of
nim. Ma:
I
108 NO..
..
*EV
I ;
. I 1
I 1
4. AVERAGE VELOClTY
I
. \
Y,.
I I I
1 1
3.537
(
1 I v,=
3)
+
I I
x
I I 1
I I
* (w)
I X =
I 1
1
mw-
1
.mnu
1
L I
I
'
m a
I I I 1 I
--'TAVE
.
E.u .
* I . mu7~ #
.I,IN
rn b
I
1
I I
I
I I t I
s
*
r.n-ou3
-
PH
1
LII*
I
d
aY>.&*d
I
l u d t U m U
II I I I I I I
VS
iZ&~
vs
I
- L"_ 1 q # 3
t
I
_. -nt -
-
r h
-
=o;llrr
c
~
H
- -X
FLOW TYPE + WAVE
c - -
FH
.c2
P~D'
I
h-3
WGflC
I
PZH3,
~ulaer
1
I
berlkm
'
8. CALCULATE VER-
I
iI rn
Y -
I X , .
I
I I 1
1
I I I
M
prlh . c . t ~
1 I 1
(
I
!J,q&2
, ,
1
I
1 I 1 I I
1 I 1. 1
I mmIE0 1 d q - L
1 I1
I
I
FLOW TYPE z
I I-4 I
~wt-
I I
WS=
1
-K
mwnb.!
I I I
)
I
I I 1 I
7. CALCULATE PH FACTOR FOR HORlZONTAL FLOW
,
I
.
I W I x 0.205
WS=
1
I VS + average veloclty I I I I I 1 1 1
mlr
I
= APL
1 6. CALCULATE LOADING FACTOR WS 1 I I - I 1 i I
I I
I
5. CALCULATE X RATIO
I
1
1 Iw
I I I I I 1 I 1
PH FACTOR FOR VERTICAL 5EC710N
.
18.2
rlm
vm+Din
a 1n5
PHv =
aJYW@W X .
x,,~nDirpcrrQm~wt.wPn-
1
I I I
'
9. CALCULATE TOTAL TWO PHASE F
HorIzmtaI
:
PH =
Vertical
:
pHV=
I P~H=.PCXPH~= ~2~ = PG x PH$ =
PC=
1 I 1
bar
P = ( P ~ xHL + PZv x h)/lD00 =
TOTAL
barlkm 1 barkm I
'
21 7 P w m
J7 J --r?ofAL
-
PROCESS C A L C U ~ A ~ OWEET N
TWO pime PLPELWES P CALCULATlON
1tPfDOPIMPI~XP~SUI m
BY.
cur
DATE
JO~T~TLE
.
Sheet 2 ~f 2
ITEM: NO.:
108 no,
. atv
J
/
Covering Medium r
rP
b
I
4 1,
~g Ttmpcrature .C = k Thcrm. cond. kcal/hm*C r
L
p'
* 7'!?L
DATA -
LlQU?D FLOW
Total pipeline length rn = No of stgrncnts Length per segment m = Total tltvation change ; rn =
Volumetric flow m3/h Density (av) ke/rn3 M Mass flow kg/h Cp Specific heat kcal/kgmC
-
L Ih Y D
Pipetire diameter
Pipslim diameter Burial depth to centre m
PJ
Inlet pressure
~2
~ x i pressure t
Total pipeline lnitjal Temperature
T1
>
bar
=
'C
'=
kg/h = Cp Specific heat kcal/kgmC =
Molecular mass M Mass flowrate
Covering
1 1 % = I s = 1 1
x t 2h/D s = 2k / h [ x + (x2- ~ ) f ]
kca1fhrn.C
lennth
1.
a
t
I I
3. Calculate Asymptotic tempsrature Ta Ta =Tg (JAP + A y/jCp)/aL
-
1
I
Ta =
-
L is segment length
'C
1 1 = 4263
1
1
I 1
I I
PROCESS CalCULATlON SHEET Sheet
(
CHK
-
'
--
d t CALCULATlON
-
W9.:
TIPmDP'DIP't XPfOUP 81
kk?
I
21 8
BURIED PIPELIhiE
1
12 : C
1 Repeat stcps 3 + Q for each segment I See sheet 2 for stepwise spreadsheet I
FEZ7
I
T2
T2 s(T1 ~a)e-aL* Ta
i'-m TOTAL
I 1
I
I
m-1
I 9. Calculrte downstream temp
1.09
0.022 0.508 0.30 1.09
::
1
I
kca1Thrn~I
-
2. Calculate heat flow ratio wr unit a = dMcp (liquid or gas)
k
I
I 1 SOU 1 Air 1 Water
I
I
*C/bar
NOTES -
s
I *
-
aF/I,OOOpsi ( x 0.00805) =
VALUE
I
I
mj/d (std)
Volumetric flow
1. Calculate heat transfer factor
I I 1
=
bara = bara =
STEP -
I
5
GAS FLOW
r
FLUID YOUtE THOhiSON COEFFICIENT = [see fig. 1, page 11.81
3
=
ins = m =
h
AP
t
DATE
1
101TITLE
100 co
REV
-
7.
%
lTERA71VE CALCULATIQN LOG FOR A BURIED PIPELINEAT.
LENGTH
I
II
I
I
m
1 I
SEGMENT Na
I
I I I I 1 I I I . I 1
I I I I I
I
1
I
I I
2
1 I I I I
3 4 5
I I I I
b 7
1 1
I
L
9
I I
I I
10
I I
I
I I
1 I I I
I I
I
.
~~~ JBL
ltP~VDP.VLP'EXPrSUR #V
(
1CH~
-
I I I I t i
I I I I I
I
I
1 1
1
I
I
I I I 1 1 I
I
I I I I
I
I
I I I I
I
I
I. I
1
I I I
I
1
II
1
1
I I
I 1 1 I I I 1
I I
I I I
I I I I I 1
I
I I
I
31 9
.
&-
1
I
1 1
g
I
I 1 I 1 7 i 1 I ELEVATION 1 PI 1 TI 1 Ta T2 I PZ l 1 1 1 I I 1 I 1 I +m 1 b a r a l ' C 1 'C I *C I baral I 1 I I I I 1 I 1 I I I I I I I I I I I I I I 1 I I I I I I I I 1 I I I ! - II I I 1 I I I I I I 1 I I I I I I I I I I I 1 I I I I 1 I 1 1 I I 1 I I I I I I 1 I I I L I I I I I 1 I I 1 I I 1 I I I I I I I I I I 1 I I I I I I I I 1 I I I I I I I I I I I I I I I 1 1 I ! 1 I I 1 I t I I I 1 I I I I I I I I I I 1 I I I I I I I 1 I
PROCESS CALCULATION SHEET
BURIED PlPElINE DATE
[
101TITLE :
Af
Sheet 2 of 2
nru: CALCULATlON 10V NU
UtV
-
TOTAL
PROCESS ENGINEERING DESIGN MANUAL
Dno
TEPIDPIEN'ISUR
32
.
Rovisien :
a
. 2/85
?-
No :
. ,
iP&3T'k.
Revision:
Date:
PROCESS DATA SWEETS :
AIR COOLER EXCHANGER
PUMP COMPRESSOR TRAYED COLUMN PACKED COLUMN
FURNACE
FILTER VESSEL
SllMMAtUES OF EQUIPMENT CHARACTERISTICS
COLUMNS
PUMPS
HEAT EXCHANGERS COMPRESSORS - TURBO-EXPANDERS AIR COOLERS FURNACES
P~~INO.:
PROCESS DATA SHEETS
TEPIDPIEXPISUR
DRUMS
0 2/85
17.0
.I
@En
1
PROCESS D A T A SHEET
E?iL. 1
TLPlDDP! VvLI 8et~lc.:
2
:
AIR-COOLER
cCP
.
PIE
Jab : ~ r r v i e e:
: llem :
Unli
I
ma
1
ha
11
1.111
d r r t l o p ~lu11ue :
1
d
mam
CHARACTERISTICS
2
n
CONSTRUCTION Tbrl p i r r ~ v n
21
0,Blgn lmnprnlun
14 4
TUB6 MATERIAL
.
b.r? bar g
-
C
.
EpE73
TGTAL
5D.3 -
.
I
Job :
krvicr :
1
8111 SUII. per urn#
1
a
35
a 37
38
a# 10
43
Unit : lltm :
.
ttP* Cnerh p r l unlt
I
1
PERFORMANCE
C.lllng Surlmce p r ek.11
DATA
CONSTRUCTION
SI
y
...
EXCHANGER
C F P
TEPIDDPI.
Pagr :
PROCESS D A T A SHEET
T u b r b r e l r -Sl.taonrrl B ~ f t l ecma.
Bwwlw lorq ' t u b ~UWMB Ganitts CO(Ln*cllol@ shall In : charmel In : Carrorlon a t + a r n r . ahall crdt ~ W U I - ~ ~ ~ S Wwlghl 40Ch *hall
fl ~ l l n q - :
: TIPI
:
llw .
tpbclng : Spaclnp :
I
nm
I h l c h ~ r t r:
SvbcIm~:
I
m
T b I ~ t n l l 8: Oul :
5mrltr : Scrlm~: SI*
I
Thlfklnmmm : T h l s k n t ~ l:
IVA
mn
I nn kr1.n : @run : mm
I
t e m ~clan* :
. -4
Full 01 ~ 1 1 1 1
kg
L
BfJZ rnAL
Pmlr :
PROCESS D A T A SHEET
GAY3
PUMP
CFP
I
Job : Smrvitr :
TEP/DOP/
1
Unit : llrm : L
FLUlD HANDLED
1 Flu14 clrrvlrlrd
2 1
Puaplnt trmper*lut?
4 I
Vlrcorltp 11 P.T.
I I
Spuilie q r r r l l r 1 6 / 4 fi*tllic ymvily r l P.T.
*C rg
Vlpor pralrutr *I .T.
.
k r l
J
J
OPERATIHQ CONDITIONS
I C~prelly O i ~ r h r r l epratrun L d i a n bn*nurr ~n ~ t i * * s n t ~nr m l sfuf*
I 10
..
49
4s
math
I
I
brr s bar a bar r
-
I I
I
1
1
PUMP 1
n
.
.. ,
.>
DRIVER
,
I
ir
Tn.
25
nfllns
kw
k
Wwa
I/ ma
27
OprrrI%n( lord Canarcltd lewd
n,
, ,.
-
kwh
kW
-
.
L
D"13
TOTAL
HiwD
COMPRESSOR
C F P
1EP.'DOP/
b
Pn9r
PROCESS D A T A SHEET
$0:
Srrvrce
.
-
Unit :
I llrm :
f LutD
1
7
-
HANDLED
t
OPERATING CONDITIONS Capacily OqC. 1 AT*
. - ,
tlrn3fh
Capacill (sucllan P.7.)
m31 h
Sve11on prcssur~
bm
Discharge prrlsut* C ~ n l p r r ~ ~ if O r l ino
bin g
f
C
COMPRESSOR -3
1 TP*
84
Nurnbc~
P5
~ S I Q OCPP,CI~V
26 87
Ellicimcy L1.1. brake h ~ r s e p o w c r
.1 28
~pcra
NmW b
k hW I/M
Uabri~ls
'
DRIVER T ypr Rating Conneclrd load
kwh kW
Swrd
tImn
Opbraling load
.
LW
. ..-a -
-
-.
--
,
.
KRVICE
*
UTEIIIIL
-
CQKihSUoY AUWAWCE
rn
NOTI!# ;
.. RLVIIIOH
8-?.95'
Vm&L
is^^ C F P
BOUIPUEWT CHARACTERlSTlCS SUMhthRY
~ ~ C I D D 'P ~
AIR
on u*
DRAWING
-
COOLERS
nr
SHEET
w
UYITS
CK~PAC~ERIITICS
--
--
1T€Y M' NUYWR
SERVICE
I# 0 i A e T E M
mm
L C Y S J ~SETWEENTL
null
t
W I Z O M T A L :M L ? V
COSITLOw
MIST L L I W I U T O R
mmu. .OOT
nu
matm
Rrn
6CTWEEY L.t.
wzluil~a
~LFPURE
~rmnrruit~
comlf mu
.
MUM
C
hrg
~
.C
HEmtmE TEWPZ l M T V ~M
fl 'C
.UTCRAL
-
Wltn T H l C X R I
m
COI#DOTm CLLOrAuaE
m
t WTr N O W r
S
rmTIl:
I
*
.
I
w mnaL IIEWSW
I
I
&ZrT
EOUIPMENT CH&AACTERIST~CJSULIIIARV
CFP
DRUMS
TEPIODPI DATE
J0a nm
. 22q
DRAWIWO W
SnEtT
w
-
-
UNITS
CMRhCtER3tTICS
r
-
f t t Y II*
2
HWlLll I
!
SCRVlCE
f LUiO
M L L HOE
-CllCULATLD
TUBL ClDC
.
wr
.
HEAT EXCWGED
kdlb
c
LY1.0. tYPt
ti
3z -
W I L OF ~ SCELU
xw *
:-
CC
LYIQ C O ~ V ~ L C T ~
OWERILL M L l l ? W E 1 1 UTE
ESTIM&TED A OPERI~~WO
-
-
d
m
------
COUDlT!WS
#ii
Csrrrr
MIEWE
bu
PRElWRE
CWITIQNS
"
*C
Tf%P€UTURE
DESION
I
)r
l
'C
TEYP€MTVRS TYPE
YAtEAIAL
ChRQBIQW
nu
ALLOIUICE PRLOSURE
DPEwLtlNC
LI
E I
-
c~olllons
I
1
PRESURE
ComDlTlOns
3
I I
TNPEUTVIIE
--
DESIGN
cl A
ht
I
m
T E M PR ~ A T ~ ~ € *c
1
II
I
TVPE
YATERHL
CORRP61011
I
mm
ALLQ*AHCE
1
I
I
MOTES :
.
I
I nEWS10M
E3:m
rnAL
-
-
flksz
ObPf - --7 E P l-RC v --. -* +
,OA r i
-
-- - --
.--*
*---_C
EOU~PMENTC H A ~ A C T E U I S T I C SSUMMARY
MEAT
-
-, 4 0 0 H'
~
~ -
A -
A
Y
I
-- -3 3 a -
W* H
~lxcn~nti~s O : M E E T n* .-.
--
...
- -. IC-
7
- -.
.-
c n ~ n ~ C t E R l ICS St
---
---1
UNITS
.- -
--
17EU ND
- . I .
.
- -- * . ----- --,
1
-
A -
--A,-,
NWBCR
pnVlCE
. !
o
m
3L
-
WJuR€
YOLECVLAR 1ElCnl - - kfif k
MG ....
fi VILUE CP/CV
4
: =
CCr3nfSslBlLltl
z
FACTOR
D
S
WECtFIC W V I T I
x
PnES'*
i
h f .
T E W EM T W E
O P E M T ~ K FLO. ~ A T L DLUGll
$LO* U T E
DILOIAME COYPIIENIW
w
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TYPE C m P R C m m R A t t Y G LOlD
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TYPE DRIVER
COUWECTEO LOAD
n
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YOtES :
L I I
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,
RLWCtON
fi3 2 2 7mAL L%3z'
EOUIPMEMf CHARACT R I f T r c r StJMMARv
C F P TE P/DDP/
COMPRESSORS JOB N*
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CHARAC I E R I S T I C S
UNIT5
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t f E U W' NUYBER
SERVICE
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-. IN. DIAM. BDTTDYI MlDDLCl TOP
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TOTAL LENGTH T l l T L
1111
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T ~ A YSPACING BQTIClYNLDDLEnOP
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TEMP. D O T T W / TOP
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RIYAL-
am C F P
tE P / ODP DATE
EOUIPUEHT CHARACTERISTICS SUMMAPY
JOB k'
tQLL'ltrUS
DIIAMWG n-
3 3 9
SHEETU~'
CHARAC.TERISTICS
UNITS
.
1
# T E Y )1'
1
<
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J
u
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JEUFZRATURL
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kg/ n)
FLOW RATE
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t
SPECIFIC OP.&VITY A T SO. F
I
*C
PRESSURE
h a
8PEC lFlC GRAVITY
b#l d
r
8 .
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WPSH AVAILABLE
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OESIEW FLOW RATE
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-DISCWARDL PRES5uRE
brr
.DlFFLREMT1Ab PRESSURE
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YATERIAL .TIP€'
%
EFFlClLUCl
.PUMP
OPERATING LOAO ,
-
I8
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&RIVER
.
CWWEC'ICD LOAD
'h
kOlLl:
llEVlSlON
EOUIPYENT CHARACT ERlSTlCS SUMMARY I E P I D P I PCOCZ
PUMPS 101 W 9
ORAWIHO N*
S H E E f W*
.
b
~
i
~
WTAL
3
PROCESS D A T A SHEET
~m
'
PACKED COLUMN
C f P
TEP/ POP/
.
Scrvica* :
3 4
Packkg IyW
8
Item : ~-
COLUMN CHARACTERlStlCS Erlnlng l a w n :y. l n ~ l d od l l d n l ~ r Pneklng dlam*ul
~
or no
1
I
,
.
.
"
mm
a
m T
%
1 Unit : .
Jab
1
*
1 plpc
Numbr ml h a s
PACKINQ CHARACTERtStlCS
Ea3
P R O C E S S D A T A SHEET
m A L
DL33 cFP TE P /
Job:
DDP/
FURNACE 1 ~ n r :l j
s*rvlc- :
ltrm :
1 Pro8 :
1
1
I 3
*
id Kcallh
Ahorb4 bml
Mar. ~ I l ~ w w b tbma l l
IIUZ
i#KC~IIII
j
OPERATING CONDITIONS
1
s L I
a 10
n I2 13 14 1I l*
t?
*a 1I 20
COHSTRUCTION
n m a l y , ~ m u u n
.
13
&llorrbla p r * a a u n drcg
t4
tubrmlarlml
25 %
X
Fual
mdlm~lmmalnr ~ D ~ V . C I I D I It o n u
art g k r
-
I
Dm3 M 3
.
I
Job : Setvice
I
Murnbmr
1
3 1
Nstur* of H u l d
S 6
S p r e l w a u i l y d 15/4 S p c l l k grrvily r T
7
Virroaity m 'I P
1
Fr+ealng poinl Mature 08 I n ~ p u r l l i ~ r
Flttrmtion lrnlrntyrr
P
.
LC
cp
OPERATING CONDITIONS
10
.
I
Prtrrure
Flow
12 13 I - . -
bar* nr3/ h
u p ~ ~ l r l l n l / i o n
P
-
bar
Y r i . prrsrur? drop
DESIGN
15
16 17
I
Drsign I*mpetatun b e l g n prtasvrm
CONDITIONS
ec brp.
I
1
.r
MATERIAL
18
40 41
REVISION
42
dale
4 44
~ n f :i 1t.m :
FILTEREO FLUID
2
14
I
:
TYPO
11
'
FILTER
CCP
T E P I DQP/
P.@.
P R O C E S S DATA SHEET
TOTAL
,
7
0
by Checked
l
3Yd
1
2
3
4
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