Copy of All Sep Calc

SEPARATOR SIZING SPREADSHEET REV: P1

DATE: FEBRUARY 1996

FILE SEPARP1.XLS

MAIN MENU

SPREADSHEET INFORMATION

VERTICAL SEPARATOR ( 2 PHASE )

HORIZONTAL SEPARATOR ( 2 PHASE )

HORIZONTAL SEPARATOR ( 3 PHASE WITH BOOT)

HORIZONTAL SEPARATOR ( 3 PHASE, NO BOOT,

WEIRPLATE PARTITION )


STANDPIPE FOR CONDENSATE )

INSTRUCTIONS

SPREADSHEET INFORMATION

HORIZONTAL SEPARATOR ( 2 PHASE )


WEIRPLATE PARTITION )

SEPARATOR SIZING SPREADSHEET REV: P1

DATE: JANUARY 1996

I.PURPOSE

The aim of the separator sizing spreadsheet is to assistthe designer in saving valuable time resources by providing a user-friendly spreadsheet in Excel to calculate sizingparameters for both horizontal and vertical separators.

II.DESIGN BASES

A. Gas residence times are calculated using the normal liquid levelas the basis. In the case of the horizontal separatorwith weirplate partition, the basis used is the height ofthe weir for the gas volume. Dished end volumes havebeen neglected for the gas residence time calculations.

B. K-values to be used as input data for the spreadsheetsare found in the GPSA Handbook, figure 7.9 on page 7-7.The K factors must be converted to m/s to be placed intothe spreadsheet. The purpose of the K-factor is fordesigns which include woven wire demisters. Demisters(mist extractors) can significantly reduce the requireddiameter of vertical separators.

C. Dished-end volume calculations have been included forboth vertical and horizontal separators. For thevertical separator, an option is provided for choosingbetween semi-ellipsoidal and semi-hemispherical ends,however, for all horizontal separators, the ends havebeen assumed to be semi-ellipsoidal.(Reference: GPSA Handbook sections SI-13.5 to SI-13.10)

D. Other standards used in calculations includeAPI RP 521 Section 5.4.2 and calculations for thestandpipe were from EXXON Criteria in Design Practice 5B(September 1978).

III.METHOD

The following procedure is a step-by step outline for thedesigner.

A. Step One: Choose the type of separator required.The separators available in this spreadsheet include:

-Horizontal, 3 Phase, with boot-Horizontal, 3 Phase, no boot, weirplatepartition.-Horizontal, 3 Phase, no boot, standpipefor condensate.-Horizontal, 2 Phase-Vertical, 2 Phase

Page 1 of 3

INSTRUCTION NOTES

SEPARATOR SIZING SPREADSHEET - INSTRUCTION NOTES

Vertical separators are usually selected when the gas-liquid ratio is high or total gas volumes are low.Horizontal separators are most efficient where largevolumes of total fluids and large amounts of dissolvedgas are present with the liquid. For more information onseparators please refer to GPSA Handbook, Section 7.

B. Step Two: After the separator type is chosen, begininputting data into the cells of the spreadsheet whichhave blue italicised text. Do not write in cells whichcontain red or black text! Input data is summarised inthe top left hand side of the spreadsheet. Feedflowrates, properties and nozzle velocity specificationsare entered in this section. Data on vessellength, diameter and liquid levels are entered on thevessel sketch. Unknown values need to be assumed,otherwise errors will occur in the results.

C. Step Three: When all blue cells are filled - including thedimensions on the sketch, the spreadsheet will calculateall relevant values. The intermediate calculations canbe found below the sketch. Final output results arelisted on the sketch and in the top section of thespreadsheet. All formulae are in red text.

D. Step Four: Before final outputs can be used, warningsmust be considered. Warnings appear in bold green text,and will appear as "OK" when there is no warning present.If a warning does exist, try to change the relevantparameters to remove or reduce the warnings. Thesegenerally relate to liquid levels in the separator and gasresidence times.

E. Step Five: Check your units!!! The units defined on thespreadsheets can be found in the nomenclature section.The notes section may also assist with understandingwhich units to use. You can change the values in theblue cells as many times as you like.

F. Step Six: When you have your final output, SAVE yourfile by choosing the "SAVE AS" option under the "FILE"menu in Excel 5. Make sure that you use a different filename to the original master copy. (this will safeguardagainst deletion of the master copy)

G. Step Seven: Your work is now ready to PRINT. You mayfind that Excel 5 does not have enough memory to displaythe spreadsheet fully. The print range has been setup for A4 landscape paper and will print only the first 2-3 pages of the spreadsheet (the rest of the spreadsheet consists ofintermediate calculations). If you find that the spreadsheetwill not fit on the paper, choose "PAGE SETUP" from the"FILE" menu in Excel 5 and reduce the size of the sheet.

Page 2 of 3

SEPARATOR SIZING SPREADSHEET - INSTRUCTION NOTES

Another option available is to choose A3 sized paper(page setup menu) to print out your spreadsheet. It isnot recommended that the print area be altered as thishas been preset. However, if the print area needs to bealtered, please use the following procedure.

"TOOLS""OPTIONS""GENERAL""MICROSOFT EXCEL 4 MENUS""OK"(HIGHLIGHT THE AREA THAT YOU WISH TO PRINT)"OPTIONS""SET PRINT AREA"

IV. ADDITIONAL NOTES

A. THE CALCULATION TITLE BLOCK

There is a title block at the bottom of each pageof the spreadsheet, similar to the title block found onthe standard DJB calculation pad. Spaces have beenprovided for entering the calculation title, projectnumber and calculation number. These spaces are accessedby moving the mouse pointer into the particular box andclicking once with the left hand mouse button. At thispoint, an object box will appear. Simply click insidethe box once using the left hand mouse button and enterthe data in the normal way. When you have finishedtyping the information, move the mouse pointer to anotherpart of the spreadsheet and click once with the left handmouse button.

NOTE: While space has been provided on the title blockfor entering the originators and checkers initials andrelevant dates, these spaces cannot be accessed by theuser. This is because signatures are required to behand written by the originator and checker.

B. MAIN MENUThe main menu on the separator sizing spreadsheetallows the user to access any of the sheets in theworkbook through the use of a macro button. Once thedesigner is in a particular worksheet, they can return tothe menu by clicking the "MENU" macro button inthe individual worksheet.

Page 3 of 3

Kvaerner Process Inida SEPARATOR SIZING SPREADSHEET

SEPARATORS

• HORIZONTAL SEPARATOR (3 phase with boot)

• HORIZONTAL SEPARATOR (3 phase, no boot, weirplate partition)

• HORIZONTAL SEPARATOR (3 phase, no boot, standpipe for condensate.)

• HORIZONTAL SEPARATOR (2 phase)

• VERTICAL SEPARATOR (2 phase)

SPREADSHEET APPLICATION

Sizing of oil/gas/water separators for the hydrocarbon production industry.

BASIS

GPSA Handbook, Volume 1, Section 7. And also Section SI - 13.5 to 13.10API RP 521, Section 5.4.2 - Sizing a Knockout Drum

REVISION HISTORY

Revision P1 issued in February 1996 - file SEPARP1.XLSWith help from Don Borchert, Rod Harper, Nerrida Scott and Mark Sloma

INSTRUCTIONS FOR USE

Spreadsheet Conventions & Format

Input Data to be entered by the user is shown on the screen in blue italicised type. When printed the input appears in italics only.

Input data is summarised at the top left hand side of the spreadsheet. Feed flowrates, properties and nozzle velocity specifications are entered in this section. Information on vessel length, diameter and liquid levels is entered on the vessel sketchdescribed below.

Output Cells containing formulae are shown in red text.Cells containing formulae have been protected.

Final output data refers specifically to gas, oil and water residence times and oil and water droplet settling times. This data is summarised at the top centre of the spreadsheet.Data on calculated nozzle sizes and other vessel specific dimensions are shown on the vessel sketch.

Warnings Warning messages will appear to the right of the output data summary to indicate when results fall outside the design criteria described in the DJB procedure. Where resultssatisfy the design requirements the message 'OK' will appear in the WARNINGS section.

Warning messages may also appear on the vessel sketch, however in this case therewill be no message if the input/output data meets the design requirements.

Messages are shown on the screen in bold green type. When printed, the messages appear in bold type and will be enclosed in double asterisks.

Date and time printed: 17-Apr-23 9:54 PM Page 1 of 2

SEPARATOR SIZING SPREADSHEET - INFORMATION

Sketch The vessel sketch appears immediately below the input section. Some input and finaloutput data is shown on this sketch as noted above. Intermediate calculation results such as volumes and flowrates are also shown on the sketch.

Calculations This section follows the sketch and includes all the equations and intermediate calculations of the spreadsheet.

Defaults These include specified residence and settling times.Defaults are the minimum design requirements that are required for comparison against calculations.

maximum nozzle velocities and liquid levels may be found in the DJB procedure.

Notes This section includes some important equations and general assumptions used in thespreadsheet.

Nomenclature Nomenclature used in the spreadsheets including units used, is detailed below the notes section.

Calculation Title Block

There is a title block at the bottom of each page of the spreadsheet, similar to the title block found onthe standard DJB Calculation pad. Spaces are provided for entering the calculation title, project number and calculation number. These spaces are accessed by moving the mouse pointer into the particular box and clicking once with the left hand mouse button. At this point an object box will appear. Simply click inside the box once using the left hand mouse button and enter the data in thenormal manner. When you have finished typing the information, move the mouse pointer to another part of the spreadsheet and click once with the left hand mouse button.

initials and relevant dates, these spaces cannot be accessed by the user. This is becausesignatures are required to be hand written by the originator and checker.

Printing

The print range is pre-set and covers all of the sections described above. Printing is carried outby selecting the 'Print' command from the normal EXCEL pull down menu and selecting 'OK'.

Date and time printed: 17-Apr-23 9:54 PM Page 2 of 2

Other recommended values for variables or constants such as K, droplet size, rV2 ,

Note: While space has been provided on the title block for entering the originators and checkers

HORIZONTAL SEPARATOR (3 phase with boot)

INPUT OUTPUT

Feed GAS OIL WATER RESIDENCE TIMES Specified Actual

Flow (t/d) 762.8 6466.0 4799.0 Shell (mins) (mins) ** WARNINGS **

20.4 815.1 1008.1 Gas residence time (seconds) 581.7

Viscosity (cP) 0.01 4.57 0.89 HLL-HLSD 3.0 12.2 OK

Oil in Gas 100 NLL-HLL 3.0 17.2 OK

Oil in Water 1000 NLL-LLL 3.0 18.6 OK

Water in Oil 500 LLL-LLSD 3.0 9.1 OK

LLSD to Outlet 3.0 11.3 OK

1500 Oil Residence Time at NLL 3.00 39.0

3750

Max vel. in Oil out nozzle (m/s) 1.0 RESIDENCE TIMES Specified Actual

Max vel. in water out nozzle (m/s) 1.0 Boot (mins) (mins) ** WARNINGS **K Value (m/sec) 0.06 HIL-HILSD 3.0 0.2 ** Warning ! Residence time insufficient **

239.9 NIL-HIL 3.0 0.3 ** Warning ! Residence time insufficient **

NIL-LIL 3.0 0.3 ** Warning ! Residence time insufficient **

LIL-LILSD 3.0 0.3 ** Warning ! Residence time insufficient **

LILSD to bottom 3.0 1.2 ** Warning ! Residence time insufficient **

Water residence time at NIL 1.8 SETTLING VELOCITY CRITERION

K Factor Gas Velocity (m/s) 0.37 m/s OK

Gas Velocity (m/s) - calculated 0.04 m/s

Oil Droplet Velocity (m/s) - Gravity Settling Method Water velocity in Boot 0.02 m/sec

Oil from Gas 0.137 m/s

Water from Oil 0.006 m/s

Oil from Water 0.037 m/s OK

Droplet fall time (Oil in gas) 21.1 secs OK

NOTE: Gas Velocity Criteria are based on NLL.

NOTES :

Rev Revised/Issued For Date Prepd Chkd AppdOWNER Item No. Page

CLIENT SEPARATOR SIZING CALCULATIONS Description Kvaerner Process India Sheet OFPROJECT P&ID Ref. Doc No.

AREA Contract No. 9167JDATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Hor-3P-With Boot

Density (kg/m3)

Droplet Size (m)

Droplet Size (m)

Droplet Size (m)

r.v2 max for inlet nozzle (kg/m.s2)

r.v2 max for gas outlet nozzle (kg/m.s2)

Mixture density (kg/m3)


SKETCH

Min. Gas Out. nozzle ID202 mm Gas = 762.76 t/d

Length T/T= 20400 mm 1559.71

Inlet GAS

HeightMinimum Inlet nozzle ID I. D. = HLSD 3800 mm 252.02 (Gas)

544 mm 5300 mm HLL 3200 mm 67.07 (HLL-HLSD)NLL 2400 mm 94.71 (NLL-HLL)

LLL 1500 mm 102.45 (NLL-LLL)

LLSD 1000 mm 49.89 (LLL-LLSD)

OIL 62.28 (LLSD-Boot)

Interface Height Min Oil Outlet nozz ID: 342 mm

2000 ID

HILSD 1200 mm 0.628 (HIL-HILSD) Oil = 6466.00 t/d

HIL 1000 mm 0.942 (NIL-HIL) 330.54

2000 mm NIL 700 mm 0.942 (NIL-LIL)

LIL 400 mm 1.100 (LIL-LILSD)

LILSD 200 mm 1.204 (LILSD-Btm)

WATER

Min. Water out nozzle ID: 265 mm 4799.00 t/d

Water = 198.36

NOMENCLATURE

LLL Low Liquid Level HIL High Interface Level

LIL Low Interface Level HLSD High Level Shut Down Gas viscosity Cp

LLSD Low Level Shut Down HILSD High Interface Level Shut Down Settling Velocity m/s

LILSD Low Interface Level Shut Down Btm Bottom Maximum vapour velocity m/s

NLL Normal Liquid Level X-Area Cross sectional area K Design vapour velocity factor m/s

NIL Normal Interface Level Proportionality constant, dimensionless.

HLL High Liquid Level

NOTES :

Rev Revised/Issued For Date Prepd Chkd Appd

OWNER Item No. Page

CLIENT SEPARATOR SIZING CALCULATIONS Description Kvaerner Process India Sheet OF

PROJECT P&ID Ref. Doc No.

AREA Contract No. 9167J

DATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Hor-3P-With Boot

Am3/h

Vol. (m3)

Vol.(m3)

m3/h

m3/h

Dp Droplet (particle diameter) m

m

Vt

VMAX

rl Liquid density kg/m3 KCR

rv Vapour density kg/m3

Boot Height (mm)


CALCULATIONS

SETTLING VELOCITIES Oil in Gas (Gravity Settling Laws method)Oil From Gas ("K" Value method) Particle size calc for determination of appropriate lawK Value (m/s) 0.06

0.37 m/s Settling Velocity 0.14 m/sGas Horiz. Velocity 0.04 m/s Settling Law Used Intermediate Law

*note 2 Law Used: Kcr Vt Dp maxActual Gas Velocity OK (m/s)

Stoke's Law 0.03 0.37 31 Intermediate Law 0.33 0.14 412 Newton's Law 18.13 0.34 22356

Oil in Water (Gravity Settling Laws method) Water in Oil (Gravity Settling Laws method)Particle size calc for determination of appropriate law Particle size calc for determination of appropriate law

Settling Velocity 0.037 m/s Settling Velocity 0.006 m/sSettling Law Used Intermediate Law Settling Law Used Stoke's LawLaw Used: Kcr Vt Dp max Law Used: Kcr Vt Dp max

(m/s) (m/s)Stoke's Law 0.03 0.118 261 Stoke's Law 0.03 0.006 776 Intermediate Law 0.33 0.037 3491 Intermediate Law 0.33 0.008 10373 Newton's Law 18.13 0.084 189513 Newton's Law 18.13 0.059 563088

NOTES

1 Equations for Stokes Law, Intermediate Law and Newtons Law are taken from GPSA Handbook, Volume 1, Section 7.

Figure 7.42. Maximum allowable vapour velocity is calculated from the equation in GPSA Handbook, Volume 1, Section 7:

3. LLSD height calculation is based on the distance between the bottom of the cylinder and the low level shut down for the oil.LILSD height calculation is based on the distance from the base of the boot dished end to the low interface level shut down for the water.

4. Information for partial volumes and dished ends was from GPSA handbook Sections SI - 13.5 to 13.10, and in particular, fig. 13.6.5 Calculations for gas residence time and area/volume calculations use the normal liquid level, NLL as the height basis. End volumes is ignored for gas volume calculations.

NOTES :



AREA Contract No. 9167JDATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Hor-3P-With Boot

*Max Allowable Velocity,Vmax

(m)

(m) (m)

Stoke's Law (Kcr = 0.025) Intermediate Law (Kcr = 0.334) Newton's Law (Kcr = 18.13)

Vt = 1488 g Dp2 (rl - rv) Vt = 3.54*g0.71 Dp

1.14 (rl - rv)0.71 Vt = 1.74 * SQRT(g Dp (rl-rv) / rv )

18m rv0.29 * m0.43

VMAX = K [ (rl - rv) / rv ] 0.5

Dmax is the upper particle size limit for each of the laws.Kcr is the critical constant for maximum particle size (from GPSA Handbook). Vt is the settling velocity in m/s.see note 1

HORIZONTAL SEPARATOR (3 phase with weir, no boot)

INPUT YEAR : 2003-04 OUTPUT

Feed GAS OIL WATER RESIDENCE TIMES Specified Actual

Flow (t/d) 406.8 3035.3 675.2 (mins) (mins) ** WARNINGS **

9.1 830.0 988.5 Gas 25.34 seconds

Viscosity (cP) 0.01 6.25 0.54

Oil in Gas 100 Right Side of Weir

Oil in Water 150 HLL-HLSD 0.4 0.57 OK

Water in Oil 438 NLL-HLL 1.0 0.28 ** Warning ! Residence time insufficient **

NLL-LLL 1.0 0.29 ** Warning ! Residence time insufficient **

10000 LLL-LLSD 1.5 1.00 ** Warning ! Residence time insufficient **

3750 LLSD to Outlet 0.3 0.24 ** Warning ! Residence time insufficient **

Max vel. in Oil out nozzle (m/s) 1.0 Oil Residence Time at NLL 0.30 1.53 OK

Max vel. in water out nozzle (m/s) 1.0

K Value (m/s) 0.14

83.62

RESIDENCE TIMES Specified Actual

(mins) (mins) ** WARNINGS **

Left Side of Weir

SETTLING VELOCITY CRITERION HIL-Weir 1.0 27.0 OK

K-Factor Gas Velocity (m/s) 2.19 m/s OK NIL-HIL 0.9 2.77 OK

Gas Velocity (m/s) - calculated 0.26 m/s NIL-LIL 1.0 2.03 OK

Oil Droplet Velocity (m/s) - Gravity Settling Method LIL-LILSD 1.0 1.91 OK

Oil from Gas 0.175 m/s LILSD to Outlet 0.3 6.82 OK

Water from Oil 0.003 m/s Oil Residence Time (Weir to NIL) 5.57 mins

Oil from Water 0.004 m/s Water Residence Time (NIL to Btm) 10.76 mins

DROPLET FALL TIMES (Left Side of Weir)

Oil in Gas (Top-Liquid) 6.1 secs OK

Water in Oil (Weir to NIL) 5.35 min OK

Oil in Water (Btm-NIL) 2.41 min OK

NOTES :1. Maximum allowable vapour velocity is calculated from the equation in GPSA Engineering data book, Vol I, Section 7, 11 th edition.2. Settling times for water and oil on the left hand side of the separator are based on normal interface level(NIL).3. Information for partial volumes and dished ends is from GPSA Engineering data book, Vol I, Section 6.

D1 ISSUED FOR DESIGN/COST ESTIMATE 4. Calculation of gas residence time and area/volume calculations use the weir height as the height basis.

Rev Revised/Issued For Date Prepd Chkd Appd End volumes are ignored.OWNER CEIL Item No. V-101 PageCLIENT Owner SEPARATOR SIZING CALCULATIONS Description 1st Stage Prod.Sep. Kvaerner Process India Sheet OF

PROJECT Old CSU De-Bottlenecking Study P&ID Ref. 9167J Doc No.

AREA New CSU Case. O 23000, W 4296 G 0.04 Contract No. 9167J

DATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Hor-3P-Weir-No Boot

Density (kg/m3)

Droplet Size (m)

Droplet Size (m)

Droplet Size (m)





SKETCH YEAR : 2003-04

Gas Outlet nozzle ID Gas = 406.78 t/d180 mm 1870.78

Length T/T = 7720 mm Inlet Nozzle ID

258 mm

Ht.(mm) GAS13.17 (Gas) Interface Weir Height,Hw = 1371 mm Ht(mm)12.82 (HIL-Weir) 610 HIL I. D. = HLSD 2057

1.31 (NIL-HIL) 520 NIL 2438 mm OIL HLL 1574 1.46 (HLL-HLSD)0.96 (NIL-LIL) 450 LIL NLL 1371 0.72 (NLL-HLL)0.91 (LIL-LILSD) 380 LILSD LLL 1168 0.74 (NLL-LLL)3.23 (LILSD-Out) WATER LLSD 380 2.55 (LLL-LLSD)

0.60 (LLSD-Out)OIL

Oil Outlet nozzle ID T/W = 6700 mm 232 mm

Oil = 3035.31 t/d

152.38

Water outlet Nozzle ID Water = 675.21 t/d

100 mm 28.46

NOTES :

D1 ISSUED FOR DESIGN/COST ESTIMATERev Revised/Issued For Date Prepd Chkd Appd

OWNER CEIL Item No. V-101 PageCLIENT Owner SEPARATOR SIZING CALCULATIONS Description 1st Stage Prod.Sep. Kvaerner Process India Sheet OF PROJECT Old CSU De-Bottlenecking Study P&ID Ref. 9167J Doc No. ###AREA New CSU Case. O 23000, W 4296 G 0.04 Contract No. 9167J


Am3/h

Vol. (m3)Vol. (m3)

m3/h

m3/h


CALCULATIONS YEAR : 2003-04

SETTLING VELOCITIES Oil in Gas (Gravity Settling Laws method)

Oil From Gas ("K" Value method) Particle size calc for determination of appropriate lawK Value, m/s 0.14 Max allowable velocity,Vmax 2.194 m/s Settling Velocity 0.18 m/sGas Horiz. Velocity 0.26 m/s Settling Law Used Intermediate Law

Law Used: Kcr Vt Dp max

Actual Gas Velocity OK (m/s)Stoke's Law 0.025 0.37 41

Intermediate Law 0.334 0.18 546 Newton's Law 18.13 0.52 29638

Oil in Water (Gravity Settling Laws method) Water in Oil (Gravity Settling Laws method)Particle size calc for determination of appropriate law Particle size calc for determination of appropriate law

Settling Velocity 0.004 m/s Settling Velocity 0.003 m/sSettling Law Used Stoke's Law Settling Law Used Stoke's LawLaw Used: Kcr Vt Dp max Law Used: Kcr Vt Dp max

(m/s) (m/s)Stoke's Law 0.025 0.004 187 Stoke's Law 0.025 0.003 1015 Intermediate Law 0.334 0.004 2501 Intermediate Law 0.334 0.005 13566 Newton's Law 18.13 0.027 135770 Newton's Law 18.13 0.050 736365

NOTE: Equations for Stokes Law, Intermediate Law and Newtons Law are taken from GPSA Handbook, Volume 1, Section 7, Figure 7.4

NOMENCLATURE

LLL Low Liquid Level X-Area Cross sectional area Btm BottomLIL Low Interface LevelLLSD Low Level Shut Down LILSD Low Interface Level Shut Down NLL Normal Liquid Level Gas viscosity CpNIL Normal Interface Level Settling Velocity m/sHLL High Liquid Level Maximum vapour velocity m/sHIL High Interface Level K Design vapour velocity factor m/sHLSD High Level Shut Down Proportionality constant, dimensionless.HILSD High Interface Level Shut Down Height of Weir, mm

NOTES :

D1 ISSUED FOR DESIGN/COST ESTIMATERev Revised/Issued For Date Prepd Chkd Appd

OWNER CEIL Item No. V-101 PageCLIENT Owner SEPARATOR SIZING CALCULATIONS Description 1st Stage Prod.Sep. Kvaerner Process India Sheet OF PROJECT Old CSU De-Bottlenecking Study P&ID Ref. 9167J Doc No. ###AREA New CSU Case. O 23000, W 4296 G 0.04 Contract No. 9167J

(m)

(m) (m)

Stoke's Law (Kcr = 0.025) Intermediate Law (Kcr = 0.334) Newton's Law (Kcr = 18.13)Vt = 1488 g Dp2 (rl - rv) Vt = 3.54*g0.71 Dp1.14 (rl - rv)0.71 Vt = 1.74 * SQRT(g Dp (rl-rv) / rv )

18m rv0.29 * m0.43

rl Liquid density kg/m3


Dp Droplet diameter mm Vt

VMAX

KCR

Hw

Dmax is the upper particle size limit for each of the laws.Kcr is the critical constant for maximum particle size (from GPSA Engineering Databook). Vt is the settling velocity in m/s.



YEAR : 2003-04

NOTES :

D1 ISSUED FOR DESIGN/COST ESTIMATE

Rev Revised/Issued For Date Prepd Chkd AppdOWNER CEIL Item No. V-101 Page

CLIENT Owner SEPARATOR SIZING CALCULATIONS Description 1st Stage Prod.Sep. Kvaerner Process India Sheet OF PROJECT Old CSU De-Bottlenecking Study P&ID Ref. 9167J Doc No. ###


TOTAL VOLUME = Volume in 2 heads + Volume in cylinder = 1 / 6 p K D3 +1 / 4 p D2 L K = 2b / D Ze = H1 / D Zc = H1 / D PARTIAL VOLUME = (1 / 6 p K D3) * f(Ze) + (1 / 4 p D2 L) * f(Zc)f(Ze) = Ellipsoidal Coefficientf(Zc) = Horizontal cylinder coefficient. For elliptical heads, b = 0.25 * D and K = 0.5

PARTIAL VOLUME IN HORIZONTAL STORAGE TANKS WITH ELLIPSOIDAL OR HEMISPHERICAL HEADS.

D

bL

H1

b



Ze f(Ze) End Vol

TOTAL Cross Sectional Area 1.000 1.000 1.898

GAS (Volume to Top)WEIR TO TOP (PART ONE) 0.44 IGNORE IGNORE

STORAGE (Volume from Bottom)Left side of weirWEIR 0.56 0.593 1.125HIL 0.250 0.156 0.297NIL 0.213 0.117 0.222LIL 0.185 0.090 0.170LILSD 0.156 0.065 0.124Right side of weirHLSD 0.844 0.934 1.773HLL 0.646 0.712 1.351NLL 0.562 0.593 1.125LLL 0.479 0.469 0.889LLSD 0.156 0.065 0.124

Fraction a Chord Area Cylinder Partial Vol Volume

of Dia. (Radians) fraction Partial + end vol. Increment

f(Zc)TOTAL Cross Sectional Area 4.67 36.05 39.85

GAS (Volume to Top) IGNOREWEIR TO TOP (Left side of weir) 0.4377 1.45 0.42 1.97 13.17 END 13.17

VOLUMESTORAGE (Volume from Bottom)Left side of weirWEIR 0.5623 1.70 0.5791 2.70 18.12 19.24 12.82 HIL 0.2502 1.05 0.1957 0.91 6.12 6.42 1.31 NIL 0.2133 0.96 0.1560 0.73 4.88 5.10 0.96 LIL 0.1845 0.89 0.1269 0.59 3.97 4.14 0.91 LILSD 0.1558 0.81 0.0994 0.46 3.11 3.23 3.23 Right side of weirHLSD 0.8436 2.33 0.9001 4.20 4.29 6.06 1.46 HLL 0.6455 1.87 0.6826 3.19 3.25 4.60 0.72 NLL 0.5623 1.70 0.5791 2.70 2.76 3.88 0.74 LLL 0.4790 1.53 0.4733 2.21 2.25 3.14 2.55 LLSD 0.1558 0.81 0.0994 0.46 0.47 0.60 0.60

NOTES :

D1 ISSUED FOR DESIGN/COST ESTIMATE

Rev Revised/Issued For Date Prepd Chkd AppdOWNER CEIL Item No. V-101 Page

CLIENT Owner SEPARATOR SIZING CALCULATIONS Description 1st Stage Prod.Sep. Kvaerner Process India Sheet OF PROJECT Old CSU De-Bottlenecking Study P&ID Ref. 9167J Doc No. ###


=H1 /D (1 end) m3

(m2)

=H1 /D Vol. (m3) (m3) (m3)


HORIZONTAL SEPARATOR (3 phase, no boot, standpipe for condensate)

INPUT OUTPUT

Feed GAS OIL WATER RESIDENCE TIMES Specified ActualFlow (t/d) 2288.0 19398.0 14396.0 (mins) (mins) ** WARNINGS **

20.4 815.1 1008.1 Gas 12.54 secondsViscosity (cP) 0.01 4.57 0.89 HLL-HLSD 0.2 0.06 ** Warning ! Residence time insufficient **

Oil in Gas 150 NLL-HLL 0.2 0.02 ** Warning ! Residence time insufficient **

Oil in Water 1000 NLL-LLL 0.2 0.22 OK

Water in Oil 500 LLL-LLSD 0.2 0.01 ** Warning ! Residence time insufficient **

LLSD to NIL 0.3 0.33 OK

1500 HIL-HILSD 15.0 0.2 ** Warning ! Residence time insufficient **

3750 NIL-HIL 3.0 0.18 ** Warning ! Residence time insufficient **

Max vel. in Oil out nozzle (m/s) 1.0 NIL-LIL 3.0 0.16 ** Warning ! Residence time insufficient **

Max vel. in water out nozzle (m/s) 1.0 LIL-LILSD 1.0 0.10 ** Warning ! Residence time insufficient **

K Value (m/s) 0.06 LILSD to Outlet 3.0 0.21 ** Warning ! Residence time insufficient **

239.9Water Level Control Band 360 mm NIL-Standpipe 0.6 minsOil Level Control Band 360 mm Oil residence time (NLL - NIL) 0.64 mins

Water residence time (NIL-Bottom) 0.5 mins

SETTLING VELOCITY CRITERION DROPLET FALL TIMES K Factor Gas Velocity (m/s) 0.37 m/s ** Warning ! Gas Vel > Max Allowable ** Oil in Gas Top-Liquid 4.8 seconds OK

Gas Velocity (m/s) - calculated 0.8 m/s Water from Oil NLL-NIL 1.5 mins ** Warning ! Residence Time Insufficient **

Oil Droplet Velocity (m/s) - Gravity Settling Method Oil from Water Btm-NIL 0.2 mins OK

Oil from Gas 0.22 m/sWater from Oil 0.006 m/sOil from Water 0.037 m/s

NOTE: Gas Velocity Criteria are based on NLL Height.

STANDPIPE CALCULATIONS - FROM VESSEL BASE INTERMEDIATE CALCULATIONS

WATER LEVEL CONTROL BAND 360 mm

WATER INTERFACE LILSD 301 mm 301.16

WATER INTERFACE HILSD 661.16 661 mm

WATER INTERFACE NIL 481 mm

DIST. BETWEEN WATER HILSD AND OIL OUTLET NOZZLE 321 mm 321.23 1.00 120.05 0.7

OIL OUTLET NOZZLE (STANDPIPE) ELEVATION, (Hs) 982 mm

DIST. BETWEEN OIL OUTLET NOZZLE AND OIL LLSD 149.4 mm 148.64 0.99

OIL LEVEL CONTROL BAND 360 mm

OIL LEVEL LLSD 1132 mm

OIL LEVEL NLL 1312 mm

OIL LEVEL HLSD 1492 mm

NOTES :



AREA Contract No. 9167JDATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Hor-3P-Standpipe

Density (kg/m3)

Droplet Size (m)Droplet Size (m)Droplet Size (m)

r.v2 max for inlet nozzle (kg/m.s2)r.v2 max for gas outlet nozzle (kg/m.s2)



SKETCH

Gas = 2288.00 t/dInlet 4680.09

Minimum Inlet nozzle ID 941 mm Length T/T= 10000 mm Minimum Gas Out Nozzle ID = 349 mm

RECOMMENDED HEIGHTS Incremental GAS

Ht. (mm)OIL LEVEL HLSD 1492 mm oil HLSD 1000 mm 16.30 (Gas)

oil HLL 950 mm 1.05 (HLL-HLSD) I. D. =OIL LEVEL NLL 1312 mm oil NLL 934 mm 0.35 (NLL-HLL) 1972 mm

oil LLL 760 mm 3.66 (NLL-LLL)

OIL LEVEL LLSD 1132 mm oil LLSD 755 mm 0.10 (LLL-LLSD)

3.32 (LLSD-HILSD)

STANDPIPE, Hs 982 mm Height of standpipe, Hs = 707 mmInterface

HILSD 661 mm water HILSD 590 mm OILwater HIL 500 mm 1.68 (HIL-HILSD)

NIL 481 mm water NIL 400 mm 1.76 (NIL-HIL)

water LIL 300 mm 1.59 (NIL-LIL)

LILSD 301 mm water LILSD 230 mm 1.00 (LIL-LILSD) WATER2.06 (LILSD-Outlet)

HEIGHT WARNINGSMinimum Water out nozzle ID = 459 mm

OKWARNING! LLSD height too low! Water = 14396.00 t/d

Minimum Oil Outlet nozzle ID = 592 mm 595.04WARNING! Distance between HILSD and standpipe is insufficient!WARNING! Distance between LLSD and standpipe is insufficient!

Oil = 19398.00 t/dOK 991.63WARNING! LILSD height too low!

NOMENCLATURELLL Low Liquid Level HIL High Interface LevelLIL Low Interface Level HLSD High Level Shut Down LLSD Low Level Shut Down HILSD High Interface Level Shut Down Gas viscosity Cp LILSD Low Interface Level Shut Down Proportionality constant, dimensionless. Settling Velocity m/sNLL Normal Liquid Level Hs Height of Standpipe, mm Maximum vapour velocity m/sNIL Normal Interface Level K Design vapour velocity factor m/s

HLL High Liquid LevelNOTES :


OWNER Item No. Page



DATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Hor-3P-Standpipe


Am3/h

Vol. (m3)

m3/h

m3/h

Dp Droplet diameter mm

KCR Vt

VMAX



CALCULATIONS Cont'd)

SETTLING VELOCITIES Oil in Gas (Gravity Settling Laws method)Oil From Gas ("K" Value method) Particle size calc for determination of appropriate law

K Value, m/s 0.06

Max allowable velocity,Vmax 0.37 m/s Settling Velocity 0.22 m/s

Gas Horiz. Velocity 0.80 m/s Settling Law Used Intermediate Law


** Maximum allowable gas velocity exceeded ** (m/s)

Stoke's Law 0.03 0.84 31

Intermediate Law 0.33 0.22 412

Newton's Law 18.13 0.42 22359 Oil in Water (Gravity Settling Laws method)Particle size calc for determination of appropriate law Water in Oil (Gravity Settling Laws method)

Particle size calc for determination of appropriate law

Settling Velocity 0.037 m/s

Settling Law Used Intermediate Law Settling Velocity 0.006 m/s

Law Used: Kcr Vt Dp max Settling Law Used Stoke's Law

(m/s) Law Used: Kcr Vt Dp max

Stoke's Law 0.03 0.118 261 (m/s)

Intermediate Law 0.33 0.037 3491 Stoke's Law 0.03 0.006 776

Newton's Law 18.13 0.08 189513 Intermediate Law 0.33 0.008 10373

Newton's Law 18.13 0.059 563088

NOTES

1.

Equations for Stokes Law, Intermediate Law and Newtons Law are taken from GPSA Handbook, Volume 1, Section 7.

Figure 7.4

2. Maximum allowable vapour velocity is calculated from the equation in GPSA Handbook, Volume 1, Section 7:

3. Settling times for water and oil are based on the normal interface level (NIL).

4. Information for partial volumes and dished ends was from GPSA handbook Sections SI - 13.5 to 13.10, and in particular, fig. 13.6.

5. Calculations for gas residence time and area/volume calculations use the NLL height as the height basis. End volumes ignored for gas volume calculations.

NOTES :


OWNER Item No. Page


AREA Contract No. 9167JDATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Hor-3P-Standpipe

(m)

(m)

(m)


Vt = 1488 g Dp2 (rl - rv) Vt = 3.54*g0.71 Dp1.14 (rl - rv)0.71 Vt = 1.74 * SQRT(g Dp (rl-rv) / rv )

18m rv0.29 * m0.43

VMAX = K [ (rl - rl) / rl ] 0.5

Dmax is the upper particle size limit for each of the laws.Kcr is the critical constant for maximum particle size (from GPSA Handbook). Vt is the settling velocity in m/s.see note 1

HORIZONTAL SEPARATOR (2 phase)

INPUT OUTPUT

Feed GAS OIL RESIDENCE TIMES Specified Actual

Flow (t/d) 520.0 1000.0 (mins) (mins) ** WARNINGS **

11.10 829.20 Gas (seconds) 59.2

Viscosity (cP) 0.02 7.00 HLL-HLSD 3.0 3.3 OK

Oil in Gas 150 NLL-HLL 3.0 19.2 OK

1500 NLL-LLL 3.0 5.1 OK

3750 LLL-LLSD 3.0 3.4 OK

Max vel. in Oil out nozzle (m/s) 1.00 LLSD to bottom 3.0 21.5 OK

0.06

31.63 SETTLING VELOCITY CRITERION (m/s)

K-Factor Gas Velocity (m/s) 0.52 OK

Gas Horiz. Velocity (m/s) - calculated 0.17

NOTE: Gas velocity critera all based on NLL. Oil Droplet Velocity (m/s) 0.23

(Gravity Settling Method)Droplet fall time (seconds) 6.4 OK

CALCULATIONS

SETTLING VELOCITIESOil From Gas ("K" Value method) Oil from Gas (Gravity Settling Laws method)K Value 0.06 m/s Particle size calc for determination of appropriate law

0.52 m/sGas Horiz. Velocity 0.17 m/s Settling Velocity 0.23 m/s

Minimum Vessel Diameter 1158 mm Settling Law Used Intermediate Law


(m/s)

Stoke's Law 0.03 0.62 47

Intermediate Law 0.33 0.23 621

Newton's Law 18.13 0.57 33733

NOTE: Equations for Stoke's Law, Intermediate Law and Newton's Law are taken from GPSA Handbook, Volume 1, Section 7.Figure 7.4

NOTES :

Rev Revised/Issued For Date Prepd Chkd AppdOWNER Item No. PageCLIENT SEPARATOR SIZING CALCULATIONS Description Kvaerner Process India Sheet OFPROJECT P&ID Ref. Doc No.AREA Contract No. 9167JDATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Hor-2P

Density (kg/m3)

Droplet Size (m)



K Value (m/s) from mist extractor data GPSA fig 7.9


Max Allowable Velocity,Vmax

Stoke's Law (Kcr = 0.025) Intermediate Law (Kcr = 0.334) Newton's Law (Kcr = 18.13) (m)

Vt = 1488 g Dp2 (rl - rv) Vt = 3.54*g0.71 Dp

1.14 (rl - rv)0.71 Vt = 1.74 * SQRT(g Dp (rl-rv) / rv )

18m rv0.29 * m0.43

Dmax is the upper particle size limit for each of the laws.Kcr is the critical constant for maximum particle size (from GPSA Handbook).Vt is the settling velocity in m/s.

HORIZONTAL SEPARATOR (2 phase)

SKETCH

520.0 t/d Inlet Minimum Gas = 1951.95

Gas OutletMinimum Inlet nozzle ID Length T/T= 10200 mm Nozzle ID = 194 mm

321 mm

GAS HeightHLSD 1800 mm 32.12 (Gas)

I. D. = HLL 1700 mm 2.79 (HLL-HLSD)

2630 mm NLL 1150 mm 16.06 (NLL-HLL)

LLL 1000 mm 4.30 (NLL-LLL)

LLSD 900 mm 2.84 (LLL-LLSD)

18.04 (LLSD-Btm)

OIL

Minimum Oil = 1000 t/dOil Outlet 50.25

Nozzle ID = 133 mm

NOMENCLATURE

LLL Low Liquid LevelLLSD Low Level Shut Down Gas viscosity CpNLL Normal Liquid Level Settling Velocity m/sHLL High Liquid Level Maximum vapour velocity m/sHLSD High Level Shut Down K Design vapour velocity factor m/s Btm Bottom Proportionality constant, dimensionless.

g Gas constant

Upper Particle Size Limit

NOTES :

Rev Revised/Issued For Date Prepd Chkd AppdOWNER Item No. PageCLIENT SEPARATOR SIZING CALCULATIONS Description Kvaerner Process India Sheet OFPROJECT P&ID Ref. Doc No.AREA Contract No. 9167JDATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Hor-2P

Am3/h

Vol. (m3)

m3/h

Dp Droplet diameter mm Vt

VMAX

KCR


rv Vapour density kg/m3 Dmax

VERTICAL SEPARATOR (2 phase)

INPUT HP2 SUCTION SCRUBBER V 7954A (EXISTING -RE-USED) OUTPUT

Feed GAS OIL RESIDENCE TIMES Specified Actual ** WARNINGS **

Flow (t/d) 3563.3 0.05 (mins) (mins)

51.20 600.0 HLL-HLSD 3.0 3862.5 OK

Viscosity (cP) 0.01 0.16 NLL-HLL 3.0 5793.7 OK

Oil in Gas 150 NLL-LLL 3.0 5793.7 OK

0.11 LLL-LLSD 3.0 3862.5 OK

10000 LLSD to bottom 3.0 5793.7 OK

10000

Max vel. in Oil outlet nozzle (m/s) 1.00 SETTLING VELOCITY CRITERION

51.20 K Factor Gas Velocity (m/s) 0.36 ** Warning ! Gas Velocity > Max Allowable **

Choose Dished end shape by clicking on arrow. Gas Velocity (m/s) - calculated 0.36

See note 6 Oil Droplet Velocity (m/s) 0.14 ** Warning ! Gas Velocity > Max Allowable**

Gravity Settling Method

Note: Gas velocity criteria based on NLL.

CALCULATIONS

LIQUID / VAPOUR SEPARATIONK Value Method Oil from Gas (Gravity Settling Laws method)(Note 2) Particle / droplet size calc for determination of appropriate lawK Value 0.11 m/sMax allow. Velocity (Vmax) 0.36 m/s Settling Velocity 0.14 m/s

Gas Velocity 0.36 m/s Settling Law Used Intermediate lawMinimum Vessel Diameter 1687 mm Law Used: Kcr Vt Dp maxMaximum allowable gas velocity exceeded (m/s)

Stoke's Law 0.03 0.67 23 Intermediate Law 0.33 0.14 310 Newton's Law 18.13 0.22 16852

NOTES :


OWNER Item No. Page

CLIENT SEPARATOR SIZING CALCULATIONS Description Kvaerner Process India Sheet OFPROJECT P&ID Ref. Doc No.AREA Contract No. 9167JDATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Ver-2P

Density (kg/m3)

Droplet Size, (m)

K Value (m/s) from mist extractor data GPSA fig.7.9




(m)


Vt = 1488 g Dp2 (rl - rv) Vt = 3.54*g0.71 Dp1.14 (rl - rv)0.71 Vt = 1.74 * SQRT(g Dp (rl-rv) / rv )

18m rv0.29 * m0.43

Dmax is the upper particle size limit for each of the laws.Kcr is the critical constant for maximum particle size (from GPSA Handbook).Vt is the settling velocity in m/s.

VERTICAL SEPARATOR (2 phase)

SKETCH HP2 SUCTION SCRUBBER V 7954A (EXISTING -RE-USED)

Min Gas Outlet Gas = 3563.30 t/d

Nozz. Size = 271 mm 2899.82

Calculated Total 300 mm (Note 6)

T/T Height: 3081 mm

150 mm Wire Mesh Demister

ID=1687mm

1181 mm (Note 5)

Inlet GAS550 mm

Min Inlet Nozzle Size = 271 mm

250 mm (Note 2)

HLSD 650 mm Volume increment

NOMENCLATURE HLL 550 mm 0.22

LLSD Low Level Shut Down

LLL Low Liquid Level 0.34

NLL Normal Liquid Level NLL 400 mm

HLL High Liquid Level

HLSD High Level Shut Down OIL 0.34

g Gas constant

Dmax Upper Particle Size Limit LLL 250 mm

LLSD 150 mm (Note 3) 0.22

Volume to LLSD including dished end = 1.59

Gas viscosity Cp

Settling Velocity (m/s)

Maximum vapour velocity (m/s)

K Design vapour velocity factor (m/s) Min Liquid Outlet Oil = 0.05 t/d

Proportionality constant, dimensionless. Nozz. Size = 50 mm 0.00

NOTES :

Rev Revised/Issued For Date Prepd Chkd AppdOWNER Item No. PageCLIENT SEPARATOR SIZING CALCULATIONS Description Kvaerner Process India Sheet OFPROJECT P&ID Ref. Doc No.


DATE AND TIME PRINTED: 17-Apr-23 9:54 PM 'file:///tt/file_convert/55cf9cfa550346d033abc111/document.xls'#$Ver-2P

Am3/h

m3

m3

m3

rL Liquid density (kg/m3) m3

rV Vapour density (kg/m3) m3

Dp Droplet diameter (m)m

Vt

VMAX

KCR m3/h

Copy of All Sep Calc

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