PROCESS CALCULATION SIZING

- Hydraulic calculation

- Separation calculation

- Utilities calculation

- Relief and Blowdown calculation

- Drainage calculation
 PROCESS CALCULATION SIZING
Hydraulic calculation

- Pressure drop, velocity calculation

- Line sizing
- Pump sizing
Velocity: Pressure drop:
High velocity in piping systems increases the following Reducing pressure drop in piping system as far as
effects: possible because :
•-Pressure Drop. •-To decreases the size of pump or compressor (Cost
•-Pipe corrosion. reduction).
•-Water hammer. •-To reduces the initial pressure (i.e. in case of gravity
•-Noise (sound) emission. flows).
In the other hand low velocities increases pipe •-To decreases the energy losses.
diameter (Increase the total cost) and also increase the •-To reduce downstream velocity of gases and the
possibility of illuviation (Sedimentation) in a piping related corrosion and noise emission.
system.
 LINE SIZING

1 L [m] v2 [m/ s]2

Pressure drop   FD     [kg/ m3] d : internal diameter, m
1000 d [m] 2
L : Pipe length (or equivalent length), m
FD  4  f f 1 ff: fanning factor
  12
FD : Darcy factor
 2   ( 
8 12 1
f f )  3  ε : effective roughness, m
Re
 (A  B) 2  ρ : density, kg / m3
 g / L [kg / m3 ].d [m].v [m / s] Re: Reynolds number
Re  1000
 g / L [cP] v: fluid velocity, m/s
16 W: Mass flowrate, kg/h
  
   Sp: cross section , m²
 
A  2.457 ln
1
 
 
0.9
 
  
7  0.27 [m] 
  d [m] 
  Re
16
 37530 
B 
 Re 
 LINE SIZING

Single Phase Liquid Lines

The following is the typical maximum velocities based on API 14E. For critical services and long
headers, the total pressure drop in the system shall be considered

Velocity

General Service Liquid Less than 4.5 m/s (15 ft/s)

If practical, flow velocity should not be less than 1 m/s for liquids containing solids to minimize
solids deposition.
 LINE SIZING
Single Phase Gas Lines

Max ∆P
Service ρV2 (Pa) Velocity (m/s)
(bar/km)

Gas Lines
P < 2000 kPag 6000 18 n/a
2000 kPag< P < 5000 kPag 7500 18 n/a
5000 kPag< P < 8000 kPag 10000 18 n/a
8000 kPag < P < 12 000 kPag 15000 18 n/a
P > 12 000 kPag 20000 18 n/a

Compressed Air and Nitrogen 6000 25 n/a

 LINE SIZING
Single Phase Gas Lines
Where pressure drop is critical like for compressor suction and discharge/interstage lines the
following guidelines should be used. The pressure drop should be prorated between the operating
pressures given.

Operating Pressure Pressure Drop

(barg) (bar/km)
0 – 35 barg 0.01 – 1.1
35 – 138 barg 1.1 – 2.7
> 138 barg P/50, where P is operating
pressure in bar abs.
 LINE SIZING
Gas/liquid two phases Lines
Two phase lines are sized based on erosional velocities. The erosion velocity is given by the
following equation
C C
ve [ ft / s]  
 g / L [lbs / ft ]
3
[ lbs / ft 3
] Where: C = empirical constant
 g / L [kg / m ]  0.062428
3

[kg / m3 ]
The values of C are as per below
SI UNITS IMPERIAL UNITS
Solids Free (Continuous Service) 122 100
Solids Free (Intermittent Service) 152.5 125
With corrosion resistance alloy 183 to 244 150 to 200
materials (Continuous Service)
With corrosion resistance alloy Up to 305 Up to 250
materials (Intermittent Service)
 PUMP SIZING
- NPSH calculation
- Suction/Discharge pressure calculation
- Pump head calculation
- Power calculation (hydraulic power)

LC

Suction
LZALL = vessel
0.3 m 2"

ΔP=1.5 bar
Destination
2"

2.3 m 1.0 m
0.5 m Pump
 PUMP SIZING
- NPSH available
The net positive suction head available (NPSHa) is the difference between the absolute pressure at the
pump suction and the vapour pressure of the pumped liquid at the pumping temperature.

It is important because for the pump to operate properly, the pressure at the pump suction must
exceed the vapour pressure for the pumped fluid to remain liquid in the pump. If the vapour pressure
exceeds the pressure at the pump suction, vapour bubbles will form in the liquid. This is known as
cavitation and leads to a loss of pump efficiency and can result in significant pump damage.

To ensure that the pump operates correctly the net positive suction head available (NPSHa) must
exceed the net positive suction head required (NPSHr) for that particular pump. The NPSHr is given by
the pump manufacturer and is often shown on the pump curve.

NPSHa = absolute pressure head at the pump suction – liquid vapour pressure head

NPSH a = hp + hst - hvpa - hf

 PUMP SIZING
- Suction pressure

Ps = Po,s + Pst,s - Pf,s Po,s: Operating pressure of suction vessel

Pst,s: suction static head
Pf,s: Friction at suction piping

- Discharge pressure

Pd = Po,d + Pst,d + Pf,d + Control Valve ΔP

Po,d: Destination Operating pressure
Pst,d: discharge static head
Pf,d: Friction at discharge piping

- Pump head

Differential Pressure: ∆P = Pd - Ps Pump Head: ∆H = ∆P x 105

ρ x g
 PUMP SIZING
- Pump power

Ph = Q x ΔH x ρ x g Ph: Hydraulic Power (kW)

DH: Pump head (m)
3600 x 1000

P: Pump power (shaft)

P = Ph/h h: Pump efficiency
 SEPARATION CALCULATION
- Separator design basis
Three principles used to achieve physical separation of gas and liquids or solids are momentum,
gravity settling, and coalescing. Any separator may employ one or more of these principles, but the
fluid phases must be “immiscible” and have different densities for separation to occur.

Type of separator: Gas-Liquid, Gas-Liquid-Liquid, Liquid-Liquid. Vertical Separator, Horizontal

Separator.
 SEPARATION CALCULATION
- Separator sizing
Sizing Separator is based on max allowable gas velocity. This velocity calculation as per:

K is factor for gravity setting of liquid droplet, depend on demister type:

K = 0.046 if NO DEMISTER
 SEPARATION CALCULATION
- Vertical Separator
Minimum length (T/T) of separator is sum
of minimum requirement of each section
in separator. Typical is as following:
Minimum residence time
From HLL to
HHLL 1-2
From NLL to HLL 1-5
From LLL to NLL 1-5
From LLLL to
LLL 1-2
Bottom tangent line to LLLL NA

Inlet device is installed with inlet nozzle, use

for initial separation purpose & improve gas
distribution inside the separator:
Inlet nozzle Gas Outlet nozzle Liquid outlet nozzle
Diffuser 6000 - 9000 Pa
Haft Open Pipe 1500 - 3750 Pa 4500 - 5400 Pa 1 m/s
No inlet device 975 - 2250 Pa
 SEPARATION CALCULATION
- Horizontal Separator

Inlet device is installed with inlet nozzle, use Minimum residence time
for initial separation purpose & improve gas from top of Demister to top tangent
minimum space req., mm req.

distribution inside the separator: line typical 300 NA

Demister thickness typical 150 NA
From HHLL to demister 600 min. NA
Inlet nozzle Gas Outlet nozzle Liquid outlet nozzle From HLL to HHLL 150 1-2
Diffuser 6000 - 9000 Pa From NLL to HLL 150 1-5
From LLL to NLL 150 1-5
Haft Open Pipe 1500 - 3750 Pa 4500 - 5400 Pa 1 m/s 150 1-2
From LLLL to LLL
No inlet device 975 - 2250 Pa Bottom tangent line to LLLL 150 - 400 NA
 UTILITIES CALCULATION
- Compressed air
Instrument air systems are critical to the
proper operation since all the instruments
and controls depend on dry, pressurized
instrument air for operation. Most systems
are designed with 100% (or more) backup in
the air compressor systems. Systems are
generally designed to provide 700 kPag air
pressure for users. Drying of the instrument
air is critical to prevent fouling and possible
freezing in the air system and instruments. A
–40°C dew point specification is common but
specifications vary according to the climatic
conditions of the site
 UTILITIES CALCULATION
- Compressed air
 UTILITIES CALCULATION
- Compressed air
 UTILITIES CALCULATION
- Compressed air
+ Air compressors (at least one) will be connected to the emergency power supply to avoid to ensure air
is available to essential/critical users, during an emergency shutdown.
The air compressors operation is normally configured in lead/lag mode. The lead compressor(s) operates
continuously. On high air demand and the instrument air pressure falls to the lower set pressure, the lag
air compressor will kick-in to make-up the shortfall.

+ Instrument Air Receiver will be installed to provide surge capacity for the Instrument Air system.
The vessel will be sized to permit a controlled shutdown of the plant in the event instrument air
compression is not available. The vessel will provide instrument air for process instruments for a
minimum of 20 minutes as instrument air pressure drops from 7.0 bar g (PAL) to 5.5 bar g

+ Utility Air Receiver shall be provided for maintaining a hold up / surge for utility air users. The Utility
Air Receiver is sized to provide a hold up time of 10 minutes of peak utility air consumption in the plant
from 10.5 barg (compressor outlet) to 8.5 barg.
 UTILITIES CALCULATION
- Fuel Gas
Fuel Gas System is provided to supply high pressure (HP) and low pressure (LP) gaseous fuel to the
following users:
HP Fuel Gas users:
 Gas Turbine Generators (GTG).

LP Fuel Gas users:

 Fire Heaters, steam boiler.
 Primary Pilot/ ignition gas for the HP and LP flare tips;
 Primary purge gas for HP/ LP flare headers.

Fuel gas key specification required:

 Heating value (MJ/Sm3)
 Temperature and Pressure
 Impurities
 UTILITIES CALCULATION
- Fuel Gas
Fuel Gas System Flow scheme
 UTILITIES CALCULATION
- Fuel Gas
+ Fuel Gas consumption estimation: Max HP fuel gas + Max LP Fuel gas
+ Fuel Gas Scrubber shall be sized to provide an adequate hold-up time for 30 seconds from max
operating pressure to min pressure required with a gas withdraw rate corresponding to one (01) GTG
fuel gas consumption. This is to facilitate smooth switch over from operating GTG to standby generator.

The Scrubber is sized based on 2-phase separator sizing method. The working volume of Scrubber shall
cover the quantity of fuel gas for 30 seconds from max operating pressure to min pressure required.
 RELIEF AND BLOWDOWN CALCULATION
- Flare System
 RELIEF AND BLOWDOWN CALCULATION
- Pressure Relief
A pressure relief valve is a safety device designed to protect a pressurized vessel or system during an
overpressure event. An overpressure event refers to any condition which would cause pressure in a vessel
or system to increase beyond the specified design pressure or maximum allowable working pressure
(MAWP).

The pressure safety valves are sized based on either one of the following contingencies:
a) Blocked Discharge
b) Fire Relief
c) Control Valve Failure
d) Thermal Expansion
 RELIEF AND BLOWDOWN CALCULATION
- Pressure Relief
 RELIEF AND BLOWDOWN CALCULATION
- Pressure Relief

+ Pressure drop in the PSV inlet line shall not exceed 3% of the set pressure based on the rated
capacity of the valve. The inlet line shall not be smaller than the inlet nozzle of the relief valve.

+ Pressure safety valve discharge piping will be sized with a recommended Mach number less than
0.7 at the rated flow rate at downstream junction with header conditions (i.e. at built-up
backpressure) assuming a single relief scenario. The discharge line shall not be smaller than the
outlet nozzle of the relief valve.

+ For two phase flow in the PSV discharge, the PSV discharge piping should be sized based on line
sizing methods for two phase flow e.g Dukler, and not based on the API RP 14E erosional velocity
criteria. Lines shall be sized such that the ρv² limit of 200000 Pa is not exceeded.
 RELIEF AND BLOWDOWN CALCULATION
- Pressure Relief
How to size the PSV:
+ Determine the relief load:
- Blocked discharge: the relief load will be taken as the inlet flowrate;
- Control valve failure: the relief load is the flowrate at control valve 100% opened
- Fire case: relief load shall be calculated based on the heat input as per API 521
- Thermal expansion: For liquid-full systems, expansion rates for the sizing of relief devices
shall be based on recommendation of API 521.

+ Determine the relief condition: Critical flow or SubCritical, based on the calculation of Critical
flow Pressure

+ Calculate the PSV orifice Area

+ Select the PSV size by using API 526.

 RELIEF AND BLOWDOWN CALCULATION
- Pressure Relief
Sizing of pressure relief valve is clearly explained in API STD 520 part 1 [in SI units]:

GAS/Critical condition

GAS/Sub-Critical condition
r = P2/P1

STEAM LIQUID
 RELIEF AND BLOWDOWN CALCULATION
- Pressure Relief
Sizing of pressure relief valve is clearly explained in API STD 520 part 1

- Kd is the effective coefficient of discharge; for preliminary sizing, use the

following values:
0.975 in Gas Service and 0.65 in Liquid Service,
- Kc is the combination correction factor,=1
- Kb is the capacity correction factor due to backpressure in case of sizing for Gas, For conventional
and pilot-operated valves, Kb=1

- Kw is the capacity correction factor due to backpressure in case sizing for Liquid

For conventional and pilot-operated valves, Kw=1

 RELIEF AND BLOWDOWN CALCULATION
- Blowdown (depressuring)
+ SDV valves are provided to
isolate the system zone. In case of
emergency, a system will be
isolated by those SDV valves.
Then the inventory fluid in the
system will be released to flare
through BDV valve.

+ The hydrocarbon fluid will be

released to flare so that the
pressure of the system will be
depressurized to lower pressure
at certain time (recommendation
from API STD 521, decrease the
pressure to 100 psig or 50 % of
the system design pressure within
15 minutes).
 RELIEF AND BLOWDOWN CALCULATION
- Blowdown (depressuring)
 RELIEF AND BLOWDOWN CALCULATION
- Blowdown (depressuring)

The blowdown simulation has performed for the following objectives:

a) To determine the peak blowdown rate and RO size during fire scenario (Fire Blowdown or Adiabatic)
b) To determine the minimum temperature for facilities (cold blowdown)
c) To determine the inlet and outlet line size of the BDV
 RELIEF AND BLOWDOWN CALCULATION
- Blowdown (depressuring)
Fire Case (to determine peak blowdown rate and RO size)
i) Initial blowdown pressure is considered as maximum operating pressure PAHH and blowdown to 6.9 barg within
15 minutes. Initial temperature is the operating temperature
ii) Liquid inventory for equipment is taken up to LAH level of the equipment
iii) The piping inventories are estimated based on the isometric drawings if available or justified from equipment
layout if isometric drawings not available.
iv) Refer to API Std 521, the heat input from fire is calculated as below:
Q=21,000FA0.82
F= 1.0 (the vessel is non-insulated)
A= wetted area that exposed to fire (ft2)
Where adequate drainage and firefighting equipment do not exist, the heat input from fire is calculated as
below:
Q=34,500FA0.82
F= 1.0 (the vessel is non-insulated)
A= wetted area that exposed to fire (ft2)
i) Wetted area exposed to fire considered is either liquid wetted area (excluding water) up to LAH level of the to
determine the heat input as per API Std. 521.
 RELIEF AND BLOWDOWN CALCULATION
- Blowdown (depressuring)

Adiabatic Blowdown (to determine peak blowdown rate and RO size)

i) Initial blowdown pressure is considered as maximum operating pressure PAHH and blowdown to 6.9
barg within 15 minutes.
ii) Initial temperature is the operating temperature
iii) Liquid inventory for equipment is taken up to NLL level of the equipment.
iv) The piping inventories are estimated based on the isometric drawings if available or justified from
equipment layout if isometric drawings not available.
 RELIEF AND BLOWDOWN CALCULATION
- Blowdown (depressuring)
Cold Blowdown Study (to determine minimum temperature for facilities)

i) Performed when plant is shut down for maintenance purpose. It is assumed depressuring of the facilities
is not engaged immediately after shutdown but initiated after the facilities have been left for a
prolonged period and have been cooled down to minimum ambient temperature.
ii) Initial blowdown pressure considered is pressure corresponding to minimum ambient temperature while
keeping a constant density system and blowdown to 0 barg.
iii) The RO size calculated in Fire case blowdown or adiabatic case blowdown (whichever resulting a bigger
RO size) will be used for cold blowdown simulation.
iv) Liquid inventory for equipment is taken up to NLL level of the equipment.
v) Metal mass is taken into credit such that upstream fluid temperature is not as low due to some heat
contribution from the wall. The wall temperature is however higher than the upstream fluid temperature
due to higher ambient temperature on the other side of the wall and low heat transfer coefficient of wall
and vapor.
The cold blowdown study is important to select the correct materials of construction for the minimum
design temperature of the equipments/piping upstream and downstream of the blowdown valve.
 RELIEF AND BLOWDOWN CALCULATION
- Blowdown (depressuring)

The blowdown inlet line shall be sized such that the maximum blowdown inlet line velocity is limited to
0.2 Mach.

For intermittent loads, blowdown outlet piping will be sized with a recommended velocity up to 0.7
Mach, at header downstream junctions conditions and assuming a single blowdown scenario.

In the lines, upstream or downstream of the blowdown valve, the value of ρv2 should not exceed 200,000
kg/ms2.
 DRAINAGE CALCULATION
- Closed Drain

The Closed Drain System is designed to collect the maintenance drains from pressurised process and
utility systems facilities. The Closed Drain Header is routed to the Closed Drain Vessel where all liquid
droplets greater than 450 microns are removed from the gas before it is flared at LP Flare Tip.

The Closed Drain System facilities installed typical includes:

•Closed Drain Headers
•Closed Drain Vessel
•Closed Drain Heater
•Closed Drain Pumps.
 DRAINAGE CALCULATION
- Closed Drain

+ CD Header: The closed drain from the upstream pressurised facilities is collected in the closed drain
headers before being routed to Closed Drain Vessel.

+ Closed Drain Vessel is designed as a horizontal knock out drum which is used for handling all the drained
liquids from pressurized systems during maintenance or service of the equipment. The design pressure of
the vessel is kept at 7 barg to avoid deflagration damaging the vessel.

+ Heater: The facilities upstream of the Closed Drain Vessel shall be depressurised to atmospheric pressure
before being drained to the Closed Drain Vessel. A heater is provided in the Closed Drain Vessel in order to
maintain the condensate temperature in the vessel above the preliminary estimated wax appearance
temperature.

+ Closed Drain Vessel Pumps: are provided to transport the liquid collected in the Closed Drain Vessel to the
Flare Scrubber.
 DRAINAGE CALCULATION
- Closed Drain
 DRAINAGE CALCULATION
- Open Drain
- Open Drain System is designed to collect hydrocarbon liquid and/or potentially contaminated water from
•. open areas or equipment operating at atmospheric pressure. The sources of the open drains include drains
from equipment drip pans/coaming, deck drains, spillages, rainwater and firewater. The Open Drain System
is segregated into Hazardous and Non-Hazardous Systems:
+Hazardous Open Drain System shall collect hydrocarbon spillage, wash down water and rain water
from any areas where hydrocarbons are expected to be present and are classified as hazardous areas. The
collection headers shall route to the Hazardous Open Drain Tank.
+Non-Hazardous Open Drain System will collect water from platform areas with no expected
hydrocarbon exposure (classified as non-hazardous areas)

The facilities for Open Drain System include:

 Hazardous Open Drain Tank,
 Hazardous Open Drain Heater,
 Hazardous Open Drain Pump,
 DRAINAGE CALCULATION
- Open Drain

•.